‘TrAlance AB 85.04 500 MAINTENANCE CA30; From Serial No. 577 076 VIBRATORY ROLLERS > Diesel engine: Deutz F6L 912, CAT 03208 NA, GM (Detroit) 3-53-T CONTENTS Page Lubricants .... 1 Every 14 days Maintenance schedule: CAT 2 Every month .. Maintenance schedule: DEUTZ 6 Every three months Maintenance schedule: GM . 10 Every six months Daily 14 Every year . Weekly 18 Special instructions READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING ANY SERVICE WORK. Correct maintenance is essential to ensure that the roller will give many years of satisfactory service and the instructions given here should therefore be carefully followed. Use the appropriate engine instruction manual in conjunction with these ‘instructions. LUBRICANTS A BC D and E refer to the maintenance schedule. Always use specified lubricants in the stated amounts. Excessive or insufficient grease or oi] will cause parts to run hot, thus inducing rapid wear. @® GREASE lithium base with EP additive (lead oleate), NLGI No. 2, Shell Alvania EP Grease 2. ENGINE OIL for API Service CD/SE, SAE 10H/30 © ENGINE OIL for API Service CD/SE, SAE 30 ‘Air temperature | Viscosity Viscosity CAT/DEUTZ GM =102¢ to +30°¢ | SAE 10W/30 | SAE 30 =10°C to +50°C | SAE 15W/40 | SAE 40 The instructions for the engine (oi] change intervals, etc.) described in the manufacturer's ‘instruction manual should be followed, in addi- tion to those listed here. © HYDRAULIC OL with anti-wear additive - Shell Tellus T 68 of1 © LUBRICATING OIL saz 90 HD (API, GL-5) © BRAKE FLUID She1T Donax HB Note Other lubrication recommendations apply if the machine is to be used under exceptionally hot or cold conditions, Pefer to the “Special instructions" or contact DYNAPAC. 1 DYWVAPAC mame irs Hes Equipment AB PO Box 504 - $-37123 KARLSKRONA + SWEDEN )MAINTENANCE SCHEDULE ROLLER WITH CATERPILLAR D3208 NA ENGINE 12.34 5678 9 N12 29 28 2726 25 24 23 22 Fig 1 1 Cooling system - filler cap 2 Engine - fuel filter 3. Engine: - valves 4 Engine - oi] level 5 Air cleaner 6 Hydraulic of] tank - sight glass 7 Hydraulic oi] tank - breather filter 8 Hydraulic of] filters (two) 9 Hydraulic oi] tank - drain 10 Battery 11 Hydraulic of1 - filler cap 12 Handbrake and foot brake 13 Brake cylinder (foot brake) 14 Drum ofl - filler plug Torque hub (only on CA 30D and CA 30PD machines) 16 7 18 19 20 21 22 23 24 25 26 27 28 29 30 31 B 4 «15 16 21 20 19 18 Service points on rollers fitted with Caterpillar erigines Scraper Drum oi] - sight Shock absorbers ai Articulated joint Steering cylinder: 3-speed gearbox a Universal joint Brakes Tyres ~ air press Wheel nuts Rear axle - Tubri Engine - lubricat Fuel tank - drain Fuel system - wat Diese? fuel - fil Engine - V-belts glass nd mounting screws s nd pump drive ure cating of] levels ing of] filter plug fer trap Jer cap CA 30 M-10202 Eng |Item in ae Lubricants fig 1 Operation with CAT engine Page see Page 1 EVERY DAY (every 10 hours of operation) 16... Scraper setting - adjust .. 1111 Coolant level = check 4.222 Engine ofl level - che a we BL 6 12. Hydraulic tank of] level ~ check .. Ne 12 .., Handbrake and foot brake - (test) adjust ...... 30... Fuel tank - replenish ... 29... Water trap - drain ...... 5... Air cleaner indicator - check s,s... EVERY WEEK (every 50 hours of operation) Engine oi] - change * and Engine oi] filter - replace * . on Air cleaner filter element - clean, and hoses an connections - inspect for leakage .... Battery - check . Drum of} level ~ check . Shock absorbers and mounting screws - inspect Articulated joint - grease .......0+6 Steering cylinder mountings - grease .. Universal joint - grease .. Tyre pressures ~ check .... Wheel nut tightness - check’ 1... : Torque hub oi] - change ** (only on D and PD machines SEE o 38 wees D 14 DAYS (every 100 hours of operation) 7 + 23 23 «2.05 D Engine valve clearances - check * Exterior of radiator - clean .. Torque hub 011 level - check (only MONTH (every 200 hours of operation) Fan belt and alternator V-belt tension - check . Engine oi] ~ change and engine oi] filter - replace ...... Air cleaner dust collector - clean .... Hydraulic oi filters - replace ........cccsscceeee Brakes - check, and adjust if necessary ........ Brake cylinder fluid level - check .....sssscsccse 3-speed gearbox and pump drive of] levels - check. Rear axle planetary gear oi] levels - check . Rear axle differential oil level - check ..... Hydraulic of? tank ~ drain off condensate . Controls, hinges and joints - lubricate . * Only on new or reconditioned engines ** Only on new rollers/torque hubs #** See the engine instruction manual CA 30 M-10202 Eng 3MAINTENANCE SCHEDULE ROLLER WITH CATERPILLAR D3208 NA ENGINE 12 34 $678 9 10112 3 14 29:28 2726 25 24 23 22 Fig 1 1 Cooling system - filler cap 2 Engine - fuel filter 3. Engine - valves 4 Engine - oi1 level 5 Air cleaner 6 Hydraulic of] tank - sight glass 7 Hydraulic of] tank - breather filter 8 Hydraulic of] filters (two) 9 Hydraulic of7 tank - drain 10 Battery 11 Hydraulic of] - filler cap 12 Handbrake and foot brake 13 Brake cylinder (foot brake) 14 Drum of] - filler plug 15 Torque hub (only on CA 30D and CA 30PD machines) 2120 19 8 16 7 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Service points on rollers fitted with Caterpillar erigines Scraper Drum 071 - sight Shock absorbers a Articulated joint Steering cylinder: 3-speed gearbox a Universal joint Brakes Tyres - air press Wheel nuts Rear axle - lubri Engine - lubricat Fuel tank - drain Fuel system - wate Diese? fuel - fil Engine ~ V-belts 15 16 7 glass nd mounting screws s nd pump drive ure cating oi] levels ing of] filter plug er trap Jer cap CA 30 M-10202 EngFat (0 Operation with CAT engine Lubricants Page see Page 1 EVERY THREE MONTHS (every 500 hours of operation) 1... Cooling system - flush . - s+. Crankcase ventilation diaphragm - inspect 1... Cooling system - replenish corrosion inhibitor vee 3... Engine valve clearances - adjust . ae 7... Hydraulic off tank breather filter - replace 37 EVERY SIX MONTHS (every 1000 hours of operation) 14... Drum of - change aie D 28 <2. Fuel tank - drain + 38 15... Torque hub of1 - change (only on D & PD machines) ....... 38 ..see D 2... Fuel filter - replace +39 = +1. Fuel system - bleed 139 EVERY YEAR (every 2000 hours of operation) 11... Hydraulic tank oi! - change ... 242. c 21... Pump drive and 3-speed gearbox oi] - change 44) D 26... Rear axle planetary gear oi] - change 245. D 26 <1. Rear axle differential oi] ~ change 2 46 D *#* See the engine instruction manual CA 30 M-10202 EngMAINTENANCE SCHEDULE ROLLER WITH DEUTZ F6L 912 ENGINE 1 2 34 5678 9 N12 np 4 5 16 31 29. roll 282726 25 «24 23 «22 2120 19 8 v7 Fig 2 Service points on rollers fitted with Deutz engines 1 Feed pump - fuel 16 Scraper. 2 Engine - valves 17 Drum oi] ~ sight glass 3. Engine - 011 level 18 Shock absorbers and mounting screws 4 Engine - fuel filter 19 Articulated joint 5 Air cleaner 20 Steering cylinders 6 Hydraulic oi] tank - sight glass 21 3-speed gearbox and pump drive 7 Hydraulic of] tank - breather filter 22 Universal joint 8 Hydraulic oi] filters (two) 23 Brakes 9 Hydraulic oi] tank - drain 24 Tyres - air pressure 10 Battery 25 Wheel nuts 11 Hydraulic of] - filler cap 26 Rear axle ~ lubricating oil levels 12 Handbrake and foot brake 27 Engine - lubricating oil filter 13 Brake cylinder (foot brake) 28 Fuel tank - drain plug 14 Drum of] - filler plug 29 Diesel fuel - filler cap 15 Torque hub (only on CA 30D and 30 Engine - V-belts & V-belt monitor CA 30PD machines) 31 Hydraulic 011 cooler CA 30 M-10202 EngLubricants Page see Page1 Item in Fig2 Operation with DEUTZ engine EVERY DAY (every 10 hours of operation) 16 ... Scraper setting - adjust 3... Engine oi1 level - check co 81 6 <2. Hydraulic tank of1 level ~ ‘check’ 1..2222122 50 12... Handbrake and foot brake - (test) adjust . 29... Fuel tank - replenish 5... Air cleaner indicator - check . 2... Engine valve clearances ~ check * EVERY WEEK (every 50 hours of operation) 3... Engine oi] - change * and Engine oi] filter - replace * ........... Air cleaner filter element - clean, and hoses and connections - inspect for leakage ...... » Battery - check ...... + Drum of} level ~ check . + Shock absorbers and mounting screws ~ inspect + Articulated joint - grease .. + Steering cylinder mountings ~ grease B>> oc Universal joint ~ grease . Tyre pressures - check . Whee? nut. tightness - chec Torque hub oi] - change ** (only on D and PD machines) . EVERY 14 DAYS (every 100 hours of operation) oe 31. 15. Engine cooling fins - clean ...... seueene nes Hydraulic of] cooler - clean externally ...ssesseseseeees 23 Torque hub oi] level - check (only on D and PD machines) 23 ...... D EVERY MONTH (every 200 hours of operation) 30... V-belt monitor - check . teereees 30... Fan belt and alternator V-belt tension - check . 3... Engine of] - change and ....... 27... engine oi] filter ~ replace ...... 5... Air cleaner dust collector - clean . e 8... Hydraulic of] filter = replace ...s.s.ee5 0 23... Brakes - check, and adjust if necessary .........5 13... Brake cylinder fluid level - check ...s.eeseee 21 ... 3-speed gearbox and pump drive of] levels - check 26 ... Rear axle planetary gear oi] levels ~ check ....... 26 ... Rear axle differential oi] level - check ....... 9... Hydraulic of] tank - drain off condensate ........ ++. Controls, hinges and joints - lubricate ........ * Only on new or reconditioned engines ** Only on new rollers/torque hubs ** See the engine instruction manual CA 30 M-10202 EngMAINTENANCE SCHEDULE ROLLER WITH DEUTZ F6L 912 ENGINE 1 2 34 5678 9 on? 6B 4 15 16 282726 25 24 23 22 2120 19 18 7 Fig 2 Service points on rollers fitted with Deutz engines 1 Feed pump - fuel 2 Engine - valves 3 Engine - oi! level 4 Engine - fuel filter 5 Air cleaner 6 Hydraulic of] tank - sight glass 7 Hydraulic oi] tank - breather filter 8 Hydraulic of] filters (two) 9 Hydraulic off tank - drain 10 Battery 11 Hydraulic off - filler cap 12 Handbrake and foot brake 13. Brake cylinder (foot brake) 14 Drum of] - filler plug 15 Torque hub (only on CA 30D and CA 30PD machines) 7 18 19 20 21 Scraper, Drum oi1 - sight glass Shock absorbers and mounting screws Articulated joint Steering cylinders 3-speed gearbox and pump drive Universal joint Brakes Tyres - air pressure Wheel nuts Rear axle - lubricating oi] levels Engine - lubricating oi] filter Fuel tank ~ drain plug Diesel fuel - filler cap Engine - V-belts & V-belt monitor Hydraulic oi1 cooler CA 30 M-10202 EngFea” Operation with DEUTZ engine Lubricants Page _see Page 1 EVERY THREE MONTHS (every 500 hours of operation) 2. Engine valve clearances - adjust . cine + Hydraulic oi] tank breather Filter ~ replace : 37 EVERY SIX MONTHS (every 1000 hours of operation) 14... Drum oil - change . Boon ele D 28... Fuel tank ~ drain: 2 38 15 12. Torque hub of] - change (oniy on D & PD machines) 2 3B ee D | 4... Fuel filter element - replace a) | = s+. Fuel system - bleed . + 40 | 1... Fuel feed pump stra it EVERY YEAR (every 2000 hours of operation) Hydraulic tank 011 - change .... Pump drive and 3-speed gearbox oi] - change . Rear axle planetary gear oi] - change Rear axle differential oi] - change e000 *** See the engine instruction manual CA 30 M-10202 EngMAINTENANCE SCHEDULE ROLLER WITH GM 3-53-T ENGINE 1234 5678 9 10112 3 4 15 16 28 27 26 25 «24 23° 22 2120 19 18 7 Fig 3 Service points on rollers fitted with GM (Detroit) engines 1 Cooling system - filler cap 16 Scraper 2 Engine - fuel filter 17 Drum of1 ~ sight glass 3. Engine - valves 18 Shock absorbers and mounting screws 4 Engine - oi] level 19 Articulated joint 5 Air cleaner 20 Steering cylinders 6 Hydraulic oi] tank - sight glass 21 3-speed gearbox and pump drive 7 Hydraulic oi] tank - breather filter 22 Universal joint 8 Hydraulic of] filters (two) 23 Brakes 9 Hydraulic oi] tank - drain 24 Tyres - air pressure 10 Battery 25 Wheel nuts 11 Hydraulic of1 - filler cap 26 Rear axle - lubricating oi] levels 12 Handbrake and foot brake 27 Engine - lubricating of] filter 13 Brake cylinder (foot brake) 28 Fuel tank - drain plug 14 Drum of] - filler plug 29 Diesel fuel - filler cap 15 Torque hub (only on CA 30D and 30. Engine - V-belts CA 30PD machines) 31 Engine air box - drain 10 CA 30 M-10202 EngItem in ; Lubricants Fig 3 Operation with GM engine Page see Page 1 EVERY DAY (every 10 hours of operation) 16... Scraper setting - adjust ....... 214 1.2) Coolant level = check ...s.e.eee e M4 + Engine oi] level ~ check Bee eestor + 14,15... B2 : Hydraulic tank of] level - check .......cceee 5 —c Handbrake and foot brake - (test) adjust ........eee...0. 16 : Fuel tank - replenish ........66 eee eee cena ial Fuel filters ~ drain ...... once eee eeee tli «Air cleaner indicator ~ check eee reared EVERY WEEK (every 50 hours of operation) 4... Engine of] = change * and 27... Engine oi] filter ~ replace * ....sseeseseeeeeeeneeeeeees 5... Air cleaner filter element - clean, and hoses and connections - inspect for leakage 18 10 ... Battery - check ........:sececcsecccessecucssecooresecars 19 ++ Drum of7 level - check .......05 eee eee 20D + Shock absorbers and mounting screws - inspect . : +++ Articulated joint - grease .. ee A ii. Steering cylinder mountings - grease ........cesseseeeeee A « Universal joint - grease .... See eee A + Tyre pressures - check .. on : sss Wheel nut tightness ~ check .... Beereneesece ees 15... Torque hub oj] - change ** (only on D and PD machines) .. D EVERY 14 DAYS (every 100 hours of operation) 3... Engine valve clearances ~ check * ....++++ : 1... Exterior of radiator ~ clean ..csessccseeeeeeseeceeees 15 121 Torque hub oi1 level - check (only on D and PD machines) D EVERY MONTH (every 200 hours of operation) 30 ... Fan belt and alternator V-belt tension - check .......... 26 4°... Engine of] ~ change and . Gyocceceecas : B2 27... engine of] filter - replace .... Fuel filter - replace .....ssseeeeeeees + Fuel system - bleed .. 5 5... Air cleaner dust collector - clean ...sssessseeeeeeeeeees 8... Hydraulic of! filter - replace ....ssscssceeceeeeeeeeeeee 23 ... Brakes - ‘check, and adjust if necessary .. é 13... Brake cylinder fluid level - check se.esseeseeeseeeeeeeee E 21... 3-speed gearbox and pump drive oi] levels - check ....... D 26... Rear axle planetary gear of] levels ~ check D 26 ... Rear axle differential of] level - check . D 9... Hydraulic of] tank ~ drain off condensate .. =... Controls, hinges and joints - lubricate .. 8 * Only on new or reconditioned engines ** Only on new rollers/torque hubs *** See the engine instruction manual CA 30 M-10202 Eng ulMAINTENANCE SCHEDULE ROLLER WITH GM 3-53-T ENGINE 7a gn 3 4 15 16 28 2726 25 «24 23° «22 «2120 19 18 7 Fig 3 Service points on rollers fitted with GM (Detroit) engines 1 Cooling system - filler cap 16 Scraper 2 Engine - fuel filter 17 Drum oi] - sight glass 3 Engine - valves 18 Shock absorbers and mounting screws 4 Engine - oi] level 19 Articulated joint 5 Air cleaner 20. Steering cylinders 6 Hydraulic of] tank - sight glass 21 3-speed gearbox and transfer box 7 Hydraulic of] tank - breather filter 22 Universal joint 8 Hydraulic of] filters (two) 23 Brakes 9 Hydraulic of] tank ~ drain 24 Tyres - air pressure 10 Battery 25 Wheel nuts 11 Hydraulic of] - filler cap 26 Rear axle - lubricating of1 levels 12 Handbrake and foot brake 27 Engine - lubricating oi] filter 13 Brake cylinder (foot brake) 28 Fuel tank - drain plug 14 Drum ofl - filler plug 29 Diesel fuel - filler cap 15 Torque hub (only on CA 30D and 30 Engine - V-belts CA 30P0 machines) 31 Engine air box - drain 12 CA 30 M-10202 Engtem in —— , Lubricants Fig3 Operation with GM engine Page see Page 1 EVERY THREE MONTHS (every 500 hours of operation) 1... Cooling system - replenish corrosion inhibitor . +++ Engine valve clearances - adjust . -++ Hydraulic oi] tank breather Filter - replace EVERY SIX MONTHS (every 1000 hours of operation) 14... Drum oi] - change . D 28... Fuel tank ~ drain . 15 ... Torque hub ofl - change (only on D & PD machines) 31111 Air box drain tube - check YEAR (every 2000 hours of operation) « lydraulic oil tank of] - change ........ Pump drive and 3-speed gearbox of] - cha Rear axle planetary gear oil - change . Rear axle differential oi7 - change Cooling system - flush .......+.++ nge *#* See the engine instruction manual CA 30 M-10202 Eng 13EVERY DAY (every 10 hours of operation) Scrapers — adjusting Adjust the scraper setting as follows: 1 Loosen al] four mounting screws. 2 Set the scraper approx. 10 mm (0.4 in) away from the drum. 3. Retighten the mounting screws. Fig 4 Front scraper 2 1 Mounting screws 2 Scraper Radiator — checking the coolant level @ CAT& GM CAUTION! AT OPERATING Coolant levels should be checked each day before TEMPERATURES THE COOLANT the machine is run. If the coolant level must be IS HOT AND PRESSURIZED. IF THE checked at operating temperature the engine should CAP IS REMOVED QUICKLY, COOLANT be switched off first. WILL BE RELEASED IN THE FORM OF STEAM AND MAY CAUSE SCALDING. USE GLOVES AND PROTECTIVE GOGGLES. } 1 Place a piece of cloth or the like over the filler cap and turn the cap to the first stop. When the pressure has fallen, press down the cap, turn it further and remove it. The coolant K level should reach up to the level tab in the l radiator. ’ 2 If necessary, replenish with water and corro- sion inhibitor (CAT 3P2044 or equivalent). In Fig 5 Radiator winter, add anti-freeze as well. 1 Filler cap Engine — checking the oil ® level Drive the roller onto a level surface and switch off the engine. Remove the dipstick (1) and check the of] level. If the oil is close to or below the lower mark, replenish with grade B1 oil for CAT & DEUTZ and B2 oil for GM, as recommended on page 1 under "Lubricants". NS Fig 6 Engine 1 Dipstick 2 Filler cap 14 CA 30 N-10202 EngFig 7 Checking the oi1 level 1 2 3 4 5 Hydraulic tank — checking Dipstick Filler cap Drain plug Lower mark Upper mark the oil level Fig 9 Hydraulic of] tank 1 Hydraulic tank — replenishing Sight glass with oil Fig 10 Battery box 1 Pump lever 2 Protective plug 3° Suction hose Fig 8 Checking the of] level 1 Dipstick 2 Filler cap a Drive the roller onto a level surface and check the level of the oi] in the sight glass (1). If the oil level is more than 2 cm (0.75 in) below the top of the sight glass, replenish with grade C 011, as recommended on page I under "Lubricants". 3. Take the suction hose (3) out of the battery box. 4 Unscrew the protective plug (2) from the hose. 5 Insert the end of the hose into a drum of new grade G hydraulic oi] as recommended on page 1 under "Lubricants", 6 Operate the pump lever (1) to pump hydraulic of] into the tank, up to the full tank mark on the sight glass. Pump the hydraulic of] through a filter into the tank. Always use this procedure when re- plenishing the of] tank. CA 30 M-10202 Eng 15Handbrake — adjusting/testing Fig 11 Handbrake 1 Adjusting knob Foot brake — testing Fuel tank — replenishing fg Fig 12 Fuel tank 1 Filler cap 1 The brake is correctly adjusted when it is just possible to pull up the lever completely. 2 Adjust the brake by turning the lever knob clockwise. Test the action of the foot brake. If necessary, adjust in accordance with "Foot brake - adjust- ing", on page 33. Replenish the fuel tank daily to the lower edge of the filler neck. Use diesel fuel. Refer to the appropriate manufacturer's instruc- tions for the grade of diesel fuel. 16 CA 30 M-10202 EngWater trap — draining CAT 1 Open the air valve (1). 2 Open the drain cock (2). 3. After the water has drained, close the air valve (1) and the drain cock (2). Replace the water trap element (3) when the inside of the water trap is so dirty that the water level is no longer visible through the glass. Fig 13. Engine 1 Air valve 2 Drain cock 3 Element. Fuel filters — draining 1 Open the drain cocks (1) on both filters and let the water drain out. 2 Close the cocks. Fig 14 Engine 1 Drain cocks Air cleaner — checking the dust indicator ® The air cleaner is fitted with a pressure-drop indicator, which is connected to a warning Tamp on the instrument panel. If the air cleaner warning lamp Tights up when the engine is running at full speed, clean the filter (see under "WEEKLY", "Air cleaner - cleaning the filter element", on page 18). Fig 15 Engine - air cleaner 1 Pressure-drop indicator CA 30 M-10202 Eng VvWEEKLY (every 50 hours of operation) Air cleaner — cleaning the main filter element Fig 16 Air cleaner Filter housing Back-up filter Outer cover/dust collector Clamp Inner cover Main filter Pressure-drop indicator Main filter — cleaning with compressed air Fig 17 Main filter Release the clamp (4) and remove the outer cover (3). Unscrew the wing nut in the centre of the filter and remove the inner cover (5). Use a clean cloth to clean the outer cover (3). Unscrew the wing nut and remove the main filter (6). Make sure that dust has not entered the filter during operation. Check that dust has not pene- trated into the engine induction pipe. If it has, this means that the connections, hoses or element Teak and must therefore be replaced. 5 Wipe clean the inside of the filter housing (1) and the induction pipes, using a clean cloth. 6 Check all connections between the air cleaner and the engine to be certain they are tight and do not Teak. NOTE Replace the back-up filter after it has been cleaned three times or at every third change of the main filter. The back-up filter cannot be cleaned, Use compressed air at a maximum pressure of 0.7 MPa (7 kgf/cm?) (100 psi). Play the compressed air up and down along the folds of the paper at 45° to the inside of the filter element. Hold the nozzle at least 1 cm (0.4 in) away from the element to avoid damaging the paper. NOTE Do not replace a filter element that has been washed in detergent until it is completely dry. 18 CA 30 M-10202 EngMain filter — cleaning by washing Battery — checking the electrolyte level Fig 18 Battery box 1 Battery NEVER USE A NAKED FLAME AND KEEP SPARKS AWAY WHEN CHECKING THE ELECTROLYTE LEVEL, SINCE EXPLOSIVE GAS IS FORMED IN THE BATTERY WHEN IT IS BEING CHARGED. 10mm (oa in) Fig 19 Battery electrolyte level 1 Cell plug 2 Electrolyte level 3 Plate If the filter element is sooty or oily, it should be washed in a solution of water and non-foaming detergent, such as “Donaldson D-1400". The element should be totally inmersed in a detergent solution and soaked for at least 15 minutes. Raise and lower the element in the solu- tion from time to time to improve the cleaning effect. Make sure that the filter element is intact before refitting it. If it has any holes or if the seals are defective, fit a new element. Shine a lamp through the filter when inspecting to ensure that it is clean and that there are no holes in it. 1 Tilt the seat forward. 2 Wipe the top of the battery clean. WARNING: THE ROLLER BATTERY CONTAINS SULPHURIC ACID. IF ACID GETS ON THE SKIN OR IN THE EYES, FLUSH IMMEDIATELY WITH LARGE QUANTITIES OF WATER AND GET MEDICAL ATTENTION. 3 Remove the cell] filler plugs and ensure that the level of the liquid is approx. 10 mm (0.4 in) above the plates, Check all the cells, If the level is low, top up to the correct level with distilled water. If the air temperature is below freezing, run the engine for a while after adding the dis- tilled water, since the water may otherwise freeze, 4 Ensure that the breather holes in the cell filler plugs are not blocked. Then replace the plugs. 5 The cable terminals should be clean and securely tightened. If corroded, clean them and coat them with acid-free petroleum jelly. CA 30 M-10202 Eng 19Drum — checking the oil level sy , 1 Drive the roller onto a level surface, so that the plug (1) is at its highest position. Later models are also fitted with a level pin (3), which should be level with the top of the frame member when the plug is at its highest position. 2 The oi1 level should reach approximately half- way up the sight glass (2), Fig 20 Checking the drum 3. Top up, as necessary, using grade D oi! as oil Tevel recommended on page i under "Lubricants", but not more than half-way up the sight glass. 1 Filler plug 2 Sight glass 4 Check the other side of the drum according to 3. Level pin (later models) 1-3 above. Shock absorbers and mounting screws — checking Ensure that the shock absorbers are undamaged and that the mounting screws are correctly tightened. Replace shock absorbers when 20-25 mm (0.75-1 in) deep cracks are detected in them. Use the blade of a knife or other pointed object when carrying out the inspection. ~~ Fig 21 Drum 1 Shock absorbers 2. Mounting screws Articulated joint oe ENSURE THAT THE VICINITY OF THE ARTICULAT- ED JOINT IS CLEAR OF PERSONAL WHEN THE EN- GINE IS RUNNING. INJURTES COULD OCCUR IF THE STEERING IS OPERATED. 1 Turn the drum section to the left so that all the grease nipples on the right-hand side of the articulated joint are accessible. Clean any dirt and grease off the four nipples. Grease each nipple with five strokes of the grease gun. Ensure that grease enters the bea- rings. 4 Turn the drum section to the right and apply grease to the nipples on the left-hand side of the articulated joint in the same manner. Use grade A grease as reconmended on page 1 under "Lubricants". Leave a little grease on the nipples after greasing, to prevent dirt from entering them, Fig 22 Grease nipples NOTE If the grease does not enter the bearings, - articulated joint it may be necessary to reduce the load on the articulated joint using a jack, and then repeat the lubrication procedure. 20 CA 30 M~10202 EngSteering cylinders — lubricating —_ Grease the left-hand steering cylinder mounting immediately after greasing the articulated joint. 1 Clean any dirt and grease off the two nipples. 2 Grease each nipple with three strokes of the grease gun. Ensure that grease enters the bearings. Use grade A grease as recommended on page 1 under "Lubricants". Leave a little grease on the nipples after greasing, to prevent dirt from entering them. 3 Grease the two nipples on the right-hand steering Fig 23. Grease nipples - cylinder in the same manner. Check that grease steering cylinder enters the bearings. Universal joint — lubricating —, CAUTION! NEVER WORK UNDER The grease nipples on the universal joint are THE ROLLER WHEN THE ENGINE accessible from underneath the roller. IS RUNNING. APPLY THE HANDBRAKE, BLOCK THE DRUM AND WHEELS. 1 Crawl under the roller and check that. the grease nipples are accessible with the grease gun. It may be necessary to drive the roller forward slightly, to rotate the universal joint and move the nipples into an accessible position. 2 Clean any dirt and grease off the two nipples. 3. Grease each nipple with two strokes of the grease gun ensuring that grease enters the bearings. Use grade A grease as recommended on page 1 under "Lubricants", Leave a little grease on the nipples after greasing, to prevent dirt from entering them. Fig 24 Grease nipples = universal joint CA 30 M-10202 Eng a1Tyre pressures ef Check the tyre pressures using a tyre pressure onse. yA] (®) The minimum tyre pressure is: : 0.11 MPa (1.1 kgf/cm?) (15.65 psi) uv 2 and the maximum tyre pressure is S50Nm 0.15 MPa (1.5 kgf/cm?) (21.3 psi). (S5kpm) (405 1b. ft) Check both tyres. Fig 25 Wheel 1 Air valve 2 Wheel nut Whee! nuts — tightening Check that the wheel nuts are tightened to a torque of 550 Nm (55 kgf m) (405 ft.1b). Check al nuts on both wheels. | | | 22 CA 30 M-10202 EngEVERY 14 DAYS (every 100 hours of operation) Radiator — cleaning the exterior caecM Ensure that air can flow freely through the radiator. If the radiator is dirty, clean it by flushing with water or by blowing through with compressed air through it. After cleaning, ensure that seals and sound-absorbers are not damaged. Hydraulic oil cooler — cleaning the exterior Ensure that air can flow freely through the cooler. If the cooler is dirty, clean by flushing with water or by blowing compressed air through it. After cleaning, ensure that seals and sound- absorbers are not damaged. Engine cooling fins — cleaning DEUTZ 1 Release the catches and remove the air ducting from the engine. 2 Clean the cooling fins carefully, preferably using compressed air, (Refer to the manufactu- rer's instruction manual for more detailed in- structions). Fig 26 Engine - cooling Fins Torque hub — checking the oil level a only applies to CA 30D and CA 30PD machines. —m~LEeR] 1 Drive the roller onto a level surface so that — the filler plug (1) is at its uppermost posi~ 6 2 Clean any dirt and grease off the area around the plugs. 3 Remove the plugs and check that the oil level is up to the level plug (2). 4 If necessary, replenish with grade Doil as recommended on page 1 under "Lubricants". 5 Refit the plugs. Fig 27. Replenishing with of7 1 Filler plug 2 Level/drain plug CA 30. M-10202 Eng 23EVERY MONTH (every 200 hours of operation) V-belt tension — check a Check the tension of the fan, water pump and alter- nator belts by pressing the belts mid-way between the alternator pulley and the water pump pulley. It should not be possible to depress the belts by more than 6-7 mm (0.25 in). Fig 28 Checking V-belt tension V-belts tensioning 1 Loosen the alternator mounting screws (A) slightly. 2 Ease the alternator outwards until the belt is again correctly tensioned. 3. Retighten the screws (A). Jv IF THE FAN GUARD HAS BEEN REMOVED, IT MUST BE REFITTED BEFORE THE ENGINE IS STARTED AND THE ROLLER OPERATED. Fig 29 Tensioning the V-belts 1 Alternator | 2 Water pump/fan 3 Crankshaft | 24 CA 30 N-10202 EngFAN BELT V-belt monitor DEUTZ Fig 30 Checking the V-belt and V-belt monitor 1 V-belt monitor 2 Belt tensioner V-belt monitor — check V-belt failure or replacement CA 30 M-10202 Eng The belt is tensioned by a spring-loaded belt tensioner (2). If the belt breaks, the belt ten- sioner will be moved outwards by the spring and will actuate the pressure switch on the belt moni- tor (1) causing the horn to sound, The V-belt monitor is also operative when the starter key is in the "OFF" position. Depress the switch (1 in Fig 30). The roller horn should sound. If the alarm device is defective, it should be repaired inmediately. 1 Park the roller in a safe place. 2 Stop the engine. 3 Disconnect the battery lead from the battery, to stop the horn. 4 Fit a new V-belt (see the engine manufacturer's instruction manual). 5 Refit the battery lead and secure it. 25V-belt tension — check DEUTZ 10-15mm (04 -06 in) Fig 31 Checking the V-belt tension 1 V-belt monitor Adjusting Fig 32. Tensioning the alter- nator V-belt V-belt tension — check Fig 33 Checking the V-belts 1 Alternator 26 Check the belt tension by pressing the belt mid- way between the alternator pulley and the crank- shaft pulley. It should not be possible to depress the belt by more than 10-15 mm (0.4-0.6 in). If the deflection is greater, the belt must be ten- sioned, At the same time, ensure that the monitor for the fan belt operates satisfactorily. The horn should sound when the monitor switch (1) is depressed. 1 Loosen the alternator mounting screws (B) and (C) and nut (0). 2 Press the alternator outwards until the belt is again correctly tensioned (see above). 3 Retighten the screws (B), (C) and the nut (D). Check the belt tension by pressing the belt mid- way between the alternator pulley and the water pump pulley. It should not be possible to depress the belts by more than 13-19 nm (0.5-0.75 ‘n) For adjustment of the alternator belt (see above for CAT, Fig 29). For adjustment of the fan belt, refer to the engine manufacturer's instruction manual. CA 30 M-10202 EngGeneral about diesel engine lubrication Engine — devitations from the normal oil change interval NOTE Irrespective of the ‘umber of hours of operation, the engine oil and engine off filter must be changed every six months. The oil filter must always be replaced when the engine ofl is changed. Engine — changing the oil CAT Fig 34 Filling up with oi] = engine i O17 filler cap Fig 35 Draining the engine oil 2_Drain plug 011 change intervals are dependent on the grade of lubricating of] and the sulphur content of the fuel. Changing the of1 every month or every 200 hours of operation is conditional on the use of engine oi] of grade "For API Service CD, SAE" and on the use of diesel fuel of good quality, with a sulphur content below 0.4%, If oi of grade "For API Service CC/SC, SAE" is used or if the sulphur content of the diesel fuel is 0.4% or above, the oi] should be changed ear- lier and more frequently (see the engine manu~ facturer's instructions). Warm up the engine thoroughly before draining the oil. Impurities in the lubricating system will then be well mixed with the oi] and will be removed with it. Furthermore, the oi] flows more readily when it is hot. Note the different oil recommendations for CAT & DEUTZ and GM (see page 1, “Lubricants"). ©, Clean the area around the oi] filler cap (1) and remove it. 2 Clean the area around the drain plug (2) and place a receptacle to hold at least 15 litres (4 US gallons) under the plug. 3 Remove the drain plug and allow the of] to drain into the receptacle while replacing the of] filters. Ensure that a receptacle is placed under the filters when they are replaced. 4 Wipe the drain plug clean. Fit it back into place and tighten it securely. CA 30 M-10202 Eng 27Engine — replacing the oil filters CAT & Fig 36 Engine 4 1 Oi] filters Engine — replenishing with oil caT @, 2 Fig 37 Engine 3 1 Filler cap 2 Dipstick 4 Remove both oi] filters (1) and discard them. They are of the disposable type and cannot be cleaned. NOTE Ensure that the old seals are not left on the filter head since leakage would then occur between the new and old seals. Clean the sealing surfaces of the filter head with a clean, lint-free cloth. Apply a thin film of clean engine oi] to the new filter seals. Screw the filters by hand until the seal seats against the filter head. Then tighten it an additional half-turn, NOTE Do not tighten the filters too much, since this may damage the seals. Replenish with fresh grade B1 oi] as reconmended on page 1 under "Lubricants". O47 capacit o 14.5 litres (3.85 US gallons), when changing the filters. o 13.5 litres (3.57 US gallons), when the filters are not changed. ee the engine oi1 level using the dipstick 2). The level should be up to the FULL mark. Do not overfill, since this may cause damage to the crankshaft seals. Refit the filler cap (1). Tighten it firmly, ensuring that it seals satisfactorily. Start and warm up the engine. Ensure that there are no oi] leaks. 28 CA 30 M-10202 EngEngine — changing the oil oO DEUTZ 1 Remove the filler cap (2). 2 Remove the drain plug (3) and allow the oil to drain out into a suitable receptacle to hold at least 13 litres (3.5 US gallons), while chang- ing the oi] filter, Clean the drain plug (3) and refit it. Fig 38a Engine Dipstick Filler cap Drain plug Lower level mark Upper level mark Engine — a) replacing the oil filter DEUTZ 1 Fit a drift or screwdriver into the shoulder of the filter (2) and slacken the filter, 2 Unscrew the filter by hand. NOTE Ensure that the old seal is not left on the filter head since leakage would then occur between the new and old seals. 4 Lightly of] the rubber seal (1) on the new filter. Fig 39 Engine 5 Screw the filter. into place by hand until the 1 Rubber seal rubber seal seats correctly and then turn the 2 Oi1 filter - shoulder filter an additional half-turn. NOTE Do not tighten the filter too much, since this may damage the seal. Engine — replenishing with oll (,\ 1 pee Replenish with new grade B1 oil as recommended on page 1 under "Lubricants". Oi1 capacity: approx. 12 1 (3.17 US gallons). 2 Check the of1 level using the dipstick (1). The Jevel should be at the upper mark (5 in Fig 38a). If necessary, replenish with more oi]. 3. Refit the filler cap (2 in Fig 38a). 4 Start and warm up the engine. Ensure that there are no oi] leaks. 3. Clean the sealing surfaces of the filter holder. CA 30 M-10202 Eng 29Engine — changing the oil yy HAL 4 YW f Fig 40 Engine 1 Drain plug © 1 Engine — replacing the oil filters (3) Fig 41 Engine 1 Filler cap 2 Disptick 3 041 filter Engine — replenishing with oil GM Clean the area around the drain plug (1) and then place a receptacle to hold at least 12 Titres (3.2 US gallons) under the plug. Clean the area around the oi1 filler cap (1 in Fig 41) and then remove the cap. Remove the drain plug and allow the oi] to drain ‘into the receptacle while replacing the oi! filter. Wipe the drain plug clean. Fit it back into place and tighten it securely. Remove the oi] filter (3) and discard it. It is of the disposable type and cannot be cleaned. NOTE Ensure that the old seal is not left on the filter head, since leakage would then occur between the new and old seals. Clean the sealing surface of the filter head with a clean, lint-free cloth. Apply a thin film of clean engine of] to the new filter seal. Screw the on filter by hand until the seal seats against the filter head. Then tighten it an additional half-turn. NOTE Do not tighten the filter too much, since ~~ this may damage the seal. Replenish with fresh grade B2oil as reconmended on page I under "Lubricants". O41 capacity: ° 10 litres (2,65 US gallons), when changing the filters 0 9 litres (2.38 US gallons), when the filters are not changed. Check the engine of] level with the dipstick (2 in Fig 41). The level should be up to the FULL mark. Do not overfill, since this may cause damage to the crankshaft seals. Refit the filler cap (1 in Fig 41). Tighten it firmly, ensuring that it seals satisfactorily. Start and warm up the engine. Ensure that there are no oil leaks. 30 CA 30 M-10202 EngFuel filters — replacing Fig 42 Fuel filter 1 Retaining screws 2 Drain cocks Fuel system — bleeding GM CA 30 M-10202 Eng Hold a suitable receptacle under the filters. 1 Remove the fuel filters by first unscrewing the drain cocks (2), Then unscrew the retaining screws (1). 2 Remove the filter element holders and lift out the filter elements. 3 Clean the filter element holders in clean diesel fuel. 4 Soak the new filter elements in diesel fuel and fit them into the filter element holders. 5 Close the drain cocks and fill the filter ele- ment holders with clean diesel fuel. 6 Fit new seals and refit the filter element holders. 7 Tighten the retaining screws only sufficiently to achieve a good seal. If air has entered the fuel system, the engine will either fail to start or will misfire. The fuel system must then be bled. 1 Stop the engine, 2 Remove both fuel filters and fill the filter element holders with fuel. 3 Remove one rocker cover and one fuel supply line, and run the engine a few revolutions, to expel the air from the system. 4 Retighten the fuel line and ensure that fuel does not leak from the pipe.Air cleaner — cleaning the dust collector ® 1 Release the catch (3) and remove the dust col- lector (1). 2 Empty the dust collector and wipe it clean. 3 Check the seals and replace any that are dam- aged. Ensure that the hoses and connections do not leak. The dust collector is fitted with a self-dis- charging valve (2). This valve discharges dust and water continuously. Fig 43. Air cleaner 1 Outer cover/dust collector 2 Valve 3. Catch Hydraulic oil filters tH — replacing Remove the hydraulic oi] filters (1). Discard the filters. They are of the disposable type and cannot be cleaned. NOTE Ensure that the old seals are not left on the filter head, since leakage would occur between the new and old seals. Clean the sealing surface of the filter heads carefully. Fig 44 Hydraulic of7 tank 3. Apply a thin film of clean hydraulic oi] to the 1 Hydraulic of1 filters new filter seals, 4 Tighten the filter by hand. First screw the filter until the seal seats against the filter head. Then tighten it an additional half-turn. NOTE Do not tighten the filter too much, since this may damage the seal. 5 Start the engine and check that there is no leakage around the filters. 32 CA 30 M-10202 EngFoot brake — adjusting NEVER WORK UNDER THE ROLLER WHEN THE ENGINE IS RUNNING. BLOCK THE DRUM AND WHEELS IF NECESSARY, Fig 45. Brake drum - inside the rear axle 1 Cams Brake cylinder — checking © the fluid level SS Fig 46 Brake cylinder - checking the fluid level 1 Filler plug If the braking system has no leaks and the brake pedal must be depressed a long way before the brakes act and the fluid level is correct, it will be necessary to adjust the brake shoes. This adjustment compensates for brake lining wear. Adjustment is achieved by means of the cams on the backplate. These are accessible from beneath the roller. Park the roller on flat ground and place chocks under the wheels. Each brake has two cams - one for each brake shoe. Both cams must be adjusted to obtain the correct setting. 1 Adjust the cam (1) until the brake lining is in contact with the brake drum, 2 Then back off the cam until the brake lining is just clear of the drum. 3. Adjust the other brake shoes in the same manner. 4 Drive the roller a few hundred metres, without using the brakes. 5 Feel the brake drums with your hand, If a brake drum is hot, this indicates that one or both of the brake shoes are in contact with.it. In that case, back off the cama little further. Allow the brake drums to cool, then carry out another trial run in the same manner, 6 Operate the roller and apply the brakes to check that they act satisfactorily. 1 Thoroughly clean the area around the filler plug (1) and remove it. 2 Ensure that the fluid level is up to the bottom of the filler hole. If the level is low, replenish to the mark with brake fluid. Use grade E brake fluid as recommended on page 1 under "Lubricants". CA 30 M-10202 Eng 333-speed gearbox — checking the oil level << B Fig 47 Checking the 3-speed gearbox oi] level 1 Level plug 2 Drain plug Pump drive — checking the oil level t Fig 48 Checking the of1 level 1 Filler plug 2 Level plug 3 Drain plug Ensure that the roller is standing on a level surface when checking the ofl level. Clean the area around the level plug (1) and remove it. Ensure that the oi] level reaches up to the plug hole. If the oi] level is low, replenish with grade D oi] as recommended on page 1 under "Lubricants". Replenish with of] through the level plug (1) hole. Refit the plug and tighten it securely. Ensure that the roller is standing on a level surface, Clean the area around the level plug (2) and Joosen the plug a few turns. Oi1 should run out if the ofl level is correct. If necessary, replenish with oil through the filler plug (1) hole until the of] runs out through the Tevel plug (2) hole. Clean the area around the filler plug before removing it. Replenish with grade D oi] as recommended on page 1 under "Lubricants". NOTE A level plug is located on each side of the pump drive. The oi1 level need only be checked on one side. 34 CA 30 M-10202 EngRear axle planetary gears — checking the oil level 1 Drive the roller onto a level surface, until one of the planetary gear level plugs (1) is in the correct position. The mark (2) on the planetary gear housing should then be horizontal. 2 Remove the level plug and check that the oi] level is up to the plug hole. If the of] level is low, replenish with of] to the correct level, through the level plug hole. Replenish with grade D of] as recommended on page 1 under "Lubricants". 3 Check the planetary gear oi] level on the other side in the manner described in 1 and 2 above. Fig 49 Checking the planetary gear oi] level 1 Filler and level plug 2 Oi] level mark Rear axle differential — checking the oil level g CAUTION! NEVER WORK UNDER THE ROLLER WHEN THE ENGINE IS RUNNING, PARK THE: ROLLER ON A LEVEL SURFACE, PLACE CHOCKS UNDER THE WHEELS. 1 Ensure that the roller is standing on a level surface. 2 Remove the level plug (2) and check that the oi] level is up to the plug hole. If the oi] level is Tow, replenish to the cor rect level through the level plug hole. Replenish with grade D of] as recommended on page 1 under "Lubricants", Fig 50 Checking the differential housing of1 level 1 Drain plug 2 Level plug CA 30 N-10202 Eng 35