John Deere pd54 Specifications
OPERATOR/SERVICE MANUAL
MODELS: SD-43, SD-54, PD-43
PD-54, PDB-43, PDB-54
RHINO MODEL SHOWN: PD54
JOHN DEERE DIESEL
A 100% employee-owned American manufacturer
REVISION: B 6/01 P/N 56322
TABLE OF CONTENTS
OPERATOR/SERVICE MANUAL
RHINO 43/54
FOREWORD ................................................................................................... 6
LIMITED WARRANTY ....................................................................................... 7
SECTION 1 - TECHNICAL DATA ...................................................................... 9 - 11
1.1 Specifications .......................................................................................... 10
1.2 Engine RPM ............................................................................................ 10
1.3 Machine Data .......................................................................................... 11
1.4 Machine Sound Level Test ...................................................................... 11
SECTION 2 - HEALTH & SAFETY ................................................................... 13 - 19
SECTION 3 - OPERATION ................................................................................. 21 - 29
3.1 Introduction and Operating Principle ...................................................... 22
3.2 Diesel Fuel .............................................................................................. 23
3.3 Engine Break-in ...................................................................................... 23
3.4 Engine Oil and Filter ............................................................................... 23
3.5 Warning Light ......................................................................................... 23
3.6 Hydraulic Oil, Filter, and Breather ......................................................... 23 - 24
3.7 Engine Coolant........................................................................................ 24
3.8 Visual Inspection ..................................................................................... 24
3.9 Air Cleaner .............................................................................................. 24 - 25
3.10 Before Starting ........................................................................................ 25
3.11 To Start ................................................................................................... 25
3.12 To Stop ................................................................................................... 25
3.13 Idling Engine ........................................................................................... 25
3.14 Warming Engine...................................................................................... 25 - 26
3.15 Parking Brake .......................................................................................... 26
3.16 Brake Light ............................................................................................. 26
3.17 To Operate ............................................................................................... 26
3.18 Forward/Reverse/Neutral ........................................................................ 26
3.19 Throttle ................................................................................................... 26
3.20 Gauges ................................................................................................... 26
3.21 Panel Fuse ............................................................................................... 27
3.22 Cold Weather Starting / Intake Heater Button ........................................ 27
3.23 Blade Lever ............................................................................................. 27
3.24 Horn/Back-up Alarm ............................................................................... 27
3.25 ROPS/FOPS/Seat Belt ............................................................................ 27
3.26 Tires/Lugnuts .......................................................................................... 27
3.27 Drum/Scrapers ........................................................................................ 28
3.28 Cleaning .................................................................................................. 28
3.29 Eccentrics ................................................................................................ 28
3.30 Compaction Tips ..................................................................................... 28
3.31 Tie Downs ............................................................................................... 28
3.32 Towing (Bypass) ..................................................................................... 28 - 29
3.33 Storage ................................................................................................... 29
SECTION 4 - MAINTENANCE........................................................................... 31 - 55
4.1 Important ................................................................................................. 32
4.2 Maintenance Schedule ............................................................................ 32
4.3 Important Maintenance Information ....................................................... 34
4.4 Engine Oil and Filter ............................................................................... 34
4.5 Additional Service Information .............................................................. 34
4.6 Hydraulic Oil and Filter .......................................................................... 34 - 35
4.7 Hydraulic Breather .................................................................................. 35
4.8 Engine Cooling System........................................................................... 35 - 36
4.8.1 Replacing Engine Coolant......................................................... 36
4.8.2 Adding Engine Coolant ............................................................. 36 - 37
4.8.3 Disposing of Coolant................................................................. 37
4.9 Air Cleaner .............................................................................................. 37
4.9.1 Air Cleaner Service ................................................................... 37
4.9.2 Air Cleaner Replacement .......................................................... 37 - 38
4.9.3 Element Storage ........................................................................ 38
4.10 Fuel Filter ................................................................................................ 38
4.10.1 Water Separator ......................................................................... 38
4.10.2 Fuel Filter Replacement ............................................................ 38 - 39
4.10.3 Bleeding Fuel System ............................................................... 39
4.10.4 Bleeding at Fuel Injection Pump ............................................... 39
4.10.5 Bleeding at Fuel Injection Nozzles ........................................... 39 - 40
4.11 Fan/Alternator Belt ................................................................................. 40
4.12 Grease Fittings ........................................................................................ 40
4.13 Frame Hinge............................................................................................ 40
4.14 Blade Pins ............................................................................................... 40
4.15 Battery ................................................................................................... 40
4.15.1 Servicing Battery....................................................................... 40 - 41
4.15.2 Battery Installation .................................................................... 41
4.15.3 Charging/Jumping Battery ........................................................ 41 - 42
4.16 Engine Crankcase Vent Tube .................................................................. 42
4.17 Engine Valve Clearance .......................................................................... 42
4.18 Emission Regulation/Engine RPM ......................................................... 42
4.19 Fuel Injectors .......................................................................................... 42 - 43
4.19.1 Test Fuel Injection Nozzles ....................................................... 43
4.20 Fuel Tank................................................................................................. 43
4.21 Fuel Lines................................................................................................ 43
4.22 Hydraulic Hoses/Connections ................................................................. 43 - 44
4.23 Forward/Reverse/Neutral Adjustment .................................................... 44
4.24 Neutral Interlock ..................................................................................... 44
4.25 Control Cables: Forward/Reverse, Throttle, Blade................................. 44
4.26 Eccentrics ................................................................................................ 45
4.26.1 Eccentric Housing Oil ............................................................... 45
4.27 Charge System......................................................................................... 45
4.28 Panel Fuse: 20 AMP................................................................................ 45
4.29 Engine Installation Guidelines ................................................................ 45 - 46
4.30 Engine Mounting..................................................................................... 46
4.31 Hardware ................................................................................................. 46
4.31.1 Loctite ....................................................................................... 46
4.32 Roll Over Protective Structures (ROPS)................................................. 46
4.32.1 Maintenance of ROPS/Seat Belts (Inspection & Repair) ......... 46
4.33 Horn/Back-up Alarm ............................................................................... 47
4.33.1 Back-up Alarm Switch .............................................................. 47
4.34 Scrapers ................................................................................................... 47
4.35 Troubleshooting ...................................................................................... 48 - 53
4.36 Electrical Troubleshooting ...................................................................... 54
4.37 Service Record ........................................................................................ 55
SECTION 5 - EXPLODED DIAGRAMS & PARTS LIST................................ 57 - 97
5.1 Hardware Key ......................................................................................... 59
5.2 Torque Charts and Guidelines ................................................................. 60 - 61
5.3 Drum Assembly ....................................................................................... 62 - 65
5.4 Main Frame ............................................................................................. 66 - 69
5.5 Radiator/Engine Mount ........................................................................... 70 - 71
5.6 Engine ................................................................................................... 72 - 75
5.7 Air Cleaner .............................................................................................. 76 - 77
5.8 Controls ................................................................................................... 78 - 81
5.9 Drive System Hydraulics ........................................................................ 82 - 85
5.10 Steering/Eccentric System Hydraulics .................................................... 86 - 87
5.11 Blade ................................................................................................... 88 - 89
5.12 Hydraulic Schematic ............................................................................... 90 - 91
5.13 Wiring ................................................................................................... 92 - 93
5.14 Decal Identification ................................................................................. 94 - 97
CALIFORNIA PROPOSITION 65 WARNING .............................................................. 99
FOREWORD
These instructions include:
Safety regulations
Operating instructions
Maintenance instructions
These instructions have been prepared for
operation on the construction site and for the
maintenance engineer.
These instructions are intended to simplify
operation of the machine and to avoid
malfunctions through improper operation.
Observing the maintenance instructions will
increase the reliability and service life of the
machine when used on the construction site and
reduce repair costs and downtimes.
Always keep these instructions at the place of
use of the machine.
Only operate the machine as instructed and
follow these instructions.
Warranty Information
Please enter the following data. This will help expedite
any service or warranty work.
1. Machine Type: _______________________
Machine S/N: ________________________
2. Engine Type: _________________________
Engine S/N: __________________________
3. VIN: _______________________________
4. Purchase Date: _______________________
5. Dealer/Distributor Information:
Name: ______________________________
Address: ____________________________
____________________________________
Observe the safety regulations as well as the
guidelines of the civil engineering trade
association. Observe safety rules for the
operation of equipment and the pertinent
regulations for the prevention of accidents.
Stone Construction Equipment, Inc. is not liable
for the function of the machine when used in an
improper manner and for other than the intended
purpose.
Operating errors, improper maintenance and the
use of incorrect operating materials are not
covered by the warranty.
The above information does not extend the
warranty and liability conditions of business of
Stone Construction Equipment, Inc.
Stone Construction Equipment, Inc.
P.O. Box 150, Honeoye, New York 14471
Phone: (800) 888-9926
Fax: (716) 229-2363
Phone #: ____________________________
Fax #: ______________________________
Location of above information:
1. Information on S/N tag.
2. Information on engine tag.
3. Information on S/N tag - if applicable.
4. Date you purchased machine.
5. Dealer machine was purchased from.
- 6 -
L i m i t e d W a r r a n t y
The Manufacturer warrants that products manufactured shall be free from defects in material and
workmanship that develop under normal use for a period of 90 days for concrete vibrators and electric
pumps, one year for Rhino®, Bulldog®, Wolfpac Rollers, trowels, Stompers®, saws, forward plates,
engine powered pumps, and 6 months for all other products from the date of shipment. The foregoing
shall be the exclusive remedy of the buyer and the exclusive liability of the Manufacturer. Our warranty
excludes normal replaceable wear items, i.e. gaskets, wear plates, seals, O-rings, V-belts, drive chains,
clutches, etc. Any equipment, part or product which is furnished by the Manufacturer but manufactured by
another, bears only the warranty given by such other manufacturer . (The Manufacturer extends the warranty
period to “Lifetime” for the drum bearings and seals for the mortar mixers, and agrees to furnish, free of
charge, the bearings and seals only upon receipt of the defective parts. The warranty is two years for
eccentric bearings on the forward plate compactors, mortar and plaster mixer drums, trowel gearboxes
and five years on the Bulldog trench roller eccentric bearings.) A Warranty Evaluation Form must accompany
all defective parts. Warranty is voided by product abuse, alterations, and use of equipment in applications
for which it was not intended, use of non-manufacturer parts, or failure to follow documented service
instructions. The foregoing warranty is exclusive of all other warranties whether written or oral, expressed
or implied. No warranty of merchantability or fitness for a particular purpose shall apply. The agents,
dealer and employees of Manufacturer are not authorized to make modification to this warranty , or additional
warranties binding on Manufacturer. Therefore, additional statements, whether oral or written, do not
constitute warranty and should not be relied upon.
The Manufacturer’s sole responsibility for any breach of the foregoing provision of this contract, with respect
to any product or part not conforming to the Warranty or the description herein contained, is at its option (a)
to repair, replace or refund such product or parts upon the prepaid return thereof to location designated
specifically by the Manufacturer. Product returns not shipped prepaid or on an economical transportation
basis will be refused (b) as an alternative to the foregoing modes of settlement - the Manufacturer’s dealer
to repair defective units with reimbursement for expenses, except labor, and be reviewed with the
Manufacturer prior to repair. A Warranty Evaluation Form must accompany all warranty claims.
Except as set forth hereinabove and without limitation of the above, there are no warranties or other
affirmations which extends beyond the description of the products and the fact hereof, or as to operational
efficiency, product reliability or maintainability or compatibility with products furnished by others. In no
event whether as a result of breach of contract or warranty or alleged negligence, shall the Manufacturer
be liable for special or consequential damages including but not limited to: Loss of profits or revenues, loss
of use of the product or any associated product, cost of capital, cost of substitute products, facilities or
services or claims of customers.
No claim will be allowed for products lost or damaged in transit. Such claims should be filed with the carrier
within fifteen days.
Effective April 1, 1998.
Bred Tough, Technology Born T o Work.
The Way It Ought T o Be.
Stone Construction Equipment, Inc.
32 East Main Street, P . O. Box 150
Honeoye, NY 14471-0150
- 7 -
Phone: 1-800-888-9926 • 1-716-229-5141
Fax: 1-716-229-2363
www.stone-equip.com • e-mail: sceny@mcimail.com
4/98 P/N 51018
1. TECHNICAL DATA
- 9 -
1. TECHNICAL DATA
MODEL
Drum Type
Dimensions
Operating Wt. (Kg)
Drum Width (cm)
H x L x W (cm)
Tires (cm)
Operating System
Engine (kW)
RPM (Hertz)
Fuel Capacity (liters)
Steering
Frame
Drive System
Eccentric Drive
Cooling
Parking Brake
Security Braking Sys.
Performance
Centrifugal Force (Kn)
Frequency (Hertz)
Total Applied Force
(Kn)
Speed
Low Gear
High Gear
(kilometers/hour)
Amplitude (mm)
Articulating Angle
Oscillating Angle
Gradeability
Inside Turning Radius
(meter)
Wall Clearance (cm)
Curb Clearance (cm)
Area Cap.
(Sq.Ft./Hr.) (M2)
STONE
SD 43
Smooth
6100# (2767)
43" (109,2)
97" x 124" x 51"
(246,4 x 315 x 124,5)
9.5 x 16 (24,1 x 40,6)
Diamond Tread
58 hp John Deere
(43.25)
2500 (41,7)
20 gal. (757)
Power
Articulating,
Oscillating
Positraction
Hydrostatic
Water
Mechanical
Hydrostatic
12,000# (53,38)
2100 (35)
14,900# (66,28)
0-2 mph (0-3,22)
0-4 mph (0-6,44)
.071" (1,80)
o
35
o
9
90%
94.25" (2,39)
2 1/2" (6,35)
14" (35,56)
37,840 sq.ft/hr.
(3515,5)
STONE
SD 54
Smooth
6540# (2966,5)
54" (137,2)
97" x 124" x 59"
(246,4 x 315 x 149,9)
9.5 x 16 (24,1 x 40,6)
Diamond Tread
58 hp John Deere
(43.25)
2500 (41,7)
20 gal. (757)
Power
Articulating,
Oscillating
Positraction
Hydrostatic
Water
Mechanical
Hydrostatic
12,000# (53,38)
2100 (35)
15,100# (67,17)
0-2 mph (0-3,22)
0-4 mph (0-6,44)
.062" (1,57)
o
35
o
9
90%
88.75" (2,25)
2 1/2" (6,35)
14" (35,56)
47,520 sq.ft/hr.
(4414,8)
1.1 Specifications Stone Rhino
STONE
PD 43
Padfoot
6409# (2907,1)
43" (109,2)
97" x 124" x 51"
(246,4 x 315 x 124,5)
9.5 x 16 (24,1 x 40,6)
Cleated Tractor
58 hp John Deere
(43.25)
2500 (41,7)
20 gal. (757)
Power
Articulating,
Oscillating
Positraction
Hydrostatic
Water
Mechanical
Hydrostatic
12,000# (53,38)
2100 (35)
15,209# (67,65)
0-2 mph (0-3,22)
0-4 mph (0-6,44)
.059" (1,50)
o
35
o
9
70%
94.25" (2,39)
2 1/2" (6,35)
14" (35,56)
37,840 sq.ft/hr.
(3515,5)
STONE
PD 54
Padfoot
6880# (3120,7)
54" (137,2)
97" x 124" x 59"
(246,4 x 315 x 149,9)
9.5 x 16 (24,1 x 40,6)
Cleated Tractor
58 hp John Deere
(43.25)
2500 (41,7)
20 gal. (757)
Power
Articulating,
Oscillating
Positraction
Hydrostatic
Water
Mechanical
Hydrostatic
12,000# (53,38)
2100 (35)
15,419# (68,59)
0-2 mph (0-3,22)
0-4 mph (0-6,44)
.053" (1,35)
o
35
o
9
70%
88.75" (2,25)
2 1/2" (6,35)
14" (35,56)
47,520 sq.ft/hr.
(4414,8)
STONE
PD 54
Padfoot
6880# (3120.7)
54" (137.2)
97' x 124' x 59'
(246.4 x 315 x 149.9)
9.5 x 16 (24.1 x 40.6)
Cleated Tractor
58 hp John Deere
(43.25)
2500 (41.7)
20 gal (757)
Power
Articulating
Oscillating
Positraction
Hydrostatic
Water
Mechanical
Hydrostatic
12,000# (53,38)
2100 (35)
15,808# (70,32)
0-2 mph (0-3,22)
0-4 mph (0-6,44)
.059" (1,50)
o
35
o
9
70%
94.25" (2,39)
7" (17,78)
14" (35,56)
37,840 sq.ft/hr.
(3515,5)
®
STONE
PDB 54
Padfoot w/blade
7275# (3300)
54" (137,2)
97" x 136" x 68"
(246,4 x 315 x 172,7)
9.5 x 16 (24,1 x 40,6)
Cleated Tractor
58 hp John Deere
(43.25)
2500 (41,7)
20 gal. (757)
Power
Articulating,
Oscillating
Positraction
Hydrostatic
Water
Mechanical
Hydrostatic
12,000# (53,38)
2100 (35)
16,075# (71,51)
0-2 mph (0-3,22)
0-4 mph (0-6,44)
.053" (1,35)
o
35
o
9
70%
88.75" (2,25)
7" (17,78)
14" (35,56)
47,520 sq.ft/hr.
(4414,8)
Standard Features: 2 drum scrappers; ROPS/FOPS; gauges – oil pressure, volt meter, coolant temp, hour meter, fuel sight, hydraulic oil sight; warning lights - oil pressure and
temperature; horn; back-up alarm; neutral safety start; padded seat w/flip-up arm rests; seat belt; secondary parking brake
1.2 ENGINE RPM
IDLE RPM 1,200 + 100 18Hz
FULL RPM 2,500 + 100 41Hz
ECCENTRIC FULL SPEED RPM 2,100 + 100 34Hz
- 10 -
1. TECHNICAL DATA
1.3 MACHINE DATA
Brakes
Service
Parking
Recommended Fuel Diesel fuel blend meeting ASTM D975 or EN 590
Premium diesel fuel conditioner is also recommended
Electric 12 Volt system battery BCI group 24
Hydraulic Oil Mobilfluid 424
Engine Oil 1st 100 hours John Deere br eak-in oil (T Y22041) then
SAE 15W/40 API CG-4 or API CF-4 6.5 quarts (6.0 liters)
Engine Coolant 50/50 Mixture antifreeze / distilled water meeting ASTM 4985,
coolant additive is also recommended
Eccentric Oil SAE 20W/50 API SJ or API SH
Hydrostatic
Automatic spring applied
800 CCA 78 amp charge system
Capacity 20 gallons (76 liters)
SD / PD 43: 1 quart (.95 liter)
SD / PD 54: 15 quarts (1.4 liters)
Engine / HP John Deere 3029DF 58 HP (43 kW) int. @ 2,500 RPM
Torque 153 ft. lbs. (208 Nm) int. @ 1,200 RPM
Fuel Economy .377 lb./hp - hr. (230 g/kWh) @ 1,600 RPM
1.4 MACHINE SOUND LEVEL TEST
Machine Type: PDB54 Rhino
Sound Level Meter Calibration Date: August 6, 1997
Meter Type: Simpson Model 886-2 Type 2
Test Date: August 6, 1997
Test Conditions:
Temperature 70° Fahrenheit / 20° Celsius
Ambient Sound 60 dba Slow Mode
Soil Condition Silts and Clays
Moisture Limit N/A
Engine Speed: 2,500 RPM / 41 Hz
Frequency: 2,100 VPM / 34 Hz
Test Site: Honeoye, New York, USA
Sound Level at Operator Position: 93 dba Without Vibe
93 dba With Vibe
- 11 -
2. HEALTH & SAFETY
- 13 -
2. HEALTH & SAFETY
SAFETY USE
These machines are designed to carry out the function
of compacting material of the non-cohesive, bituminous
and granular varieties.
Safety Precautions
If used correctly they will provide an effective and safe
means of compaction and meet the appropriate
performance standards.
It is essential that the operator of the machine is
adequately trained in its safe operation, be authorized
to operate it, and have sufficient knowledge of the
machine to ensure that it is in full working order before
being put to use.
- 14 -
2. HEALTH & SAFETY
Safety Precautions
Before using this equipment, study this entire manual
to become familiar with its operation. Do not allow
untrained or unauthorized personnel, especially
children, to operate this equipment. Use only factory
authorized parts for service.
FOLLOW SAFETY INSTRUCTIONS
Carefully read all safety messages and decals in this manual
and on your machine safety signs. Keep decals in good
condition. Replace missing or damaged decals. Be sure
new equipment components and repair parts include the
current safety signs. Replacement safety signs and decals
are available through your dealer.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
When warning decals are destroyed or missing, contact
the Manufacturer immediately at 1-800-888-9926 for
replacement. For the safety of yourself and others, it is
imperative that the following rules are observed.
Failure to do so may result in serious injury or death.
If you do not understand any part of this manual and need
assistance, contact your dealer.
UNDERSTAND SIGNAL WORDS
A signal word DANGER, WARNING, or CAUTION is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
This notation appears before warnings in the text. It means that
the step which follows must be carried out to avoid the possibility
of personal injury or death. These warnings are intended to help
the technician avoid any potential hazards encountered in the
normal service procedures. We strongly recommend that the
reader takes advantage of the information provided to prevent
personal injury or injury to others.
- 15 -
2. HEALTH & SAFETY
USE COMMON SENSE WHEN HANDLING FUELS
Transport and handle fuel only when contained in approved safety
container.
Do not smoke when refueling or during any other fuel handling
operation.
Do not refuel while the engine is running or while it is still hot.
If fuel is spilled during refueling, wipe it off from the engine
immediately and discard the rag in a safe place.
Do not operate the equipment if fuel or oil leaks exist - repair
immediately.
Never operate this equipment in an explosive atmosphere.
Operator must always be seated with seat belt on when
roller is running.
Never allow more than one person on roller.
Always turn engine off before dismounting from roller.
Always apply parking brake when not in use.
Never park roller on a hill.
Never operate roller on slope greater than 15 degrees.
Do not operate the roller in standing water.
Safety Precautions
Ear protection required when operating this equipment.
Exposure to loud noise can cause impairment or loss of
hearing.
HOT SURFACES
Muffler, engine, and engine shroud may be hot.
Allow all components in the engine compartment to cool before
performing any service work.
Never operate unit in a poorly ventilated or enclosed area.
Avoid prolonged breathing of exhaust gases.
Engine exhaust fumes can cause sickness or death.
- 16 -
2. HEALTH & SAFETY
Qualified personnel only. No untrained operators. Serious injury may
occur.
Users must be trained to operate this roller. Read the Operator's
Manual and Engine Owner's Manual. Learn to operate this roller
safely.
Do not articulate on grades larger than 15o, roller may tip over.
Do not operate across the sides of hills, roller may tip over.
Do not operate at the edge of mats or roads, roller may tip over.
Do not stand. Be seated, with seat belt on, when roller is running.
Do not park the roller on hills.
Always turn off engine and apply brake before dismounting.
Caution: Escaping hydraulic fluid under pressure can have sufficient
force to penetrate the skin, causing serious personal injury.
Hydraulic system produces high pressures--incorrect hose replacement
can cause serious personal injury. When performing service, refer to
Operator's Manual for hose identification and connections.
Hydraulic fluid escaping under pressure from a very small hole can be
almost invisible. Use a piece of cardboard or wood to search for
possible leaks.
Never use your hands to detect pressure leaks.
Hydraulic tank temperature can reach 180
Safety Precautions
o
F maximum.
SERVICE COOLING AND HYDRAULIC SYSTEMS SAFELY
Pressurized release of fluids from hydraulic or coolant systems can
cause serious burns.
Shut off engine. Only remove filler cap when cool enough to touch
with bare hands. Slowly loosen cap to first stop to relieve pressure
before removing completely.
Never perform any work on the roller while it is running. Before
working on the roller, stop the engine and disconnect the spark plug
wire(s) to prevent accidental starting, block drums to prevent rolling.
Keep engine cover closed during the operation.
Keep hands, clothing and jewelry away from all moving parts.
Keep all guards in place.
- 17 -
2. HEALTH & SAFETY
Keep feet clear of all drums.
Keep work area free of bystanders.
For foot protection wear steel toe shoes or toe pads.
Caution: Keep away from the machines articulation area
when the engine is running.
Only start engine from operators seat.
Before starting machine, make sure that there are no persons
or obstacles near or under machine.
PRACTICE SAFE MAINTENANCE
Understand service procedure before doing work. Keep area clean
and dry.
Safety Precautions
Never lubricate, service, or adjust machine while it is moving. Keep
hands, feet, and clothing from power-driven parts. Disengage all
power and operate controls to relieve pressure. Lower equipment
to the ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be raised for
service work.
Keep all parts in good condition and properly installed. Fix damage
immediately. Replace worn or broken parts. Remove any buildup
of grease, oil, or debris.
Disconnect battery ground cable (-) before making adjustments on
electrical systems or welding on machine.
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital,
and fire department near your telephone.
- 18 -
2. HEALTH & SAFETY
Starting fluid (ether) is highly flammable. Do not use or an explosion
or fire may result.
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appropriate to
the job.
Prolonged exposure to loud noise can cause impairment or loss of
hearing.
Wear a suitable hearing protective device such as earmuffs or
earplugs to protect against objectionable or uncomfortable loud
noises.
Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while
operating machine.
Safety Precautions
PREVENT BYPASS STARTING
Avoid possible injury or death from engine runaway.
Do not start engine by shorting across starter terminal. Engine will
start with drive system engaged if normal circuitry is bypassed.
Start engine only from operators seat with seat belt on and
forward/reverse in neutral.
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the environment and
ecology. Potentially harmful waste used with John Deere equipment
includes such items as oil, fuel, coolant, brake fluid, filters, and
batteries.
Use leakproof containers when draining fluids. Do not use food or
beverage containers that may mislead someone into drinking from
them.
Do not pour waste onto the ground, down a drain, or into any water
source.
Air conditioning refrigerants escaping into the air can damage the
Earths atmosphere. Government regulations may require a certified
air conditioning service center to recover and recycle used air
conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste from your
local environmental or recycling center.
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3. OP ERATION
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3. OPERATION
3.1 INTRODUCTION AND OPERATING PRINCIPLE
This roller is ergonomically engineered to optimize operator interface with the total machine its really user
friendly. Besides good visibility to the roll-edge, as well as the work surface, youll find that the controls are
exactly in the right places for maximum comfort. And it is very convenient to monitor all the consumables fuel,
hydraulic oil, etc.
Our common sense approach to servicing is a valuable benefit. Thanks to our modular design, everything that
needs servicing is located behind one of the easy-access service panels or is under the rear cowl.
For maneuverability and productivity, nothing beats the proven performance of center-point articulation. Because
the drum and tires track each other exactly, tight turns are achieved smoothly. The roller is equipped with full
positive traction, front to rear and side to side, which keeps the roller moving through various conditions.
Theres power steering a feature no operator wants to be without. A variable hydrostatic drive system provides
infinitely variable speed control from 0 to 4 mph. The eccentric delivers a centrifugal force sufficient to
compact all types of soil. Superior vibration isolation to the operator is achieved by mounting heavy-duty shock
mounts between the eccentric and support frames.
The following instructions were compiled to provide you information on how to obtain long and trouble-free use
of the roller. Periodic maintenance of the roller is essential. Read this manual in its entirety and follow the
instructions carefully. Failure to do so may cause injury to you or a bystander.
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3. OPERATION
3.2 DIESEL FUEL
Do not mix oil with fuel. The engine has a separate oil
reservoir in the crankcase. Diesel fuel blend meeting
ASTM D915 or EN590 and a premium diesel fuel
conditioner is recommended.
WARNING
FUEL IS BOTH TOXIC AND FLAMMABLE. DO
NOT SMOKE WHILE WORKING WITH FUEL.
DO NOT USE NEAR OPEN FLAME. ALWAYS
STOP ENGINE BEFORE REFUELING. CLEAN UP
SPILLED FUEL BEFORE STARTING. AVOID
FIRES BY KEEPING ENGINE CLEAN OF
ACCUMULATED GREASE AND DEBRIS.
START, STORE, AND REFUEL ON LEVEL
GROUND TO PREVENT PERSONAL INJURY. DO
NOT RUN UNIT IN AN ENCLOSED, NONVENTILATED AREA. AVOID PROLONGED
BREATHING OF VAPORS AND SKIN CONTACT.
SERIOUS ILLNESS OR LOSS OF LIFE COULD
RESULT.
KEEP THE VENT HOLE IN FUEL TANK CAP
OPEN. IF VENT HOLE IS PLUGGED, PRESSURE
MAY BUILD UP IN TANK, CAUSING
DANGEROUS SPRAYING OF FUEL WHEN TANK
CAP IS REMOVED. A VACUUM MAY ALSO BE
CREATED DURING OPERATION, WHICH
COULD STOP FUEL FLOW. DIESEL FUEL IS
MANDATORY FOR USE IN THIS ENGINE.
ALWAYS USE CLEAN FUEL. LOW QUALITY OR
CONTAMINATED FUEL WILL DAMAGE FUEL
INJECTION COMPONENTS.
DIESEL FUEL STORED IN GALVANIZED
CONTAINERS REACTS CHEMICALLY WITH
THE ZINC COATING ON THE CONTAINER. THE
CHEMICAL REACTION CREATES POWDERY
FLAKES OF ZINC SULFIDE. IF WATER IS
PRESENT IN THE FUEL, A ZINC HYDROXIDE
GEL WILL FORM.
3.3 ENGINE BREAK-IN
IMPORTANT Read Engine Manual for break-in
requirements. 1st 100 hours John Deere break-in oil
only (TY 22041). Do not add oil until level is in the
add area on the dipstick. Do not fill above the
crosshatched area on the dipstick. 1st 100 hours run
engine at full throttle. Operate engine at heavy
loads, do not idle longer than 5 minutes. Check oil
frequently, do not exceed 100 hours with break-in
oil.
3.4 ENGINE OIL AND FILTER
Change oil and filter at 100 hours, then every 250
hours. Use SAE 15W-40 API CG-4 or API CF-4. Refer
to Engine Manual for additional oil types and
recommendations. Do not mix different brands or
types of oil. Mixing oils can degrade lubrication
performance.
3.5 WARNING LIGHT
Unit is equipped with a warning light for low pressure
and/or hot engine temperature.
Specifications:
Oil pressure at full speed: 40 50 psi
(2.75 3.45 bar)
Coolant temperature range: 180° - 202°F
(82° - 94°C)
3.6 HYDRAULIC OIL, FILTER, BREATHER
WARNING
PRESSURIZED RELEASE OF FLUIDS FROM
HYDRAULIC SYSTEM CAN CAUSE SERIOUS
BURNS. SHUT OFF ENGINE. ONLY REMOVE
BREATHER CAP WHEN COOL ENOUGH TO
TOUCH WITH BARE HANDS. SLOWLY LOOSEN
CAP TO FIRST STOP TO RELIEVE PRESSURE
BEFORE REMOVING COMPLETELY.
Check the hydraulic oil level. Use the sight gauge
located on the hydraulic tank. A 1/4 1/2 air bubble
will be seen at the top of the gauge showing the fluid
level.
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3. OPERATION
For satisfactory operation, the following oil
conditions apply:
1. Accurate level readings can be checked
only when the fluid is cold.
2. If the natural color of the fluid has become black
or milky, it is possible that an overheating or
water contaminant problem exists.
3. Do not mix hydraulic fluids. Mobil 424 is
recommended for the hydraulic system.
CAUTION: After a new unit has run 5 hours, the
oil filter should be changed. This is to rid the
system of any trapped contamination from the wearin of the parts. Refer to Maintenance for hydraulic
filter change.
3.7 ENGINE COOLANT
WARNING
CHECK COOLING SYSTEM CAREFULLY.
EXPLOSIVE RELEASE OF FLUIDS FROM
PRESSURIZED COOLING SYSTEM CAN
CAUSE SERIOUS BURNS.
To check coolant level:
1. Shut off engine, allow to cool.
2. Only remove filler cap when cool enough to
touch with bare hands. Slowly loosen cap to
first stop to relieve pressure before removing
completely.
3. Remove cap, coolant level should just touch the
bottom of radiator filler neck. If coolant is
required, see Adding Coolant in the
Maintenance section of this manual.
IMPORTANT: Do not overfill radiator. Refer to
Coolant Maintenance if additional coolant is
required. Never pour cold liquid into a hot
engine, as it may crack cylinder head or block.
DO NOT operate engine without coolant for even
a few minutes. If coolant leaks or abnormal
temperature is detected, contact a service
technician immediately.
replace the water pump seal. Contact your engine
distributor or servicing dealer for repairs.
3.8 VISUAL INSPECTION
Make a thorough inspection of the engine compartment
daily. Look for oil or coolant leaks, worn fan belt,
loose connections and trash build-up. Remove trash
build-up and have repairs made as needed if leaks are
found.
NOTE:Wipe all fittings, caps, and plugs before
performing any maintenance to reduce the chance of
system contamination.
Air intake system hoses and connections for
cracks and loose clamps.
Fan belt for cracks, breaks, or other damage.
Water pump for coolant leaks.
3.9 AIR CLEANER
IMPORTANT: The air intake system must not leak.
Any leak, no matter how small, may result in engine
failure due to abrasive dirt and dust entering the
intake system.
1. Inspect all intake hoses (piping) for cracks.
2. Check clamps on piping which connect the air
cleaner and engine.
3. Squeeze dust unloader valve (A) on air cleaner
assembly to remove dust deposits. If clogged,
remove and clean the dust unloader valve. Replace
if damaged.
IMPORTANT: Do not operate engine without the
dust unloader valve.
NOTE:It is normal for a small amount of leakage to
occur as the engine cools down and parts contract.
Excessive coolant leakage may indicate the need to
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3. OPERATION
WARNING
BEFORE STARTING ENGINE IN A CONFINED
BUILDING, INSTALL PROPER OUTLET
EXHAUST VENTILATION EQUIPMENT.
ALWAYS USE SAFETY APPROVED FUEL
STORAGE AND PIPING. NEVER RUN THE
ROLLER WITHOUT THE PANELS IN PLACE OR
SEVERE PERSONAL INJURY MAY OCCUR.
3.10 BEFORE STARTING
1. Check for proper fluid levels, engine oil,
coolant, fuel, and hydraulic oil.
2. Check the air cleaner.
3. Check throttle, levers, and controls for smooth
operation.
4. Check seat belt, horn, and back-up alarm
operation.
3.12 TO STOP
WARNING
ALWAYS OBEY THE FOLLOWING
PROCEDURES BEFORE DISMOUNTING FROM
THE ROLLER.
1. Place the forward/reverse lever in the NEUTRAL
position.
2. Throttle engine down to its slowest speed.
3. Turn key switch to OFF position to stop the
engine. Remove ignition key.
NOTE:Before stopping an engine that has been
operating at working load, idle engine at
least 2 minutes.
3.13 IDLING ENGINE
3.11 TO START
1. Operator must always be seated and seat belt
must be worn.
2. Forward/reverse must be in NEUTRAL position
and eccentric switch should be in OFF position.
3. Throttle should be set at idle.
4. Turn key clockwise until the engine cranks over.
Release the key when the engine starts.
DO NOT crank engine for more than 20
seconds at a time.
5. Check all gauges for normal engine operation.
If operation is not normal, stop the engine and
determine the cause.
NOTE:If temperature is below 0° C (32° F), it may be
necessary to use cold weather starting aid. See Cold
Weather Starting later in this section.
WARNING
DO NOT USE STARTING FLUID (ETHER).
ENGINE IS EQUIPPED WITH INTAKE HEATER.
AN EXPLOSION OR FIRE MAY RESULT. REFER
TO COLD WEATHER STARTING
INSTRUCTIONS.
IMPORTANT: Avoid excessive engine idling.
Prolonged idling may cause the engine coolant
temperature to fall below its normal range. This, in
turn, causes crankcase oil dilution, due to
incomplete fuel combustion, and permits formation
of gummy deposits on valve, pistons, and piston
rings. It also promotes rapid accumulation of
engine sludge and unburned fuel in the exhaust
system.
3.14 WARMING ENGINE
IMPORTANT: To assure proper lubrication,
operate engine at idle with no load for 5 minutes.
Extend this period when operating at temperatures
below freezing.
1. Check oil pressure gauge as soon as engine
starts. If gauge needle does not rise above
minimum oil pressure specification of
(1.05 bar) (15.0 psi) within 5 seconds, stop the
engine and determine the cause. Normal
engine oil pressure is (3.45 bar + 1.03 bar)
(50 + 15 psi) at rated full load speed
(1800 2500 rpm) with oil at normal operating
temperature of 105° C (221° F).
2. Watch coolant temperature gauge. Do not
place engine under full load until it is properly
- 25 -
3. OPERATION
warmed up. The normal engine coolant
temperature range is 82° - 94° C (180° - 202° F).
NOTE:It is good practice to operate the engine under
a lighter load and at lower speeds than normal for the
first few minutes after start-up.
WARNING
NEVER OPERATE ON SLOPES GREATER THAN
15 DEGREES OR TIPPING MAY OCCUR.
3.18 FORWARD/REVERSE/NEUTRAL
3.15 PARKING BRAKE
WARNING
BLOCK THE DRUMS TO PREVENT ROLLING
OF THE MACHINE OR SEVERE PERSONAL
INJURY MAY OCCUR. NEVER PARK ROLLER
ON A HILL.
When engine is not running, the brake is applied.
When the engine is running and the forward/reverse
lever is in NEUTRAL, the brake will apply within 2
seconds.
3.16 BRAKE LIGHT
When the key is turned to ON, the brake light should
come on within 2 seconds. Shifting into forward or
reverse, the light should go out.
3.17 TO OPERATE
The forward/reverse lever should be aligned with
NEUTRAL on the console when the roller is moving
neither forward nor backward with the engine running.
The neutral interlock switch should not allow the
engine to start unless the forward reverse lever is in
neutral.
3.19 THROTTLE
Pull throttle out to increase engine speed. Push throttle
to reduce engine speed. For best performance, run
engine at full throttle.
3.20 GAUGES
IMPORTANT: Any time an electric gauge or meter
does not register correctly, replace it with a new
one. Do not attempt to repair it.
Oil Pressure Gauge Indicates engine oil pressure.
IMPORTANT: Follow Manufacturers "Before
Starting" and "Break-in" procedures on engine.
Always allow engine to warm up five minutes
before applying load.
Start and apply full throttle. Move forward/reverse
lever slowly forward to gain speed desired. The same
procedure is for reverse. To slow down, move
forward/reverse lever toward NEUTRAL.
To gain power or speed by moving forward/reverse
lever slightly off of NEUTRAL will produce the
greatest amount of torque. Moving the lever all the
way forward or reverse will give the greatest amount
of speed.
Coolant Temperature Gauge Indicates the
engine coolant temperature.
Volt Meter Indicates charging current within
electrical system.
Hour Meter Indicates the operating hours of the
engine while key switch is in the ON position. The
hour meter should be used as a guide for scheduling
maintenance.
WARNING
AVOID LEAVING THE KEY ON WHEN
MACHINE IS NOT RUNNING. THIS WILL
HAVE AN EFFECT ON THE HOUR METER
READINGS.
- 26 -
3. OPERATION
3.21 PANEL FUSE 20 AMP
Protects electrical system.
WARNING
NEVER USE FUSE WITH A DIFFERENT RATING
FROM THAT SPECIFIED. SERIOUS DAMAGE
TO THE ELECTRICAL SYSTEM OR A FIRE MAY
RESULT.
3.22 COLD WEATHER STARTING / INTAKE
HEATER BUTTON
WARNING
DO NOT USE STARTING FLUID (ETHER).
ENGINE IS EQUIPPED WITH AIR INTAKE
HEATER. AN EXPLOSION OF FIRE MAY
RESULT. FOR COLD WEATHER STARTING, SEE
INSTRUCTIONS BELOW.
1. Turn the key to the ON position (do not crank
engine).
2. Press INTAKE HEATER BUTTON for
approximately 30 seconds. Start engine using
starter switch. As soon as the engine starts, release
button.
3. Never operate the starter for more than 20
seconds at a time. If engine does not start,
release the starter switch and wait at least one
minute before trying again.
4. Do not adjust the throttle setting. Allow the
engine to idle for 5 minutes to warm up. At
temperatures below freezing, extend warm up
time.
3.23 BLADE LEVER (OPTIONAL)
3.24 HORN AND BACK-UP ALARM
Check operation daily. It is the drivers responsibility
to operate equipment safely.
3.25 ROPS / FOPS / SEAT BELT
Inspect daily. Certified factory installed for operator
protection. Do not remove or modify.
WARNING
DANGER: AVOID CRUSHING. DO NOT JUMP
IF MACHINE TIPS. ALWAYS WEAR SEAT
BELT.
DO NOT OPERATE THIS MACHINE IF THE
ROLLOVER PROTECTIVE STRUCTURE
(ROPS) IS STRUCTURALLY DAMAGED,
SHOWS CRACKS, IS NOT PROPERLY
SECURED AS ORIGINALLY INSTALLED, OR
HAS BEEN ROLLED. DO NOT REPAIR,
MODIFY, OR ADD ATTACHMENTS TO ROPS
UNLESS AUTHORIZED IN WRITING BY THE
MANUFACTURER.
DO NOT ADD ATTACHMENTS TO THE
MACHINE THAT INTRUDE INTO OPERATORS
PROTECTIVE AREA, REDUCE VISIBILITY,
RESTRICT EMERGENCY EXITS, OR ADD
WEIGHT EXCEEDING CERTIFICATION
WEIGHT OF ROPS. DO NOT OPERATE
MACHINE UNLESS SEAT BELT CONFORMING
TO SAE AND/OR ASAE STANDARDS IS
FASTENED. SEE OPERATORS MANUAL OR
CONTACT YOUR DEALER FOR COMPLETE
INSPECTION REQUIREMENTS AND
MAINTENANCE INSTRUCTIONS.
Controls the leveling blade height for pre-leveling
loose soil.
IMPORTANT: Do not use the blade to dig or
bulldoze or machine damage may occur.
3.26 TIRES/LUG NUTS
WARNING
DO NOT EXCEED RATED PRESSURE 35 PSI.
Clean and check daily:
1. Tires are properly inflated.
2. Lug nuts are in place and tight
190 ft. lbs. (140 Nm).
- 27 -
3. OPERATION
3.27 DRUM/SCRAPPERS
Clean and inspect daily to prevent excess mud and
debris from building up. Replace if missing or worn.
Pad drum scrappers are adjustable, see Maintenance
section.
3.28 CLEANING
WARNING
DIRT AND MUD BUILT UP WILL REDUCE
MACHINE PERFORMANCE AND/OR CAUSE
FAILURES.
Use pressurized water to remove dirt and mud. Clean
and inspect entire machine daily. Use extra care when
cleaning radiator and oil cooler.
When cleaning machine, caution should be used
around regulator area. Direct spraying of the
regulator is not good. (Regulator should be covered
or protected if direct spraying will happen).
Excessive water pressure may also loosen wire
connections or start terminals corroding. After
cleaning, all terminals should be dried if wet and
connections checked for proper seating.
3.29 ECCENTRICS
When vibratory compaction is necessary, engage
eccentrics by pushing the vibration switch to the ON
position. For best performance run engine at full
rpm. The eccentrics should be turned off whenever
the roller is stopped or stopped to change direction.
Do not run the eccentric on any non-yielding surface
such as concrete or aged asphalt.
3.30 COMPACTION TIPS
Avoid sharp turns, steer gradually. If articulation is a
new concept, we suggest the operator take 20 minutes
or so to get used to the feel of the unit.
Recommended compaction speed should be at
3 m.p.h. or less to achieve a uniform compaction.
WARNING
DO NOT ARTICULATE ON GRADES LARGER
THAN 15, ROLLER MAY TIP OVER.
DO NOT OPERATE ACROSS THE SIDES OF
HILLS, ROLLER MAY TIP OVER.
DO NOT OPERATE AT THE EDGE OF MATS OR
ROADS, ROLLER MAY TIP OVER.
DO NOT STAND, ALWAYS WEAR SEAT BELT.
3.31 TIE DOWNS
WARNING
TIE DOWNS ARE NOT INTENDED FOR LIFTING
PURPOSES.
Equipment is equipped with front and rear tie down
rings for shipping purposes. Use only these tie downs
to secure unit.
3.32 TOWING (BYPASS)
WARNING
NEVER PUSH OR PULL THE ROLLER WITH THE
ENGINE OFF. WHEN ENGINE IS NOT RUNNING,
THE BRAKE IS APPLIED. WHEN THE ENGINE
IS RUNNING AND THE FORWARD/REVERSE
LEVER IS IN NEUTRAL, THE BRAKE WILL
APPLY WITHIN 2 SECONDS.
In an emergency or during a breakdown, it may be
necessary or desirable to tow the roller. This may be
accomplished by mechanically releasing the brake and
bypassing the transmission pump. If these procedures
are followed carefully, the roller may be moved short
distances at LOW speed without running the engine.
The brake is located in the front wheel motor, which
drives the drum of the roller. There is an access hole in
the front frame to assist in releasing the brake. Refer to
the Drum Assembly #39 22770 Kit Bypass to identify
these parts. The threaded hole in the center of the
wheel motor requires a M12 bolt long enough to extend
beyond the frame when fully engaged. A bolt, washer,
and nut is included in a separate package for this
- 28 -
3. OPERATION
purpose. Fully install the nut and washer on the bolt.
Insert this assembly through the hole in the frame such
that the washer is over the hole with the nut against the
outside of this washer. Thread the bolt, finger tight
into the wheel motor to the bottom of the hole. Now
tighten the nut against the washer until the brake is
compressed and released. This should require about 44
ft. lbs. torque. Do not torque the bolt. Be careful not
to over-torque beyond releasing the brake.
The bypass valve is located on the transmission pump.
The seat and battery plate should be removed for
access to the transmission pump. The bypass valve is
controlled by a shaft with cross-drilled holes and
maybe a slot in the end. This shaft may be turned
manually to open the valve and allow the motor to turn.
The valve is fully open with two revolutions of the
shaft. DO NOT OPEN VALVE PAST TWO TURNS.
The valve must be fully closed for normal operation.
The torque required to close the valve is only 7 to 10 ft.
lbs.
DAMAGE MAY RESULT FROM OVERTORQUING.
3.33 STORAGE
IMPORTANT: The front wheel motor has a rubber
plug in the M12 hole to prevent contamination.
Reinstall the rubber plug after towing
1. Store the roller on level ground with drums
blocked and parking brake on.
2. Remove the key. Operations of roller by
untrained persons could result in personal injury.
3. During extended storage, drums can be coated with
any type of oil or grease to prevent rusting.
4. Storage instructions for the engine are stated in the
Engine Manual and should be carried out.
- 29 -
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