PIN 11 14 66 MAINTENANCE CA 51/55 VIBRATORY ROLLERS Caterpillar 03208 diesel engine Hydromatik & Rockwell CONTENTS Page Page Lubricants ....... 1 Every three weeks .7 Maintenance schedule . 2 Every month ... 219 Daily . 6 Every three months + 26 Weekly 9 Every six months 27 Every 14 days 6 Every year .... + 28 Special instructions . poeaad READ THROUGH THE INSTRUCTIONS BEFORE COMMENCING ANY SERVICE WORK. Proper maintenance is essential to ensure that the roller will give many years of satisfactory service and the instructions given here should therefore be followed carefully. Also keep the engine instruction manual near at hand. LUBRICANTS ABC Dand E refer to the maintenance schedule. Always use high grade lubricants in the stated amounts. Ex- cessive grease or oi] will cause parts to run hot, thus causing rapid wear. @ Grease with lithium base and EP additive (lead oleate), NLGI No. 2, Shel1 Alvania EP Grease 2. Q@BENGINE OIL For API Service CD/SE, SAE 10/30 Air temperature The instructions for the diesel engine (of1 change 32°C and above | SAE 10N/30 | intervals, etc) described 712°C = 0°C | SAE 10W | in the manufacturer's in- = 7°C = 432°C | SAE 20 struction manual should be above +32°C_: | SAE 30 followed, in addition to the measures listed here. Q©PHyDRAULIC OIL with anti-wear additive - Shell Tellus 011 T 68 ©) LUBRICANTS OIL SAE 90 HO (APT, GL-5) ©)BRAKE FLUID she11 Donax HB Note Other LUBRICANTS will be required if the roller is to be used under exceptionally hot or cold conditions (refer to "Special instructions" on page 37 or get in touch with OYNAPAC). DYNAPRA fC M=10046~4 ENG Dynapac Heavy Equipment AB PO Box 604-S-371 23 KARLSKRONA-SWEDEN Tel, 0455-229 20-Telex 43041 dynkar Telecopier 0455-295 39MAINTENANCE SCHEDULE 19 18 17 16 1 30. f ! 29. Hv 28 2 Fig 1 Service points 1 Engine V-belts 17. Universal joint 2 Fuel filter 18 Tyre pressures 3° Engine 19 O11 levels in rear axle 4 Air cleaner 20 Wheel nuts 5 Hydraulic of] sight glass 21 Fuel tank drain plug 6 Pump drive 22 Engine oi] filter 7 Handbrake, foot brake 23° Fuel system water trap 8 Battery 24 Drum extension 9 Brake cylinder (foot brake) 25 Shock absorbers and mounting 10 Tachometer cable screws 11 Drum gear 26 Drum of1 filler plug 12 Scraper 27 «Hydraulic of] filler cap 13° Articulated joint 28 Hydraulic oi] filter (qty 3) 14 Steering cylinder (two) 29 Coolant filler cap 15 3-speed gearbox 30 Fuel filler cap 16 Wheel brakes 31 Cooling system 2 CA 51/55 M-10046 ENGlitem in Operation Page = Lubricants fig 1 see Page 1 DAILY (every 10 hours of operation) al. aE Fill the fuel tank .... Check the engine oi] level 23.11) Drain the water trap .... 29 2.1 Check the engine coolant level . Baceacees 5 11. Check the of] Tevel in the hydraulic off tank III Test the handbrake and the foot brake ... 1211. Adjust the scraper setting WEEKLY (every 50 hours of operation) Check the tension of the fan and alternator V-belts 9 Clean the air cleaner filter element. Check that hoses and connections do not leak . 10 Check the battery ret Check the hydraulic tank breather holes .....ccsccsss 12 Check the drum gear oi1 level .. eooeisieeeas Check the shock absorbers and mounting screws - 2 Check the 011 level in the drum eet Lubricate the articulated joint Lubricate the steering cylinder Lubricate the universal joint Check the tyre pressures ... Check the wheel nuts Change the engine oi1* Replace the engine oi] filter . een eas ooo 27 ieee beeen 26 3. 14 se VW wae 18... 20 2.4 ieee Aten Bere oO EVERY 14 DAYS (every 100 hours of operation) Clean the outside of the radiator Check the engine valve clearances* Hee Seem EVERY THIRD WEEKS (every 150 hours of operation) ee ais Change the engine of] ..... 00 Replace the engine valve clearances* * — Only on new or reconditioned engines. ** See the engine instruction manual. CA 51/55 M-10046 ENG 3MAINTENANCE SCHEDULE 123 4 § 6 23. 22 | . 30- 29. 31 28 27 Fig 1 Service points 1 Engine V-belts 2 Fuel filter 3. Engine 4 Air cleaner 5 Hydraulic oi] sight glass 6 7 8 9 Pump drive Handbrake, foot brake Battery Brake cylinder (foot brake) 10 Tachometer cable 11 Drum gear 12 Scraper 13 Articulated joint 14 Steering cylinder (two) 15 3-speed gearbox 16 Whee! “brakes 7 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Universal joint Tyre pressures Oi] levels in rear axle Wheel nuts Fuel tank drain plug Engine of] filter Fuel system water trap Drum extension Shock absorbers and mounting Screws, Drum oi] filler plug Hydraulic oi] filler cap Hydraulic ofl filter (qty 3) Coolant filler cap Fuel filler cap Cooling system CA 51/55 10046 ENGItem in Operation Page Lubricants fig 1 see Page 1 EVERY MONTH (every 200 hours of operation) Clean the air cleaner dust collector Check the oi] level in the pump drive . Check the fluid level in the brake cylinder : Lubricate the tachometer cable (only prev. versions)... Replace the hydraulic ofl filters (qty 3 for Hydromatik) . Check the drum gear brake Drain the brake housing*** Bo Lubricate the drum gear shaft seal*** . Check the drum extension (to be checked every month if the roller is operated on crushed rock) .... 23 Check the oi1' level in the 3-speed gearbox ... 7 Check the oi] level in the rear axle differential . Check the rear axle brakes and adjust them if necessary 19... Check the of eve’ in e rear axle p EVERY THREE MONTHS (every 500 hours of operation) 3... Adjust the engine valve clearances** .......... 29 1. Top up the corrosion inhibitor in the coolant™* . EVERY SIX MONTHS (every 1000 hours of operation) Drain the fuel tank Change the oi] in the drum . Check the drum extension (this should be checker every six months if the roller is run on sand or clayey soil) fe 000 oe EVERY YEAR (every 2000 hours of operation) Replace the fuel filter Bleed the fuel system Change the of1 in the Change the oi] in the pump drive. Change the ofl in the rear axle di in the 3-speed gearbox . Change the oi] in the rear axle planetary gears Change the of] in the hydraulic tank . Flush the cooling system . Inspect the crankcase ventilation diaphragn** . e090 oo ** See the engine instruction manual *** Only Funk units CA 51/55 M-10046 ENG 5DAILY (every 10 hours of operation) — F Filling up with fuel Fill up the fuel tank to the Tower edge of the Ss filler pipe with diesel fuel each day. eS ke = <= ! —— Fig 2 Fuel tank 1 Filler pipe Engine — checking the oll level /,) Drive the roller onto a level surface and switch off the engine. Remove the dipstick (1) and check the oi] Tevel. If the oi] is close to the lower mark, top up with grade B of] in accordance with "Lubricants" on page 1. Fig 3. Engine 1 Dipstick 2 Filler cap a CA 51/55 M-10046 ENGWater trap — draining Open the drain cock (1) and let the water drain. The glass bowl must never be more than half full of water. Fig 4 1 Drain cock Radiator — checking the @ coolant level The cooling system should be at operating temperature and the engine should be stationary. / WARNING THE COOLANT IS PRESSURIZED. IF THE CAP 1 Place a piece of cloth or the like over the “TS REMOVED QUICKLY, COOLANT filler cap and turn the cap to the first stop. WILL BE RELEASED IN THE FORM When the pressure has fallen, press down the OF STEAM AND MAY CAUSE SERIOUS cap, turn it and remove it. The coolant level INJURY. USE GLOVES AND PRO- should reach the level tab in the radiator. TECTIVE GOGGLES. 2 When necessary, top up with water and corrosion inhibitor (CAT 3P2033 or equivalent). In win- ter, add anti-freeze as well. Fig 5 Radiator CA 51/55 M-10046Hydraulic oil level — check 1 Drive the roller onto a level surface and check the level of the of] in the sight glass. 2 If the oi] is close to the LOW mark, top up to the FULL mark with grade C oi] in accordance with "Lubricants" on page 1. Fig 6 a O41 level - Hydraulic tank A Full B Low Hydraulic tank — replenishing withoill 1 2 3 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 } i hydraulic of] of grade C as recommended on page LT under "Lubricants". Gs ite 6 Insert the pump lever (1) to pump hydraulic of] Fig 6 b Battery box into the tank, up to the full tank mark on the sight glass. 1 Pump lever 2 Protective plug 3 Suction hose Handbrake — adjusting The brake is correctly adjusted when it is just possible to pull the lever right up. If the lever offers negligible resistance to being pulled right up, turn the handle in the direction of the + arrow until the brake is correctly adjust- ed. If the resistance is too great, turn the handle in the direction of the - arrow. Fig 7 Handbrake The handbrake may be adjusted in three ways: A Released position B Applied position a By turning the brake lever handle as shown in Fig 7. b By adjusting both of the brake cable connec- tions. c By adjusting the brake shoe adjusting screw 1 (1 in Fig 8). 8 CA 51/55 M-10046 ENGFoot brake — testing Test the action of the foot brake. If necessary, adjust in accordance with the instructions on page 25. Scraper — adjusting ry —— Adjust the setting as follows: | / 4 1 Release all four screws. 2 Set the scraper about 15-20 mm from the drum. le | AO - 3 Tighten the screws again. WEEKLY (every 50 hours of operation) V-belt tension — check Check the tension of the cooling fan, water pump and alternator V-belts by pressing them down with the thumb at a point mid-way between the alter- nator pulley and the water pump pulley. It should not be possible to depress the belts by more than 6-7 mm. Fig 10 Checking the V-belts V-belts tensioning 1 Release the alternator mounting screws (A) slightly. 2 Press the alternator outwards until the V-belts are again correctly tensioned. 3. Tighten bolts A. Fig 11 Tensioning the. IF THE FAN GUARDS HAVE BEEN REMOVED, THEY MUST V-belts BE REPLACED BEFORE THE ENGINE IS STARTED AND THE ROLLER IS MOVED. 1 Alternator 2 Water pump/Fan 3. Crankshaft CA 51/55 M-10046 ENG 9Air cleaner — cleaning the ® filter element NOTE The air cleaner is fitted with an indica- tor. The main filter should be cleaned when the indicator is showing red. 1 Release the overcentre catches (4) and remove the outer cover (3). 2 Remove the wing nut in the centre of the filter and remove the inner cover (5). Clean the outer cover (3) with a clean cloth. 3 Remove the wing nut and withdraw the main filter (6). Do not remove the back-up element. | 4 Check whether any dust has penetrated the filter during operation. Check also that there are no dust deposits in the engine insuction pipe. If there are, this indicates that the connection hoses or the element leak and must therefore be replaced. Fig 12 Air cleaner 5 Wipe the inside of the filter housing (1) and ‘the induction pipes clean, using a clean cloth. Filter housing Back-up element 6 Check that the connections and the hoses be- Outer cover/dust collector tween the filter housing and the engine are in~ Overcentre catches tact and do not Teak. Inner cover Main filter Pressure drop indicator NOTE Replace the back-up filter by a new one every third time the main filter is re- placed or cleaned. The back-up element cannot be cleaned. Cleaning with compressed air Use compressed air at a maximum pressure of 0.7 MPa (7 kgf/cm?), of the paper on the outside of the filter element. Hold the nozzle at least 2-3 cm away from the ele- ment to avoid damaging the paper. | Play the compressed air up and down along the folds | | Fig 13. Main filter 10 CA 51/55 M-10046 ENGCleaning by washing 1 If the filter element is sooty or oily, it should be washed in a solution of water and non-foaming detergent, such as "Donaldson 0-140". Immerse the element in the detergent solution and leave it for at least 15 minutes. Raise and lower the element in the solution from time to time to improve the cleaning effect. Fig 14 Filter element - check- ‘ing the tightness 2 Check that the filter element is intact before refitting it. If it has any holes or if the seals are defective, fit a new element. NOTE Discard the filter element after it has been washed 6 times. Do not fit a filter element that has been washed in detergent, until it is completely dry. 3. Wipe the inner cover clean, fit the element in- to the filter housing and tighten the element and the inner cover firmly by means of the wing nut. 4 Wipe the outer cover clean and refit it. Check the outer cover seals and replace any that are damaged. Battery — checking the electrolyte level 1 Tip the seat forward. 2 Wipe the top of the battery clean. Swi Fig 15 Battery CA 51/55 M-10046 iNEVER USE_A NAKED FLAME WHEN CHECKING THE ELECTROLYTE LEVEL, SINCE EXPLOSIVE GAS IS FORMED IN THE BATTERY WHEN IT IS BEING CHARGED. F, 10mm Fig 16 Battery electrolyte Tevel 1 Cell plug 2 Electrolyte level 3 Plate Breather holes in the hydraulic tank filler cap Fig 17 Filler cap - hydraulic~ oi] tank 1 Breather holes 12 3 Remove the cel plugs and check that the level of the electrolyte is about 10 mm above the plates. Check the levels in all the cells. If the level is lower, top up to the correct level with di- stilled water. If the air temperature is below freezing, run the engine for a while after adding the dis- tilled water, otherwise the water may freeze. 4 Check that the breather holes in the cell plugs are not clogged. Then replace the plugs. 5 The cable terminals should be clean and secure- ly tightened. If they are corroded, clean them and coat them with petroleum jelly. Remove the filler cap and check that the breather holes are not clogged. If necessary, wash the filler cap in hydraulic oi1 or diesel fuel and blow it dry with compressed air. CA 51/55 M-10086 ENGDrum gearbox oil level — check (KORDEL and FUNK types) Fig 18a Checking the oi] level = KORDEL drum gear 1 Level plug 2 Filler plug / ae Ld ta. Fig 18b Checking the off level ~ FUNK drum gear 1 Level plug 2 Filler plug Shock absorbers and mounting ‘screws — checking CA 51/55 M-10046 ENG 1 Drive the roller onto a level surface. the plug about 3 turns. O41 should flow out past the plug if the drum gear contains the correct amount of ofl. Top up, as necessary, using grade D of] in accordance with "Lubricants" on page 1. 5 Refit the plugs. Check that the shock absorbers are undamaged and that the mounting screws are tight. Replace shoc absorbers when 20-25 mm deep cracks are detected ‘in them. Use a knife or other sharp object to check the depth of cracks. Dry around the level plug (1) and then unscrew k 13Drum. oil level — check % Fig 19 Level control - eccentric housing 1 Level plug 2 Filler plug Articulated joint — lubricating —_ MAKE SURE THAT NOBODY IS IN THE VICINITY OF THE ARTICULATED JOINT WHILE THE ENGINE IS RUNNING. THEY COULD BE CRUSHED If THE STEERING IS Fig 20 Grease nipples - articulated joint 14 Drive the roller onto a level surface so that the filler plug (2) is vertically above the drum shaft. Wipe any dirt and grease away from the area around the level plug (1) and unscrew it about 3 turns. O11 should flow out past the level piug if the eccentric housing contains the correct quanti- ty. NOTE This check should be carried out on both sides of the drum. If necessary, top up with grade D of] in accordance with "Lubricants" on page 1. Turn the drum section to the left so that all articulated joint grease nipples on the right side are accessible. Wipe any dirt and grease off the grease nipples. Grease each nipple with five strokes of the grease gun. Check that grease enters the bear- ings. 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, Leave a little grease on the nipples after greasing, to prevent dirt from entering them. NOTE If the grease does not enter the bearings, it may be necessary to relieve the articu- lated joint of load, using a jack, and then repeat the lubrication procedure. CA 51/55 M-10046 ENGSteering cylinders — _ lubricating Fig 21 Grease nipples = steering cylinders Universal joint — lubricating —_ WARNING NEVER WORK UNDER THE ROLLER WHILE THE ENGINE IS RUNNING. APPLY THE HANDBRAKE. BLOCK THE DRUM AND WHEELS IF NECESSARY. Fig 22 Grease nipples + universal joint Grease the left-hand steering cylinder mounting immediately after greasing the articulated joint. 1 2 The grease nipples on the universal joint are acces- Wipe any dirt and grease off the two nipples. Grease each nipple with three strokes of the grease gun. Check that grease enters the bear- ings. Use grade A grease in accordance with “Lubri cants" on page 1. Leave a little grease on the nipples after greasing, to prevent dirt from entering them. Grease the two nipples on the right-hand steering cylinder in the same manner. Check that grease enters the bearings. sible from underneath the roller. 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. Wipe any dirt and grease off the two nipples. Grease each nipple with two strokes of the grease gun. Check that grease enters the bear. ings. Use grade A grease in accordance with “Lubri cants" on page 1. Leave a little grease on the nipples to prevel dirt from entering them. nt CA 51/55 M-10046 ENG 15Tyre pressures Or Fig 23. Wheel 1 Air valve 2 Wheel nut Wheel nuts — tightening EVERY 14 DAYS ‘every 100 hours of operation) Radiator — cleaning the exterior Check the tyre pressures, using the tyre pressure gauge included in the rojler tool kit. The minimum tyre pressure should not be below 0.11 NPa (1.1 kgf/cm?) and the maximum tyre pressure should not exceed 0.15 MPa (1.5 kg?/cm?), Check both tyres. Check that the wheel nuts are tightened a torque of 550 Nm (55 kgf m). Check that air can flow freely through the radia- tor. If the radiator is dirty, clean it by flush- ing with water or blowing with compressed air. After cleaning, check that any seals and sound- absorbers are not damaged. 16 CA 51/55 M~10046 ENGEVERY THIRD WEEKS (every 150 hours of operation) Engine — devitations from the normal oil change interval Engine — oil change Fig 24 Filling up with oil - engine 1 O11 filler cap Fig 25 Draining the oil - engine 2 O41 drain plug NOTE Irrespective of the number of hours of operation, the ofl and of] filter must be changed at least once every 6 months. The oi] filter must always be replaced when the oi] is changed. Oi1-change intervals are dependent on the quality of the lubricating oil and the sulphur content of the fuel. Oil changes every third week or every 150 hours of operation are conditional on the use of oi] of grade "For API Service CD/SE SAE" and on the use of diesel fuel of good grade and with a sulphur content below 0.4 %. If of] of grade “For API Service CC/SC, SAE" is used, or if the sulphur content of the fuel is 0.4 % or above, the oi] must be changed at shorter ee ae (see the engine manufacturer's instruc- tions). 1 Warm up the engine thoroughly before draining the oi]. Impurities in the lubricating system will then be well mixed with the of] and will be removed with it. Furthermore, the of] flows more readi- ly when it is hot. 2 Clean the area around the oi] filler cap (1) and then remove the cap. Clean the area around the drain plug (2) and place a receptacle to hold at least 15 litres under the plug. 4 Remove the drain plug and allow the oi] to drain into the receptacle. Allow the oil to drain out while replacing the oil filters. 5 Wipe the drain plug clean. Fit it back into place and tighten it securely. M-10046 ENG 7Engine — oil filters replacement Fig 26 Engine 1 Oil filters Engine — replenishing with oil o Fig 27. Engine 1 071 filler cap 2 Dipstick 1 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 will 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 layer of clean engine of1 to the new filter seals. Tighten the filters by hand until the seal seats against the filter head. Then tighten them an additional half-turn. NOTE Do not tighten the filters too hard, since this may damage the seals. Fill up with fresh grade B of] in accordance with "Lubricants" on page 1. Oi] required: 12.5 litres, when changing the filters 11.4 litres, when the filters are not changed The quantities of oi] required for engines with serial Nos above 90N44128 or with recalibrated dipsticks are: 14,5 litres, when changing the filters 13.5 litres, when the filters are not changed tee the engine oi] level with the dipstick 2). The level should be up to the FULL mark. Do not overfill since this may cause damage to the crankshaft packing boxes. Refit the filler cap (1). Tighten it firmly, ensuring that it seals satisfactorily. Start the engine and warm it up. Check that there are no oi] leaks. Start the engine and warm it up. Check that there are no oi] leaks. “18 CA 51/55 M-10046 ENGEVERY MONTH (every 200 hours of oper ion), Air cleaner — checking the ® dust indicator Fig 28 Air cleaner 1 Quter cover/dust collector 2 Valve 3. Catch Pump drive oil level — check Funk pump drive g Fig 29 Pump drive ~ Funk type 1 Filler plug 2 Level plug 3 Drain plug Release the catch (3) and remove the outer cover (1). Empty the outer cover and wipe it clean. Check the seals and replace them if they are damaged. Check that hoses and connections are tight. The dust collector is fitted with a self- discharging valve (2). This valve discharges dust and water continuously. Drive the roller onto a level surface and stop the engine. Clean the area around the level plug (2) and unscrew the plug a few turns. Oi] should run out if the ofl level is correct. If it is necessary to top up the oil, clean the area around the filler plug, remove it and top up with of1 through the filler plug (1) hole unti] the ofT runs out through the level plug (2) hole. Fil] up with grade D of] in accordance with “Lubricants” on page 1. NOTE A level plug is located on each side of the pump drive. The o/1 level need only be checked on one si CA 51/55 M-10046 ENG 19Renondin pump drive Fig 30 Pump drive - Renondin 1 Filler plug 2 Level plug 3 Drain plug Dynapac pump drive Fig 31 Pump drive - Dynapac 1 Filler plug 2 Level plug 3 Drain plug Drive the roller onto a level surface and stop the engine. Clean the area around the level plug (2) and unscrew the plug a few turns. Oi] should run out if the oil level is correct. If it is necessary to top up the oi1, clean the area around the filler plug, remove it and top up with of] through the filler plug (1) hole until the of] runs out through the level plug (2) hole. Fill up with grade D oil in accordance with "Lubricants" on page 1. NOTE A level plug is located on each side of the pump drive. The oil level need only be checked on one side. Drive the roller onto a level surface and stop the engine. Clean the area around the level plug (2) and unscrew the plug a few turns. O11 should run out if the of] level is correct. If it is necessary to top up the oi], clean the area around the filler plug, remove it and top up with oi] through the filler plug (1) hole until the of] runs out through the level plug (2) hole. Fill up with grade D oil in accordance with "Lubricants" on page 1. NOTE A level plug is located on each side of the pump drive. The oi] level need only be checked on one side. 20 CA 51/55 M-10046 ENGBrake cylinder fluid level — check Clean the area around the filler plug (1) thoroughly and remove it. Check that the fluid is up to the bottom of the filler hole. If necessary, top up to the correct level with brake fluid. Use grade E brake fluid in accordance with "Lubricants" on page 1. Fig 32 Checking the fluid level ~ brake cylinder 1 Filler plug Tachometer cable — lubricating Release the cable at the tachometer and pour grade (only previous versions) 8 oil in between the sheath and the cable. Hydraulic system filters replacement i] 1 2 1 Remove the oi] filters (1), (2) and (3) and dis- card them. They are of the disposable type and cannot be cleaned. NOTE Ensure that the old seals are not left in position. Leakage will otherwise occur be- tween the new and old seals. 2 Clean the sealing surfaces of the filter holders thoroughly. 3 Apply a thin layer of hydraulic of1 to the seals of the new filters. 4 Screw the filters into place by hand. Fig 33 Hydraulic filter First screw the filter in until its seal seats 1 Suction filter, prop. syst. against the filter head. Then tighten it an 2 Suction filter, vibr. syst. additional half-turn, 3 Return filter, after cooler NOTE Do not tighten the filter too mich as this may damage the seal. 5 Start the engine and check that no hydraulic of] leaks out around the filters. CA 51/55 M-10046 ENG