Operating instructions Maintenance instructions

Transcription

1 Operating instructions Maintenance instructions Origina operating instructions BW 100 AD-4 / BW 120 AD-4 / BW 125 AD-4 BW 100 AC-4 / BW 120 AC-4 / BW 125 AC-4 S/N > / S/N > / S/N > / S/N > / S/N > S/N > / S/N > / S/N > / S/N > / S/N > Tandem Vibratory Roer Combination Roer Cataogue No /2012

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3 Foreword Aways keep this manua cose at hand, e.g. in the too compartment of the machine or in a speciay provided container. These operating and maintenance instructions are part of the machine. 1 Foreword These machines are products from the wide product range of machines for earth and asphat construction, refuse compaction and stabiizing/recycing. You shoud ony operate the machine after you have been instructed and in compiance with these instructions. s vast experience in connection with state-of-the-art production and testing methods, such as ifetime tests of a important components and highest quaity demands guarantee maximum reiabiity of your machine. Stricty observe the safety reguations. This manua comprises: For your own persona safety you shoud ony use origina spare parts from. Safety reguations Operating instructions maintenance instructions Troube shooting Pease observe aso the guideines of the Civi Engineering Liabiity Association Safety Rues for the Operation of Road Roers and Soi Compactors and a reevant accident prevention reguations. For your machine offers service kits to ease maintenance. In the course of technica deveopment we reserve the right for technica modifications without prior notification. Using these instructions wi hep you to become famiiar with the machine. avoid mafunctions caused by unprofessiona operation. Compiance with the maintenance instructions wi enhance the reiabiity of the machine on construction sites, proong the ifetime of the machine, reduce repair costs and downtimes. wi not assume iabiity for the function of the machine if it is handed in a way not compying with the usua modes of use, if it is used for purposes other than those mentioned in these instructions. These operating and maintenance instructions are aso avaiabe in other anguages. Apart from that, the spare parts cataogue is avaiabe from your deaer against the seria number of your machine. Your deaer wi aso suppy you with information about the correct use of our machines in soi and asphat construction. The above notes do not constitute an extension of the warranty and iabiity conditions specified in the genera terms of business of. We wish you successfu work with your machine. GmbH Copyright by No warranty caims can be odged in case of damage resuting from operating errors, insufficient maintenance and wrong fues and ubricants. Pease note This manua was written for operators and maintenance personne on construction sites. 3

4 Foreword Pease fi in... Machine type (Fig. 1)... Seria-number (Fig. 1 and 2)... Engine type (Fig. 3)... Engine number (Fig. 3) i Note Fig. 1 Suppement the above data together with the commissioning protoco. During commissioning our organisation wi instruct you in the operation and maintenance of the machine. Pease observe stricty the safety reguations and a notes on risks and dangers Fig. 2 Fig. 3 4

5 Tabe of Contents 1 Foreword 3 2 Technica Data 9 3 Safety reguations 17 4 Indicators and Contros Genera notes Description of indicators and contro eements Operation Genera Tests before taking into operation Eectronic immobiizer Adjusting the operator's seat Starting the engine Starting with jump wires Driving the machine Stopping the machine, operating the parking brake Shutting down the engine Switching the vibration on and off Switching the gravity sprinking system on and off Switching the pressure sprinking system on and off Switching the tire sprinking system on and off (ony AC) Actuating the emergency stop switch Mounting/removing the chip spreader Fiing/emptying the chip spreader Operating the chip spreader Towing Loading/transport 67 Maintenance Genera notes on maintenance Fues and ubricants Tabe of fues and ubricants Running-in instructions Maintenance tabe 78 Every 10 operating hours Check the engine oi eve Checking the fue eve Check the hydrauic oi eve Checking the hydrauic oi fiter eement 83 5

6 Tabe of Contents 6.10 Check the cooant eve Check the water separator Checking the water eve Checking the emusion eve Checking the chip spreader and ceaning the spreading beam 85 Every 50 operating hours Checking fue ines and camps Servicing the chip spreader 87 Every 250 operating hours Changing engine oi and oi fiter Checking, ceaning, repacing the combustion air fiter Check the air intake ines Ceaning radiator and hydrauic oi cooer Checking, tensioning, repacing the V-bet Checking radiator hoses and hose camps Checking, adjusting the scrapers 97 Every 500 operating hours Battery service Change the fue fiter Drain the fue tank sudge 101 Every 1000 operating hours Checking, adjusting the vave cearance Check the engine mounts 104 Every 2000 operating hours Changing hydrauic oi and breather fiter Changing the hydrauic oi fiter Changing the cooant Repacing the fue ines Check the injection vaves 109 Every 3000 operating hours Checking the fue injection pump 111 As required Checking the tire pressure Ceaning the water sprinker system Draining the water sprinker system, maintenance in case of frost Fiing the provision tank for the windscreen washer system Tightening torques for screws with metric unified thread Engine conservation 117

7 Tabe of Contents 7 8 Troube shooting Genera notes Engine 121 Disposa Fina shut-down of machine 124 7

8 Tabe of Contents 8

9 2 Technica Data 9

10 Technica Data Fig. 4 BW 100 AD-4 Dimensions in mm A 1728 B 1076 C 475 D 700 H 1800 H K 255 L 2475 O 38 S 13 W 1000 BW 120 AD BW 125 AD Weights Operating weight with ROPS (CECE) Operating weight with ROPS (CECE) and empty chip spreader2 Mean axe oad (CECE) Mean static inear oad (CECE) Max. operating weight Dimensions Inner track radius Length with chip spreader** Width with chip spreader** 10 BW 100 AD-4 BW 120 AD-4 BW 125 AD-4 kg kg kg kg/cm kg mm mm mm

11 Technica Data 1 Trave characteristics Working speed with vibration Trave speed Max. gradabiity without/with vibration (soi dependent) Drive Engine manufacturer Type Cooing Number of cyinders Rated power ISO 9249 Rated power SAE J 1349 Rated speed Fixed engine speed 1 Fixed engine speed 2 Eectrica equipment BW 100 AD-4 BW 120 AD-4 BW 125 AD-4 km/h km/h % / / /30 kw hp min-1 min-1 min-1 V Kubota D 1703-M-EU34 Water Kubota D 1703-M-EU34 Water Kubota D 1703-M-EU34 Water hydrost. hydro-mech. hydrost. hydro-mech. hydrost. hydro-mech. +/- Osci.-articu. hydrost. 30/7 Osci.-articu. hydrost. 30/7 Osci.-articu. hydrost. 30/7 Hz mm kn front + rear hydrost. 70/ /23 front + rear hydrost. 70/ /28 front + rear hydrost. 60/ /29 Gravity feed Gravity feed Gravity feed approx. 40 approx. 220 approx. 28 approx. 6,5 approx. 40 approx. 220 approx. 32 approx. 6,5 approx. 40 approx. 220 approx. 32 approx. 6,5 Brake Service brake Parking brake Steering Type of steering Steering operation Steering/osciation ange Exciter system Vibrating drum Drive system Frequency 1/2 Ampitude Centrifuga force 1/2 Water sprinker system Type Fiing capacities Fue (diese) Water tank capacity Hydrauic oi Engine oi 1 2 The right for technica modifications remains reserved Optiona equipment 11

12 Technica Data Fig. 5 Dimensions in mm A B C D H H2 K L O S W BW 100 AC BW 120 AC BW 125 AC Weights Operating weight with ROPS (CECE) Axe oad, drum (CECE) Axe oad, whees (CECE) Static inear oad (CECE) Whee oad (CECE) Max. operating weight Dimensions Inner track radius 12 BW 100 AC-4 BW 120 AC-4 BW 125 AC-4 kg kg kg kg/cm kg kg mm

13 Technica Data 1 Trave characteristics Working speed with vibration Trave speed Max. gradabiity without/with vibration (soi dependent) Drive Engine manufacturer Type Cooing Number of cyinders Rated power ISO 9249 Rated power SAE J 1349 Rotary speed (nomina speed) Fixed engine speed 1 Fixed engine speed 2 Eectrica equipment BW 100 AC-4 BW 120 AC-4 BW 125 AC-4 km/h km/h % / / /30 kw hp rpm rpm rpm V Kubota D 1703-M-EU34 Water Kubota D 1703-M-EU34 Water Kubota D 1703-M-EU34 Water / / /60-15 hydrost. hydro-mech. hydrost. hydro-mech. hydrost. hydro-mech. degree Osci.-articu. hydrost. 30/7 Osci.-articu. hydrost. 30/7 Osci.-articu. hydrost. 30/7 Hz mm kn front hydrost. 70/ /23 front hydrost. 70/ /28 front hydrost. 60/ /29 Pressure Standard Pressure Standard Pressure Standard approx. 40 approx. 220 approx. 20 approx. 28 approx. 6,5 approx. 40 approx. 220 approx. 20 approx. 28 approx. 6,5 approx. 40 approx. 220 approx. 20 approx. 28 approx. 6,5 Tires Number of tires Tire size Brake Service brake Parking brake Steering Type of steering Steering operation Steering/osciation ange Exciter system Vibrating drum Drive system Frequency 1/2 Ampitude Centrifuga force 1/2 Water sprinker system Type Interva contro Fiing capacities Fue (diese) Water tank capacity Emusion Hydrauic oi Engine oi 13

14 Technica Data 1 14 Subject to technica aterations.

15 Technica Data The foowing noise and vibration data acc. to - EC Machine Reguation edition 2006/42/EC - the noise reguation 2000/14/EG, noise protection guideine 2003/10/EC - Vibration Protection Reguation 2002/44/EC were determined during conditions typica for this type of equipment and by appication of harmonized standards. During operation these vaues may vary because of the existing operating conditions. Noise vaue Sound pressure eve on the pace of the operator: LpA = 84 db(a), determined acc. to ISO and EN 500 Guaranteed sound power eve: LWA = 106 db(a), determined acc. to ISO 3744 and EN 500 Danger Wear your persona noise protection means (ear defenders) before starting operation. Vibration vaue Vibration of the entire body (driver s seat) The weighted effective acceeration vaue determined according to ISO 7096 is 0.5 m/s2. Hand-arm vibration vaues The weighted effective acceeration vaue determined according to ISO 5349 is 2.5 m/s2. 15

16 Technica Data 16

17 3 Safety reguations 17

18 Safety reguations Genera Exampes for unintended use are: This machine has been buit in compiance with the atest technica standard and compies with the appicabe reguations and technica rues. However, dangers for persons and property may arise from this machine, if: work with vibration on hard concrete, cured bitumen ayers or extremey frozen ground ceaning the drums whie driving or changing nozzes during trave. driving on unstabe subbases or insufficient grip or too sma contact area (danger of tipping over) it is used for purposes other than the ones it is intended for, it is operated by untrained personne, it is changed or converted in an unprofessiona way, Passing over high borders (e.g. curbstones, embankments, trenches, pothoes) unauthorized use of pubic roads the safety instructions are not observed. Using the machine for towing Each person invoved in the operation, maintenance and repair of the machine must therefore read and compy with these safety reguations. If necessary, this must be confirmed by obtaining the signature of the customer. Transporting persons, except the machine driver, is prohibited. Furthermore, the foowing obviousy aso appies: Remaining dangers, remaining risks appicabe accident prevention instructions, generay accepted safety and road traffic reguations, country specific safety reguations. It is the duty of the operator to be acquainted with these instructions and to appy these accordingy. This appies aso for oca reguations concerning different types of handing work. Shoud the recommendations in these instructions be different from the reguations vaid in your country, you must compy with the safety reguations vaid in your country. Intended use This machine must ony be used for: Compaction of bituminous materia, e.g. road surface ayers. Starting and operation of the machine in exposive environments and in underground mining is prohibited. Despite carefu work and compiance with standards and reguations it cannot be rued out that further dangers may arise when working with and handing the machine. Both the machine as we as a other system components compy with the currenty vaid safety reguations. Nevertheess, remaining risks cannot be rued out competey, even when using the machine for the purpose it is intended for and foowing a information given in the operating instructions. A remaining risk can aso not be excuded beyond the actua danger zone of the machine. Persons remaining in this area must pay particuar attention to the machine, so that they can react immediatey in case of a possibe mafunction, an incident or faiure etc. A persons remaining ion the area of the machine must be informed about the dangers that arise from the operation of the machine. ight compaction work in earth construction (road sub-bases). Unintended use Reguar safety inspections Dangers may arise from the machine when it is used for purposes other than the one it is intended for. Have the machine inspected by an expert (capabe person) as required for the conditiosn the machine is working under, but at east once every year. Any danger caused by intended use is the soe responsibiity of the customer or driver/operator, the manufacturer cannot be made iabe. 18

19 Safety reguations Who is aowed to operate the machine? Ony trained, instructed and authorized persons of at east 18 years of age are permitted to drive and operate this machine. For operation of the machine the responsibiities must be ceary specified and compied with. Persons under the infuence of acoho, medicine or drugs are not aowed to operate, service or repair the machine. Maintenance and repair work requires specific knowedge and must therefore ony be performed by trained speciaists. Caution Paragraphs marked ike this highight possibe dangers for machines or parts of the machine. i Note Paragraphs marked ike this contain technica information for the optima economica use of the machine. Environment Paragraphs marked ike this point out practices for safe and environmenta disposa of fues and ubricants as we as repacement parts. Changes and conversions to the machine Observe the reguations for the protection of the environment. Unauthorized changes to the machine are prohibited for safety reasons. Loading/transporting the machine Origina parts and accessories have been speciay designed for this machine. Loading with oading ramp We wish to make expicity cear that we have not tested or approved any parts or accessories not suppied by us. The instaation and/or use of such products may have an adverse effect on the active and/or passive safety. Use ony stabe oading ramps of sufficient oad bearing capacity. The ramp incination must be ess than the gradabiity of the machine. Make sure that persons are not endangered by the machine tipping or siding off. During demonstration and when oading the machine do not remain in the danger zone of the machine. The manufacturer expicity excudes any iabiity for damage caused by the use of non-origina parts or accessories. Aways empty the chip spreader 1 before transport. Damage, deficiencies, misuse of safety instaations After driving the machine onto the transport vehice attach the articuation ock. Machines which are not safe to operate or in traffic must be immediatey taken out of service and sha not be used, unti these deficiencies have been propery rectified. Loading by crane / oading the machine with a ifting bet2 Safety instaations and switches must neither be removed nor must they be made ineffective. Engage the articuation ock. Aways use shackes on the ifting points or on the ifting bet for oading the machine. Notes on safety in the operating and maintenance instructions With the chip spreader attached the machine must not be ifted with ifting bets, because of the changed centre of gravity. Danger Paragraphs marked ike this highight possibe dangers for persons. Check a ifting points and ifting bet for damage before ifting the machine. Damaged or in any other way in their functionaity impaired ifting points or a damaged or in its functionaity impaired ifting bet must not be used. 1 2 Optiona equipment Optiona equipment 19

20 Safety reguations Lifting tacke must ony be attached to oads by expert personne (quaified person). Max. towing speed 1 km/h, max. towing distance 500 m. Do not overoad the ifting bet. Before reeasing the muti-disc brake secure the machine against unintended roing. Lift the machine ony with suitabe ifting gear. Use ony safe ifting gear of sufficient oad bearing capacity Minimum ifting capacity of ifting gear: see operating weight in chapter "Technica Data". Checking the Ro Over Protective Structure (ROPS) Do not ift or ower the machine jerkiy. The tension must aways be effective in vertica direction. The machine must not swing about when being ifted. i Note On machines with cab the ROPS is an integra part of the cab. Do not step or stand under suspended oads. The frame of the machine must not be warped, bent or cracked in the area of the ROPS fastening. After ifting hook the ifting bet back into its receptace. The ROPS must not show any rust, damage, hairine cracks or open fractures. Have the ifting tacke inspected by an expert (propery trained person) once every year. The actua weight of the machine must not exceed the testing weight of the ROPS. After 5 years repace the ifting bet with a new one. The ROPS must not ratte about when driving. This indicates that it is not propery fastened. A boted connections must compy with the specifications and shoud be absoutey tight (observe the tightening torques). Screw and nuts must not be damaged, bent or deformed. Aways empty the chip spreader 1 before transport. Lashing Aways use shackes on the ifting points for ashing down the machine. With the cab assembed check aso the state of the cabin mounts (rubber eements and screws). Check a ashing points for damage before ashing down the machine. Do not use a damaged or in any other way impaired ashing points. No accessories may be weded or boted on and no additiona hoes must be dried without the consent of the manufacturer, since this wi impair the strength of the unit. Lash the machine down, so that it is secured against roing, siding and turning over. Never attach the ashing gear to the chip spreader. After transport Operate the machine ony with the fodabe ROPS2 propery fastened and the fastening screws tightened with the correct tightening torque. The ROPS must therefore aso not be straightened or repaired if it is damaged. A defect ROPS must generay be repaced with an origina spare part in cose coordination with the manufacturer. Starting the machine After transport reease the articuation ock again and store it in the receptace. Before starting Towing the machine The machine must ony be operated from the driver s seat. You shoud generay use a tow bar. spreader3 attached the machine With the chip must not be towed backwards Optiona equipment Optiona equipment Optiona equipment Use ony machines which are serviced at reguar intervas. Become acquainted with the equipment, the contro eements, the working principe of the machine and the working area. Wear your persona protective outfit (hard hat, safety boots, etc.). Wear ear defenders.

21 Safety reguations Driving the machine Before mounting the machine check whether: persons or obstructions are beside or under the machine the machine is free of oiy and combustibe materia a grips, steps and patforms are free of grease, ois, fue, dirt, snow and ice engine hood is cosed and ocked Persons in the danger area Before taking up work, aso after breaks, you shoud aways convince yoursef that the danger zone is free of persons or obstructions, especiay when driving in reverse. Give warning signas, if necessary. Stop work immediatey if persons remain in the danger zone, despite the warning. Use steps and grips to mount the machine. the machine shows any obvious fauts Do not step or stand in the articuation area of the machine when the engine is running. Danger of squashing a guards and safety eements are in pace Driving steering, brakes, contro eements, ight system and warning horn work correcty Aways wear the seat bet when driving. the seat is correcty adjusted mirrors (if present) are cean and correcty adjusted. Before starting the machine check whether: Do not drive on bases with insufficient oad bearing capacity. Do not start the machine with defective gauges, contro ights or contro eements. Do not take any oose objects with you or fasten them to the machine. On machines with ro over protection system you must aways wear your seat bet Do not drive on ice and snow. In events of emergency and in case of danger actuate the emergency stop switch immediatey. Do not use the emergency stop switch as service brake. Restart the machine ony after the danger that caused the actuation of the emergency stop switch has been eiminated. Starting If the engine oi pressure contro ight ights up stop the engine immediatey. Start and operate the machine ony from the driver s seat. If the machine has contacted high-votage power ines: For starting set a contro evers to 'neutra position'. do not eave the operator s stand warn others from coming cose to or touching the machine if possibe drive the machine out of the danger zone have the power switched off Do not use any starting aids ike start piot or ether. After starting check a gauges and contro ights. Starting with jump wires Connect pus to pus and minus to minus (ground cabe) aways connect the ground strap ast and disconnect it first A wrong connection wi cause severe damage in the eectric system. Do not start the engine by shorting the eectric terminas on the starter motor, because the machine may start to drive immediatey. Starting and operation of the machine is cosed rooms and trenches Keep the cabin doors cosed. Do not adjust the driver s seat whie driving. Do not cimb onto or off the machine whie the machine is driving. Change the trave direction ony at standsti. Exhaust gases are highy dangerous Aways ensure an adequate suppy of fresh air when starting and operating in cosed rooms and trenches Operate the machine ony from the operator s stand. Do not use the machine to transport persons. 21

22 Safety reguations You shoud therefore aways drive straight up or down a sope. In case of unusua noises and deveopment of smoke perform troube shooting and have the faut corrected. For roers with a drum width of 1 m or ess there is a considerabe risk of tipping over near edges (e.g. curbstones, embankments, trenches, pothoes) when driving over these edges. Aways keep a sufficient distance to excavation was and embankments and do not use working methods that coud impair the stabiity of the machine. Behaviour in traffic Do not work with vibration on hard concrete, cured bitumen ayers or extremey frozen ground. Match the speed to the working conditions. Do not make extreme steering movements when driving with high speed, danger of tipping over Aways keep a sufficient distance when passing through subways, under bridges, tunnes, eectric power ines etc. Aways give way to oaded transport vehices. Switch the ights on if the visibiity is poor. Driving on incinations and sopes Keep away from edges and embankments. Do not drive on gradients exceeding the maximum gradabiity of the machine. Checking the effect of vibration When compacting with vibration you must check the effect on nearby buidings and underground suppy ines (gas, water, sewage, eectric power), if necessary stop compaction work with vibration. On sopes drive extremey carefu and aways directy up or down the sope. Change to a ower gear before starting to drive. Wet and oose sois consideraby reduce the ground adhesion of the machine on incinations and sopes. Higher risk of accident Do not work with vibration on hard concrete, cured bitumen ayers or extremey frozen ground. Danger of bearing damage Incination Parking the machine Park the machine on eve, firm ground. Before eaving the machine: Max % return the contro ever to neutra position appy the parking brake shut the engine down and pu off the ignition key Do not jump off the machine, but use hand grips and access steps. Mark machines, which coud be in the way, with a ceary visibe sign Fig. 6 Parking on sopes and incinations The tipping ange was measured in static condition on eve, hard ground with the machine stopped, no steering and without vibration. With oose soi, acceeration/deceeration, running vibration, steering or attached accessoriies the tipping ange may be consideraby ower. Driving across sopes shoud therefore be stricty avoided, because of the high risk of tipping over and the reated risk of severe or even fata accidents. Appy appropriate measures (e.g. with meta whee chocks, to be provided by the operating company) tp secure the machine against roing away. Refueing Do not inhae any fue fumes. Refue ony with the engine stopped and the auxiiary heater switched off. Aways use access steps. 22

23 Safety reguations Do not refue in cosed rooms. Working on hydrauic ines No open fire, do not smoke. Aways depressurize the hydrauic ines before starting to work on them. Hydrauic oi escaping under pressure can penetrate the skin and cause severe injury. If injured by hydrauic oi seek medica advice immediatey as otherwise severe infections may resut. Do not spi any fue. Catch running out fue, do not et it seep into the ground. Wipe off spied fue. Keep dirt and water away from the fue. A eaking fue tank can cause an exposion. Ensure tight fit of the fue tank cover, if necessary repace immediatey. Fire protection measures Famiiarise yoursef with the ocation and the operation of fire fighting equipment. Observe a fire reporting and fire fighting possibiities. Mounting and removing the chip spreader1 When adjusting the hydrauic system do not stand behind or in front of the drum/whees. Do not change the setting of high pressure reief vaves. Drain hydrauic oi at operating temperature - danger of scading Catch running out hydrauic oi and dispose of environmentay. Aways catch and dispose of bioogica hydrauic ois separatey. When mounting or removing the chip spreader do not step between the chip spreader and the machine whie the engine is running. Park the machine on a eve and soid base to mount or remove the chip spreader and shut down the engine. Do not start the engine after draining off the hydrauic oi. After finishing work (with the system sti depressurized) check a connections and fittings for eaks. Changing hydrauic hoses A hydrauic hoses must be inspected visuay at reguar intervas. Mount and remove the chip spreader when it is empty. Hydrauic hoses must be changed immediatey if: Maintenance Observe the maintenance tasks described in the operating and maintenance instructions, incuding the exchange of parts. the outer ayer is worn down to the meta ining (e.g. chafing, cuts, cracks) embrittement of the outer ayer (deveopment of cracks in the hose materia) deformation under pressurized and depressurized condition, which are not in accordance with the norma shape of the hydrauic hose deformation in bends, e.g., squeezes, kinks, ayer separation, formation of bisters eakages. non-observance of the instaation requirements. separation of the hydrauic hose from the fitting corrosion of the fitting, which impairs the function and the strength. Do not mix up hoses by mistake. damage or deformation of the fitting, which impairs the function and strength of the hose/ hose connection. Maintenance work must ony be carried out by quaified and authorized personne. For overhead service and assemby work use the provided access instaations or any other safe access adders and work patforms. Do not use machine parts as access steps. Keep unauthorized persons away from the machine. Do not perform maintenance work with the machine driving or the engine running. Park the machine on horizonta, eve and stabe ground. Pu the key out of the ignition switch. Lock the articuated joint with the articuation ock. 1 Optiona equipment 23

24 Safety reguations Ony genuine hydrauic hoses ensure that the correct type of hose (pressure range) is used at the right pace. Working on the fue system Working on the engine Catch running out fue, do not et it seep into the ground and dispose of environmentay. Do not inhae fue fumes. No open fire, do not smoke, do not spi any fue. Shut the engine down before opening the engine compartment hood. Working on whees and tires Drain the engine oi at operating temperature danger of scading Exposion-ike bursting of tires and parts of rims and tires can cause severe or even deady injuries. Wipe off spied oi, catch running out oi and dispose of environmentay. Store used fiters and other oiy materias in a separate, speciay marked container and dispose of environmentay. Do not eave any toos or other objects, which coud cause damage, in the engine compartment. Check and change the cooant ony when the engine is cod. Catch the cooant and dispose of environmentay. You shoud ony assembe tires if you have the necessary experience and with the proper equipment. If necessary have the tires mounted by a speciaised workshop. Ensure correct tire pressure and do not exceed the highest specified pressure. Check tires and whees every day for pressure drop, cuts, buges, damaged rims, missing whee studs and nuts. Do not drive with damaged tires or whees. Non-sticking emusions for tires must ony be made up of a mix of water and a concentrated antistick agent according to the instructions of the manufacturer. Observe the reguations for the protection of the environment. Working on eectrica equipment Before working on eectrica equipment disconnect the battery and cover it with insuating materia. Do not use any fuses with higher Ampere ratings and do not repair fuses with a piece of wire. Fire hazard Ceaning Aways disconnect the battery before starting to wed on the machine. Do not cean the machine whie the engine is running. Working on the battery Do not use gasoine or other combustibe substances for ceaning purposes. When working on the battery do not smoke, no open fames. When using steam ceaning equipment do not subject eectrica components and insuating materias to the direct water jet, but cover them beforehand. Do not et your hands or cothes come in contact with acid. In case of injuries caused by acid, fush off with cear water and consut a doctor. Meta objects (e.g. toos, rings, wrist watches) must not contact the battery poes - danger of short circuit and burns After maintenance work When recharging maintenance free batteries remove the pugs to avoid the accumuation of exposive gases. When using an externa battery to start the machine foow the respective instructions. Dispose of od batteries environmentay. Switch the charging current off before removing the charge camps. Ensure good ventiation, especiay when charging the battery in a cosed room. 24 Do not guide the water jet into the exhaust or into the air fiter. Reinsta a protective devices after competing the maintenance work. Repair Mark a defective machine by attaching a warning tag to the steering whee. Repair work must ony be performed by quaified and authorized persons. Use our repair instructions for this work.

25 Safety reguations Exhaust gases are highy dangerous Aways ensure an adequate suppy of fresh air when starting in cosed rooms Test The safety of compaction equipment must be checked by a speciaist as required in dependence on the appication and the operating conditions, however at east once every year. Information and safety stickers/decas on the machine Keep safety stickers in good and egibe condition (see parts manua) and compy with their meaning. Repace damaged and iegibe stickers/decas. 25

26 Safety reguations 7 Box B Box A F 11/15A F 68/20A F 12/15A F 139/30A F 08/15A F 04/10A F 09/15A F 119/10A F 10/15A F 30/10A F 07/15A F 45/10A F 41/10A F 23/10A F 05/15A F 48/10A = STOP Fig. 7 Stickers and decas BW 100/120/125 AD-4 1 Warning sticker - Danger of crushing 9 2 Brief operating instructions 3 Warning sticker - Danger of tipping over1 10 Information sticker - Guaranteed sound capacity eve 4 Information sticker - Ba vave vibration 11 Information sticker - Lashing point 5 Information sticker - Aocation of fuses 12 Information sticker - Lifting point 6 Maintenance sticker 13 Information sticker - Engine oi drain 7 Operation sticker - Trave ever 14 Prohibition sticker - High pressure ceaner 8 Operation sticker - Water sprinking system 15 Information sticker - Hydrauic oi Information sticker - Water 16 Information sticker - Low suphur fue 1 26 ony BW 100 AD-4 17 Information sticker - Diese

27 Safety reguations 7 Box B Box A F 11/15A F 68/20A F 12/15A F 139/30A F 08/15A F 04/10A F 09/15A F 119/10A F 10/15A F 30/10A F 07/15A F 45/10A F 41/10A F 23/10A F 05/15A F 48/10A = STOP Fig. 8 Stickers and decas BW 100/120 AC-4 1 Warning sticker - Danger of crushing 2 Brief operating instructions 10 Information sticker - Guaranteed sound capacity eve 3 Operation sticker - Brake reeasing device 11 Information sticker - Emusion 4 Warning sticker - Danger of tipping over1 12 Information sticker - Lashing point 5 Information sticker - Aocation of fuses 13 Information sticker - Lifting point 6 Maintenance sticker 14 Information sticker - Engine oi drain 7 Operation sticker - Trave ever 15 Prohibition sticker - High pressure ceaner 8 Operation sticker - Water sprinking system 16 Information sticker - Hydrauic oi 9 Information sticker - Water 17 Information sticker - Low suphur fue 1 ony BW 100 AC-4 18 Information sticker - Diese 27

28 Safety reguations Fig. 9 Fig. 12 Operation sticker - Fodabe ROPS1 Operation sticker - Centra ifting device3 Fig. 10 Fig. 13 Warning sticker - Fodabe ROPS1 Information sticker - Main battery switch4 S_0019 S_0005 Fig. 11 Fig. 14 Instruction sticker - Aways wear your seat bet2 Information sticker - Biodegradabe hydrauic oi Optiona equipment Optiona equipment Optiona equipment Optiona equipment Optiona equipment

29 Safety reguations Fig. 15 Fig. 18 Information sticker - Panoin 461 Operation sticker "Chip spreader" 4 Fig. 16 Fig. 19 Operation sticker - Edge cutter 2 Warning sticker "Chipping temperature" Fig. 17 Information sticker - Ba vave, vibration 3-stages3 (ony AD) Optiona equipment Optiona equipment Optiona equipment 4 5 Optiona equipment Optiona equipment 29

30 Safety reguations 30

31 4 Indicators and Contros 31

32 Indicators and Contros Fig

33 Indicators and Contros tem 1 Instrument custer 2 Rotary switch for ighting1 12 Interva switch for pressure sprinking system1 3 Rotary switch for working ights1 13 Fuse box 4 Rotary switch for seat heating1 14 Start switch 1 5 Rotary switch for fashing beacon 6 Rotary switch for hazard ight system1 16 Push button for manua vibration 7 Rotary switch for vibration, manua or automatic1 17 Trave ever 8 Emergency stop push button 19 Rotary switch for edge cutter1 9 Push button for warning horn 20 Water eve gauge 10 Rotary switch for direction indicators1 11 Rotary switch for gravity feed sprinking sys1 Optiona equipment 15 Ba vave, vibration (ony AD) 18 Throtte ever 21 Foot switch for rubber tire sprinking system (ony AC) or foot switch for fow divider (ony AD)1 33

34 Indicators and Contros 4.1 Genera notes 4.2 Description of indicators and contro eements If you are not yet famiiar with the contro and dispay eements on this machine you shoud read this section thoroughy before starting any operation on the machine. Here a functions are described in detai. The section "Operation" contains ony brief descriptions of the individua contro steps. Fig. 21 No. 1 = Instrument custer i Note With the ignition switch in position "I" a gauges and instruments are switched on for a moment. a yeow = Warning ight for seat contact monitoring whie machine is traveing warning buzzer sounds, engine is shut down after 4 seconds. = Warning ight for seat contact monitoring with machine at rest engine is shut down when trave ever is moved out of "0"-position. b yeow c red 34 = Preheating contro ight Lights in ignition switch position "II" Preheating for starting at ow temperatures = Engine oi pressure warning ight fashes when the engine oi pressure is too ow, the warning buzzer sounds, the engine is shut down after 10 seconds.

35 Indicators and Contros Check engine oi eve, repair the engine if necessary. d yeow Position "right" = Trave ight on, with ignition switch in position "I". = Charge contro amp Lights if the battery is not being charged. Check the V-bet, if necessary repair the generator. e red = Engine temperature warning ight Fashes when the engine overheats (110 C), the warning buzzer sounds. Switch off vibration, run engine with ide speed or shut down engine if necessary, cean engine oi cooer and radiator, if necessary repair engine. f green = Indicator contro ight No. 3 = Rotary switch for working ight2 g red = Parking brake warning ight Lights when the parking brake is appied Position "eft" h = Operating hour meter Counts the operating hours whie the engine is running. Maintenance work is to be carried out in accordance with the indicated operating hours. i = Fue eve gauge Fig. 23 = Working ight off Position "right" = Working ight on, with ignition switch in position "I" Fig. 24 No. 4 = Rotary switch for seat heating3 Position Left = Seat heating off Position Right = Seat heating on Fig. 22 No. 2 = Rotary switch for ighting1 Position "eft" = Light off Position "midde" = Side ight on, with ignition switch in position "I" 1 Optiona equipment 2 3 Optiona equipment Optiona equipment 35

36 Indicators and Contros Fig. 25 Fig. 27 No. 5 = Rotary switch for fashing beacon1 No. 7 = Rotary switch for vibration, manua or automatic3 Position "eft" = Fashing beacon off Position "right" = Fashing beacon on Position "eft" = Pre-seection for vibration activation during trave via the vibration push button in the trave ever Position "right" = Pre-seection for automatic activation and deactivation of vibration when exceeding or faing beow a certain sow trave speed. Fig. 26 No. 6 = Rotary switch for hazard ight system2 Position "eft" = Hazard ight system switched off Position "right" = Hazard ight system switched on. Warning ights in switch and indicator contro ight in the instrument custer start fashing Optiona equipment Optiona equipment Fig. 28 No. 8 = Emergency stop push button 3 Optiona equipment

37 Indicators and Contros Position "midde" = Direction indicators disabed. Danger Danger of accident Use ony in events of emergency during operation. Do not use as parking brake. Restart the machine ony after the danger that caused the actuation of the emergency stop switch has been eiminated. The machine is braked immediatey, the engine is shut down. actuate switch off/unock = press the button competey down, it automaticay ocks in fuy pressed position. Position "eft or right" = Front and rear direction indicators on the corresponding side are fashing. Indicator contro ight in instrument custer fashes. i Note If the cabe to the chip spreader is pugged in, the green contro ight in the rotary switch wi aso fash as a function contro. If the contro ight does not fash, one of the indicators on the vehice or on the chip spreader is defective. = Turn button cockwise. Restart the engine. Fig. 31 Fig. 29 No. 9 = Push button for warning horn No. 11 = Rotary switch for gravity feed sprinking system Position "eft" = Gravity sprinking system switched off Position "right" = Gravity sprinking system switched on Fig. 30 No. 10 = Rotary switch for direction indicators1 1 Optiona equipment 37

38 Indicators and Contros (4) 10A = (F119) Engine (5) 10A = (F30) Seat heating1 (6) 10A = (F45) Edge cutter1 (7) 10A = (F23) Warning horn (8) 10A = (F48) pre-heating system Fuse box B (1) 15A = (F11) Head ights, eft1 (2) 15A = (F12) head ights, right1 (3) 15A = (F08) Direction indicators1 and working head ights Fig. 32 (4) 15A = (F09) Parking and tai ight, eft1 No. 12 = Interva switch for pressure sprinker system (5) 15A = (F10) Parking and tai ight, right1 Position 0 = Interva and pressure sprinking system switched off. (7) 10A = (F41) Fashing beacon1 Position 11 = Permanent sprinking and function test. further positions (6) 15A = (F07) Hazard ight1 (8) 15A = (F05) Socket1 = various sprinking intervas. Box B Box A F 11/15A F 68/20A F 12/15A F 139/30A F 08/15A F 04/10A F 09/15A F 119/10A F 10/15A F 30/10A F 07/15A F 45/10A F 41/10A F 23/10A F 05/15A F 48/10A Fig. 34 Main fuse for battery 80A = F 00 Fig. 33 No. 13 = Fuses Danger Fire hazard Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fuse box A (1) 20A = (F68) Potentia 30 (2) 30A = (F139) Engine soenoid (3) 10A = (F04) Gauges 1 38 Optiona equipment

39 Indicators and Contros Caution Run the engine warm for a short whie before starting work. Do not rev up a cod engine to high ide speed/fu oad speed. Do not shut down the engine a of a sudden from fu oad speed, but et it ide for about 2 minutes. Fig. 35 No. 14 = Start switch Position "P"/"0" = Ignition off, key can be pued out Position "I" = Ignition on, a warning and contro ights in the instrument custer ight up for a moment *test function(, the ighting szstem can be switched on. Position "II" = Pre-heating position, at temperatures beow +10 C, hod the ignition key in position "II" for up to 30 seconds, the preheating contro ight in the instrument custer ights. i Fig. 36 No. 15 = Ba vave, vibration (ony AD) Position upward = Vibration of both drums Position downward = Vibration of front drum ony Note The engine can ony be started if the trave ever is in braking position and the emergency stop switch is unocked. The starter switch is designed with a re-start ock. For a new starting attempt the ignition key must first be turned back to position "0". Position "III" = Turn further against spring pressure, the engine starts, turn the ignition key back to position "I" once the engine has started. Fig. 37 Ba vave, vibration 3-stages 1 (ony AD) Position upward = Vibration of front drum ony Position horizonta = Vibration of both drums 1 Optiona equipment 39

40 Indicators and Contros Position downward = Vibration of rear drum ony Fig. 40 No. 18 = Throtte ever Fig. 38 No. 16 = Push button vibration press = to switch the vibration on and off. Position "MAX II" Position "MAX I" = Fu oad position 2500 rpm, operating position for driving and vibration. = Fu oad position 2400 rpm, operating position for driving and vibration. Position "MIN" = Ide speed position Fig. 39 No. 17 = Trave ever Position "0" = Neutra position for engine start, brake cosed. Position "I" = Forward trave without vibration Fig. 41 Position "II" = Reverse trave without vibration Position "III" = Max. forward/reverse trave with vibration Position "midde" = Edge cutter stops at the presenty reached position No. 19 = Rotary push button for edge cutter1 Position "eft" = Edged cutter is raised. Position "right" = Edged cutter is owered Optiona equipment

41 Indicators and Contros Fig. 42 Fig. 44 No. 20 = Water eve gauge Foot switch for fow divider1 (ony AD) shows the water eve inside the water tank. press = fow divider switched on reease = fow divider switched off Fig. 43 No. 21 = Foot switch for tire sprinker system (ony AC) Fig. 45 press = Sprinker system switched on No. 22 = Rotary switch/button for windscreen wiper/washer2 reease = Sprinker system switched off Position "eft" = The windscreen wiper is switched on Position "midde" = The windscreen wiper is switched off Position "right" (button) = The windscreen wiper/washer is switched on 1 2 Optiona equipment Optiona equipment 41

42 Indicators and Contros I I II II Fig. 46 Fig. 47 No. 23 = Ba vave, brake reeasing device (ony AC) No. 24 = Main battery switch1 i Danger Danger of accident Aways secure the ba vave of the brake reeasing feature with the ocking screw when cosed. Before reeasing the parking brake secure the machine against unintended roing by using appropriate means (e.g. meta whee chocks). Stricty foow the description and the safety instructions in chapter "Towing". Position "I" = Brake appied Position "II" = Brake reeased i Note The main battery switch is ocated inside the battery compartment. Position "I" (90 up) = Disconnects the batteries from the vehice eectrics in case of burning cabes and fire in the engine compartment, protection against unauthorized use, during weding work on the machine. Can be removed. Position "II" (horizonta) = Operating position, engine can be started. Note Reease the brake by turning the steering whee in cockwise direction. Fig. 48 No. 25 = Ba vave for chip spreader Optiona equipment Optiona equipment

43 Indicators and Contros Position "I" = Pre-seection vibration, rear drum Position "II" = Pre-seection chip spreader Fig. 49 No. 26 = Adjustment ever for chip quantity1 to the eft = ower chip quantity towards the right = higher chip quantity Fig. 50 No. 27 = Lever to side the chip spreader2 to the eft = The chip spreader sides to the eft to the right = The chip spreader sides to the right 1 2 Optiona equipment Optiona equipment 43

44 Indicators and Contros 44

45 5 Operation 45

46 Operation 5.1 Genera If you are not yet acquainted with the contros and indicating eements on this machine you shoud thoroughy read chapter "Indicators and contro eements" before starting work. 5.2 Tests before taking into operation Before the everyday use or before a onger working period the foowing tests and inspections must be performed. A indicators and contro eements are described in detai in this chapter. Danger Pease observe stricty the safety reguations in the corresponding section of this instruction manua Park the machine on ground as eve as possibe. Check: fue tank and fue ines for eaks Screw connections function of steering function of emergency stop function of parking brake machine for ceaniness, damage presence of the appropriate operating and maintenance instructions proper maintenance of the machine i Note For a description of the foowing tasks refer to the chapter "maintenance every 10 operating hours". Engine oi eve, top up if necessary Fue eve, top up if necessary. Hydrauic oi eve, top up if necessary. Cooant eve, top up if necessary Dry air fiter service indicator Water eve, top up if necessary. Emusion eve, top up if necessary Air pressure in tires 1 46 Checking the chip spreader1 and ceaning the spreading beam Optiona equipment

47 Operation Eectronic immobiizer Adjusting the operator's seat Before starting the engine the anti-theft protection* must be disarmed by entering a code. Danger Danger of accident b Do not adjust the seat whie driving. a Fig. 51 i Note With the eectronic immobiizer armed, the ight emitting diode (a) (Fig. 51) fashes sowy. Sowy enter the six-digit user code. i Note When entering the code, the ight emitting diode (6) ights up with every digit. Press the diamond button. The eectronic immobiizer is now disarmed and the engine can be started within the next 15 minutes. 1 Fig. 52 To adjust the seat in ongitudina direction push the ever 1 (Fig. 52) outwards. Pu the ever (2) up and adjust the backrest. Operate the ever (3) to adjust the weight of the operator. i Note In its setting the ever (3) is ocked in upwards direction. This ock can be reeased by pressing the ever down against the end stop. Then adjust the operator's weight by siding the ever downwards. Optiona equipment 47

48 Operation 5.5 Starting the engine Danger Danger of accident Danger of injury Wear your persona noise protection means (ear defenders) before starting operation. Start the engine ony from the operator s seat. Caution In this chapter it is assumed that the operator is fuy acquainted with the function of the different contro eements on the machine. Fig. 53 Fig. 55 Set the throtte ever (Fig. 55) to position "MIN". Fig. 56 Fasten your seat bet (Fig. 53). Check, whether the emergency stop switch (Fig. 56) is unocked. Fig. 54 Shift the trave ever (Fig. 54) to position "0". Fig Turn the ignition key (Fig. 57) to position "I".

49 Operation With cod ambient temperatures hod the ignition key up to 30 seconds in position "II"; the preheating contro ight (b) (Fig. 58) ights up. As soon as the engine ignites return the ignition key to position "I". The engine oi pressure warning ight and the charge contro ight go out. The parking brake warning ight stays on. Caution Run the engine warm for a short whie before starting work. Do not rev up a cod engine to high ide speed/fu oad speed. Fig. 58 A contro and warning ights (Fig. 58) in the instrument custer ight up for approx. 3 seconds. The engine oi pressure warning ight (c) fashes, the charge contro ight (d) and the parking brake warning ight (g) stay on. Caution Run the starting process for maximum 20 seconds without interruption and pause for a minute between starting attempts. If the engine has not started after two attempts perform troube shooting. i Note The starter switch is designed with a re-start ock. For a new starting attempt the ignition key must first be turned back to position "0". Fig. 59 Turn the ignition key (Fig. 59) through position "II" to position "III", the starter wi crank the engine. 49

50 Operation 5.6 Once the engine is running switch on a powerfu consumer (working ight, etc.). Starting with jump wires Caution If no powerfu consumer is switched on votage peaks may occur when separating the connecting cabes between the batteries, which coud damage eectrica components. After starting disconnect the negative poes (ground cabe) first and the positive poes after. Switch off the consumer. Cose the battery compartment with the cover. Fig. 60 Remove the cover from the battery compartment (Fig. 60). Fig. 61 Caution A wrong connection wi cause severe damage in the eectric system. Ony use a 12 Vot battery to bridge the machine. When jump starting with an externa battery connect both pus poes first. Then connect the ground cabe first to the minus poe of the current suppying battery and then to engine or chassis ground, as far away from the battery as possibe (Fig. 61). Start as described under 'Starting the engine'. 50

51 Operation 5.7 Driving the machine Caution During operation the throtte ever aways remains ocked in one of the fu oad positions. Contro the trave speed with the trave ever. Danger Danger of accident Wet and oose sois consideraby reduce the ground adhesion of the machine on incinations and sopes. Soi conditions and weather infuences impair the cimbing abiity of the machine. Do not drive up and down incinations which exceed the maximum gradabiity of the machine (see chapter "technica data"). Driving across sopes shoud therefore be stricty avoided, because of the high risk of tipping over and the reated risk of severe or even fata accidents. Fig. 63 You shoud therefore aways drive straight up or down a sope. For roers with a drum width of 1 m or ess there is a considerabe risk of tipping over near edges (e.g. curbstones, embankments, trenches, pothoes) when driving over these edges. Caution Do not operate jerkiy Do not drive without wearing your seat bet. Disengage the trave ever (Fig. 63) out of braking position and move it sowy to the desired trave direction. Position "I" = max. forward trave without vibration Before starting to drive make sure that the drive range is absoutey safe. Position "II" = max. backward trave without vibration Drive and operate the machine ony from the driver s seat. Position "III" = Max. forward/backward trave with vibration Fig. 62 Fig. 64 Aways give way to oaded transport vehices Set the throtte ever (Fig. 62) to fu oad position "Max I" or "MAX II". The parking brake warning ight (g) (Fig. 64) in the instrument custer goes out. 51

52 Operation Important notes on trave operation To continue driving occupy the seat and put on the seat bet within 4 seconds. The warning ights go out and the warning buzzer stops to sound. If the engine stops restarting is required. Caution When changing the trave direction hod the trave ever for a moment in "0"-position, unti the machine has stopped, before actuating to the new trave direction. Do not operate jerkiy Contro the trave speed with the trave ever. When driving up and down incinations move the trave ever sowy back towards neutra to brake the machine. Seat contact switch1 Fig. 65 With the machine parked the warning ight for the seat contact switch (a) (Fig. 65) ights up together with the parking brake warning ight (g) when the driver's seat is not occupied. The machine cannot drive. i Note When moving the trave ever out of braking position the engine wi be shut down immediatey. Danger Danger of accident If the seat is not occupied when the machine is driving, the warning buzzer wi sound, the engine wi be shut down after 4 seconds and the parking brake wi cose Optiona equipment

53 Operation 5.8 Stopping the machine, operating the parking brake 5.9 Shutting down the engine Fig. 68 Fig. 66 Shift the trave ever (Fig. 66) sowy to "0"-position. The machine is automaticay braked by the hydrostatic drive and the parking brake is appied. Shift the trave ever (Fig. 68) sowy to position 0. The machine is automaticay braked by the hydrostatic drive and the parking brake is appied. Fig. 69 Fig. 67 The parking brake warning ight (g) in the instrument custer (Fig. 67) ights up. The parking brake warning ight (g) (Fig. 69) in the instrument custer ights up. 53

54 Operation 5.10 Switching the vibration on and off Danger Risk of damage When compacting with vibration you must check the effect of nearby buidings and underground suppy ines (gas, water, sewage, eectric power), if necessary stop compaction with vibration. Fig. 70 Set the throtte ever (Fig. 70) to position "MIN" (ide speed). Caution Caution Danger of bearing damage Do not activate the vibration on hard (frozen, concrete) ground. Do not shut down the engine a of a sudden from fu oad speed, but et it ide for about 2 minutes. Caution Switch on vibration ony with the throtte ever in fu oad position "MAX I" or "MAX II". Vibration at standsti causes transverse ruts, therefore: switch the vibration on ony after shifting the trave ever to the desired trave direction. Switch the vibration off before stopping the machine. Fig. 71 Turn the start switch (Fig. 71) to position "0" and pu out the ignition key. Danger Danger of accident Secure the machine against unauthorized use, pu the ignition key out. Mark machines, which coud be in the way, with a ceary visibe sign. 54

55 Operation Pre-seecting vibration (ony AD) Switching the vibration on Fig. 72 Fig. 74 Set the throtte ever (Fig. 74) to position "Max I" or "MAX II". Caution Destruction of hydrauic components Switch the ba vave ony when the vibration is switched off. Pre-seect the desired drum or drums with the ba vave (Fig. 72). Vibration in manua mode Fig. 75 Actuate the vibration push button (Fig. 75) ony after shifting the trave ever to the desired trave direction. i Fig. 73 Turn the rotary switch for vibration in manua or automatic mode (Fig. 73) anti-cockwise to the symbo "Manua". Note When shifting the trave ever through position "III" to position "I" or "II", the vibration wi be automaticay switched off. Switching the vibration off Caution Aways switch the vibration off before stopping the machine. Press the vibration push button again. 55

56 Operation Vibration in automatic mode i Note In automatic mode the vibration is switched on when exceeding a trave speed of 1.3 km/h. Vibration is switched off at a speed beow 1.3 km/ h. Fig. 78 Pu the trave ever (Fig. 78) out of zero position (braking position) and shift it sowy to the desired trave direction forward or backwards ("III") i Note The vibration comes on at a ow trave speed. Fig. 76 Turn the rotary switch for vibration in manua or automatic mode (Fig. 76) cockwise to the symbo "AUTOMATIC". When shifting the trave ever through position "III" to position "I" or "II", the vibration wi be automaticay switched off. Switching the vibration off Switching the vibration on Shift the trave ever sowy to position 0. The machine is deceerated and the vibration wi automaticay switch off at a ow trave speed. Fig Set the throtte ever (Fig. 77) to position "Max I" or "MAX II".

57 Operation 5.11 Switching the gravity sprinking system on and off 5.12 Switching the pressure sprinking system1 on and off Fig. 79 Turn the rotary switch for gravity feed sprinking system (Fig. 79) to the right, the gravity feed sprinking system is switched on. Fig. 80 Check the water eve indicator on the water tank (Fig. 80) whether the water tank is fied. Turn the rotary switch for gravity feed sprinking system to the eft, the gravity feed sprinking system is switched off. Fig. 81 Switch the interva switch for pressure sprinking (Fig. 81) to the desired fow interva. Position "0" = Sprinker system switched off Position "1" to "10" = Interva sprinking pre-seected Position "11" 1 = Permanent sprinking pre-seected Optiona equipment 57

58 Operation Fig. 84 Fig. 82 Shift the trave ever out of braking position towards "0"-position (Fig. 82) to switch the pressure sprinker system on. i Note i Note The parking brake warning ight (g) (Fig. 84) in the eft hand instrument custer ights up. With the pressure sprinker system switched on sprinking wi continue for another 30 seconds. The sprinker system wi ony work when the trave ever is in direction "0"-position. This is aso the testing position for interva position "11". Fig. 85 To switch off the pressure sprinking system switch the interva switch for pressure sprinking (Fig. 85) to position "0". Fig To switch off the pressure sprinker system return the trave ever to the position "brake cosed" (Fig. 83).

59 Operation 5.13 Switching the tire sprinking system on and off (ony AC) 5.14 Actuating the emergency stop switch Danger Danger of accident In events of emergency and in case of danger actuate the emergency stop switch immediatey. Start trave operation of the machine ony after the danger that caused the actuation of the emergency stop switch has been eiminated. Fig. 86 Actuate the foot switch (Fig. 86). Caution Do not use as service brake. The deceeration is extremey high. In case of frequent use the wear on the muti-dics brakes wi be very high. The tire sprinking system is switched on. Reease the foot switch. The tire sprinking system is switched off. Fig. 87 Press the button of the emergency stop switch (Fig. 87) competey down, it automaticay ocks in fuy pressed position. i Note Shuts the engine down and coses the brake. Turn the button cockwise to unock the emergency stop switch. Start the engine again, see chapter "Starting the engine". 59

60 Operation 5.15 Mounting/removing the chip spreader1 Danger Danger of accident When mounting or removing the chip spreader do not step between the chip spreader and the machine whie the engine is running. Park the machine on a eve and soid base to mount or remove the chip spreader and shut down the engine. Mount and remove the chip spreader when it is empty. Fig. 89 Insert the bot (Fig. 89) and secure it with the cotter pin. Mounting the chip spreader Fig. 90 Connect the chip spreader hydrauicay and eectricay with the machine (Fig. 90). Fig. 88 Lift the chip spreader by the ifting points (Fig. 88) and hook it carefuy into the fixing points on the machine. Disassembing the chip spreader Empty the chip spreader, see section "Fiing/ emptying the chip spreader". Danger Danger of accident Aways stand the chip spreader on eve and firm ground Optiona equipment

61 Operation Fig. 91 Fig. 94 Turn the ba vave for the chip spreader to position "I" (Fig. 91). Danger Danger of accident Before puing out the bot (Fig. 94) make sure that the chip spreader is mounted correcty. Remove the cotter pin and pu out the bot. Lift the chip spreader out of the fastening points on the machine and pace it on eve and firm ground. Fig. 92 Disconnect the chip spreader hydrauicay and eectricay from the machine (Fig. 92). Fig. 93 Hook the chip spreader to the fastening points (Fig. 93). 61

62 Operation 5.16 Fiing/emptying the chip spreader1 i Note Aways empty the chipping hopper before transporting the machine. Fiing Caution Fi ony with dry chippings. The chippings must not contain more than 1% of asphat, otherwise the spreading beam may become stuck. Do not fi with more than 200 itres of chippings, as otherwise the permitted tota weight woud be exceeded. The temperature of the materia to be spread must not exceed 80 C, as otherwise the shaft wi be damaged. Fig. 96 Fig. 95 Fig. 97 Fi the chippings container with no more than 200 itres of chippings (Fig. 95) (specific weight of chippings 1.5 t/m³). Emptying Fod up the fap (Fig. 96). Loosen the star knobs (Fig. 97), fod down the spreading screed and aow the chipping to tricke out. Cean the spreading screed. Danger Danger of injury Never enter the spreader shaft area whie the spreader shaft is running. Empty the hopper ony with the engine off Optiona equipment

63 Operation 5.17 Operating the chip spreader1 Preparing the spreading process Fig. 100 Set the required chipping quantity with the chipping quantity adjustment ever (Fig. 100). i Note The setting may be corrected whie traveing. Fig. 98 Turn the vibration ba vave down (B) (Fig. 98) for chip spreading without vibration. Turn the vibration ba vave to horizonta position (A) for chip spreading with vibration of front drum. Caution With the ba vave in horizonta position (A) (Fig. 98) foow the instructions for work with vibration, see chapter "Switching vibration on and off". Fig. 101 Operate the ever (Fig. 101) to side the chip spreader to eft or right to the desired speading position. Fig Turn the ba vave for the chip spreader to position "II" (Fig. 99). Optiona equipment 63

64 Operation Switching the chip spreader on and off 5.18 Towing Danger Danger of accident Danger of injury Before reeasing the parking brake secure the machine against unintended roing by using appropriate means (e.g. meta whee chocks). Use a towing vehice with sufficient traction and braking power for the unbraked towed oad. Use a tow bar. Using the machine as towing vehice is not permitted. Fig. 102 Switch the chip spreader on and off with the vibration button (Fig. 102). The machine cannot be steered. Do not touch hot engine parts. Caution Tow the machine ony after having reeased the parking brake. Towing speed 1 km/h, max. towing distance 500 m. With the chip spreader1 attached the machine must not be towed backwards. Fig Tow the machine by the front or rear towing eye 1 (Fig. 103). Optiona equipment

65 Operation Reeasing the brake (ony AD) Reeasing the brakes on drum and rubber whees (ony AC) I 2 II Fig. 104 Remove two pugs (Fig. 104). Fig. 106 Unscrew the fastening screw (1) (Fig. 106). Switch the ba vave (2) over. Position "II" = Brake reeased Turn the steering whee sowy approx. two turns in cockwise direction. After towing Danger Danger of accident Fig. 105 Press both screws (Fig. 105) in against springs. Tighten both screws aternatey and in steps with 35 Nm unti they bottom. Before oosening the drawbar secure the machine against unintended roing by using appropriate means (e.g. meta whee chocks). The machine must ony be started without the mechanica brake reeasing device being activated. Aways secure the ba vave of the brake reeasing feature (ony AC) with the ocking screw. 65

66 Operation counter it with the hexagon nut (ony AC-machines). Fig. 107 Competey reease both screws (Fig. 107) to cose the brake. Fig. 108 Screw both pugs (Fig. 108) back in and tighten them with 20 Nm. I 2 II Fig Switch the ba vave (2) (Fig. 109) back to position "I", turn the ocking screw back in and

67 Operation 5.19 Loading/transport Loading with oading ramp Danger Danger of accident Life hazard Use ony stabe oading ramps of sufficient oad bearing capacity. The ramp incination must be ess than the gradabiity of the machine. Make sure that persons are not endangered by the machine tipping or siding off. During demonstration and when oading the machine do not remain in the danger zone of the machine. Fod the fodabe ROPS back. Loading by crane Caution Aways empty the chip spreader 1 before transport. Fod down the fodabe ROPS2 for transport. Loosen the eye bots (Fig. 111) and adjust the camping pates verticay. After driving the machine onto the transport vehice attach the articuation ock. Fig. 111 Danger Danger of accident Life hazard Engage the articuation ock. Drive the machine carefuy on the transport vehice. Aways use shackes on the ifting points for oading the machine. Check a ifting points for damage before ifting the machine. Do not use a damaged or in any other way impaired ifting and points. Lifting tacke must ony be attached to oads by expert personne (quaified person). Lift the machine ony with suitabe ifting gear. Use ony safe ifting gear of sufficient oad bearing capacity Minimum ifting capacity of ifting gear: see operating weight in chapter "Technica Data". Do not ift or ower the machine jerkiy. The tension must aways be effective in vertica direction. Fig After driving the machine onto the transport vehice swing the articuation ock (Fig. 110) out of its receptace and fasten it with the bot to the eye. Secure the bot with the cotter pin. Optiona equipment The machine must not swing about when being ifted. Do not step or stand under suspended oads. 2 Optiona equipment 67

68 Operation Caution Aways empty the chip port. spreader 1 before Engage the articuation ock. Fod down the fodabe ROPS2 trans- ifting gear: see operating weight in chapter "Technica Data". Do not ift or ower the machine jerkiy. The tension must aways be effective in vertica direction. The machine must not swing about when being ifted. Do not step or stand under suspended oads. After ifting hook the ifting bet back into its receptace. Have the ifting tacke inspected by an expert (propery trained person) once every year. After 5 years repace the ifting bet with a new one. Engage the articuation ock. Fod down the fodabe ROPS4 Fig. 112 Fod the vandaism protection down to protect the dashboard. Use the four ifting eyes (Fig. 112) on the support egs to ift the machine. Loading with a ifting bet3 Danger Danger of accident Life hazard With the chip spreader attached the machine must not be ifted with ifting bets, because of the changed centre of gravity. Engage the articuation ock. Check a ifting tacke for damage before ifting the machine. Do not use damaged or in any other way impaired ifting tacke. Fig. 113 Lifting tacke must ony be attached to oads by expert personne (quaified person). To ift the machine pu out the ifting eye from the bracket and hook it into the ifting gear (Fig. 113). Do not overoad the ifting bet. Use ony safe ifting gear of sufficient oad bearing capacity Minimum ifting capacity of Optiona equipment Optiona equipment Optiona equipment 4 Optiona equipment

69 Operation Fig. 114 Fig. 115 Reattach the ifting eye to the bracket after the ifting process (Fig. 114). Fod up the covers on front and rear frames. Lash the machine down, so that it is secured against roing, siding and turning over. Use the ashing eyes (Fig. 115) on front and rear frame for this purpose. Lashing Danger After transport Danger of accident Life hazard Aways use shackes on the ifting points for ashing down the machine. Check a ashing points for damage before ashing down the machine. Do not use a damaged or in any other way impaired ashing points. Lash the machine down, so that it is secured against roing, siding and turning over. Danger Life hazard Operate the machine ony with the fodabe ROPS1 propery fastened and the fastening screws tightened with the correct tightening torque. After transport reease the articuation ock again and store it in the receptace. Caution Never attach the ashing gear to the chip spreader. Fig Pu the bot out of the articuation ocking bar and swing the ocking bar back into its receptace (Fig. 116). Optiona equipment 69

70 Operation Fig. 117 To fod up the fodabe ROPS aign the camping pates on both sides verticay (Fig. 117). Fig. 118 Fod up the fodabe ROPS (Fig. 118). Turn the camping pates to horizonta position and tighten the eye bots with a tightening torque of Nm. 70

71 6 Maintenance 71

72 Maintenance 6.1 Genera notes on maintenance When performing maintenance work aways compy with the appropriate safety reguations. Thorough maintenance of the machine guarantees far onger safe functioning of the machine and proongs the ifetime of important components. The effort needed for this work is ony itte compared with the probems that may arise when not observing this rue. Drums with inside zinc ining are not suitabe to store fue. When choosing the storage pace for fue make sure that spied fue wi not harm the environment. Do not et the hose stir up the surry at the bottom of the drum. The fue drum must rest for a onger period of time before drawing off fue. The rest in the drum is not suitabe for the engine and shoud ony be used for ceaning purposes. The terms right/eft correspond with trave direction forward. Aways cean machine and engine thoroughy before starting maintenance work. For maintenance work stand the machine on eve ground. Aways remove the main battery switch for a maintenance work. Perform maintenance work ony with the motor switched off. Reieve hydrauic pressures before working on hydrauic ines. Before working on eectric parts of the machine disconnect the battery and cover it with insuation materia. Notes on the performance of the engine On diese engines both combustion air and fue injection quantities are thoroughy adapted to each other and determine power, temperature eve and exhaust gas quaity of the engine. If your engine has to work permanenty in "thin air" (at higher atitudes) and under fu oad, you shoud consut the customer service of or the customer service of the engine manufacturer. Notes on the cooing system Prepare and check cooant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing. When working in the area of the articuated joint attach the articuation ock (transport ock). The cooant is prepared by mixing a cooing system protection agent (ethyene gyco) into the cooant. Environment During maintenance work catch a ois and fues and do not et them seep into the ground or into the sewage system. Dispose of ois and fues environmentay. Keep used fiters in a separate waste container and dispose of environmentay. Catch biodegradabe ois separatey. Notes on the fue system The ifetime of the diese engine depends to a great extent on the ceaniness of the fue. 72 Keep fue free of contaminants and water, since this wi damage the injection eements of the engine. Mixing with cooing system protection agent is necessary in a cimatic zones. It prevents corrosion, owers the freezing point and raises the boiing point of the cooant. Notes on the hydrauic system During maintenance work on the hydrauic system ceaniness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Sma partices can produce futes in vaves, cause pumps to seize, cog nozzes and piot bores, thereby making expensive repairs inevitabe. If, during the daiy inspection of the oi eve the hydrauic oi eve is found to have dropped, check a ines, hoses and components for eaks.

73 Maintenance Sea externa eaks immediatey. If necessary inform the responsibe customer service. 6.2 Do not store drums with hydrauic oi outdoors, or at east under a cover. Water can be drawn in through the bunghoe when the weather changes. Engine oi We recommend to use the fiing and fitering unit with fine fiter to fi the system. This ensures finest fitration of the hydrauic oi, proongs the ifetime of the hydrauic oi fiter and protects the hydrauic system. Cean fittings, fier covers and the area around such parts before disassemby to avoid entering of dirt. Do not eave the tank opening unnecessariy open, but cover it so that nothing can fa in. Fues and ubricants Quaity Lubrication ois are cassified according to their performance and quaity cass. Ois according to other comparabe specifications may be used. If ow suphur fue (< 0.05%) is used, you must ony use engine ois of API1-cassification CF, CF-4, CG-4, CH-4 and CI-4. For operation of an engine with high suphur fues it is recommended to use an engine oi of cassification CF or higher with a tota base number of at east 10. Caution Engine ois of cassification CJ-4 must not be used Oi viscosity Since ubrication oi changes its viscosity with the temperature, the ambient temperature at the operating ocation of the engine is of utmost importance when choosing the viscosity cass (SAEcass). Optima operating conditions can be achieved by using the foowing oi viscosity chart as a reference. Ambient temperature Viscosity over 25 C SAE 30 SAE10W-30 SAE 15W-40 0 C to 25 C SAE 20 SAE10W-30 SAE 15W-40 beow 0 C SAE 10 SAE10W-30 SAE 15W-40 Oi change intervas The ongest permissibe time a ubrication oi shoud remain in an engine is 1 year. If the foow1 American Petroeum Institute 73

74 Maintenance ing oi change intervas are not reached over a period of 1 year, the oi change shoud be performed at east once per year, irrespective of the operating hours reached. API: CF, CF-4, CG-4,CH-4 and CI-4 = 250 operating hours The fue eve shoud aways be topped up in due time so that the fue tank is never run dry, as otherwise fiter and injection ines need to be bed. Winter fue Danger Fire hazard Fues Diese fues must never be mixed with gasoine. Quaity For winter operation use ony winter diese fue, to avoid cogging because of paraffin separation. At very ow temperatures disturbing paraffin separation can aso be expected when using winter diese fue. Cetan index number: The recommended minimum index number for the Cetan vaue is 45. A Cetan index number higher than 50 shoud preferaby be used, especiay at ambient temperatures beow 20 C and when working at atitudes of 1500 m and more. Diese fue specifications: With respect to the percentage (ppm) of suphur the fue used in the engine must compy with a reevant exhaust emission reguations in the are of use of the engine. Cooant Aways use a mixture of anti-freeze agent and cean, dehardened water with a mixing ratio of 1:1. It is highy recommended to use a fue with a suphur content of ess than 0,10 % (1000 ppm). Under particuary extreme temperature conditions you shoud consut the service representation of the engine manufacturer with respect to the antifreeze agent to be used. When using a diese fue with a high suphur content of 0.50 % (5000 ppm) to 1.0 % ( ppm), the engine oi change intervas must behaved. There are various types of anti-freeze agents avaiabe. For this engine you shoud use ethyene gyco. Before fiing in the cooant mixed with anti-freeze agent the radiator must be fushed with cean water. This procedure shoud be repeated two to three times to cean the inside of radiator and engine bock. Caution Do not use any fues with a suphur content of more than 1,0 % (10000 ppm). It is recommended to use diese fue that compies with the specifications EN590 or ASTM D975. Diese fue with the designation no. 2-D is a destiate fue with ow voatiity, which is especiay suitabe for industria engines and heavy-duty commercia vehices (SAE J313 JUN87). Since KUBOTA diese engines with a rated power of ess than 56 kw (75 HP) compy with the exhaust emission standard of EPA1-stage 4, the use of ow or utra-ow suphur fue is mandatory for these engines, if the engines are operated within the vaidity area of the EPA standard. As an aternative to no. 2-D you may aso use diese fue no. 2-D S500 or S15; with ambient temperatures beow -10 C the diese fue no. 1-D S500 or S15 shoud be used fir no. 1-D Mixing the anti-freeze agent: Prepare a mixture of 50 % anti-freeze agent and 50 % ow minera, cean water. Stirr we before fiing it into the radiator. The method for mixing water and anti-freeze agent depends on the brand of the anti-freeze agent. In this respect see standard SAE J1034 and aso the standard SAE J814c. Add anti-freeze agent: If the cooant eve drops because of evaporation,ony cean water is to be used for topping up. In case of eakages you must aways fi in anti-freeze agents of the same brand and the same mixing ratio. Caution Do not mix different cooants and additives of any other kind. United States Environmenta Protection Agency

75 Maintenance Do not use any radiator ceaning agent after the anti-freeze agent has been mixed in. The antifreeze agent aso contains a corrosion protection agent. If this mixes with ceaning agent it may cause the deveopment of sudge, which coud damage the cooing system. Anti-freeze concentration 50% = -37 C Environment Cooant must be disposed of environmentay. Minera oi based hydrauic oi The hydrauic system is operated with hydrauic oi HV 46 (ISO) with a kinematic Viskosität von 46 mm2/s bei 40 C und 8 mm2/s bei 100 C betrieben. For topping up or for oi changes use ony high-quaity hydrauic oi, type HVLP according to DIN 51524, part 3, or hydrauic ois type HV according to ISO 6743/3. The viscosity index (VI) shoud be at east 150 (observe information of manufacturer). Bio-degradabe hydrauic oi The hydrauic system can aso be operated with a synthetic ester based biodegradabe hydrauic oi. The bioogicay quicky degradabe hydrauic oi Panoin HLP Synth.46 meets a demands of a minera oi based hydrauic oi according to DIN In hydrauic systems fied with Panoin HLP Synth.46 aways use the same oi to top up. When changing from minera oi based hydrauic oi to an ester based bioogicay degradabe oi, you shoud consut the ubrication oi service of the oi manufacturer for detais. Caution Check the fiter more frequenty after this change. Perform reguar oi anayses for content of water and minera oi. Repace the hydrauic oi fiter eement every 500 operating hours. 75

76 Maintenance 6.3 Tabe of fues and ubricants Assemby Fue or ubricant Summer Winter Quantity Attention Observe the eve marks Engine - Engine oi Engine oi API: CF, CF-4, CG-4, CH-4 or CI-4 approx. 6.5 itres SAE 10W-40 (-20 C to +40 C) ( PN ; 20 ) SAE 10W-30 (-15 C to +30 C) SAE 15W-40 (-15 C to + 40 C) SAE 30 (+5 C to +30 C) SAE 10 (-30 C to -5 C) - Fue Diese Winter diese fue (down approx. 40 itres to -12 C) - Cooant Mixture of water and anti-freeze agent ( PN ; 20 ) approx. 4 itres Hydrauic system Hydrauic oi (ISO), HLP 46 ( PN ; 20 ) or ester based biodegradabe hydrauic oi approx. 28 itres Sprinker system - Rubber tire sprinker system 1 76 Water Anti-freeze mixture water 1 Emusion approx. 220 itres approx.20 Mix water and anti-freeze agent by foowing the instructions of the manufacturer.

77 Maintenance 6.4 Running-in instructions The foowing maintenance work must be performed when running in new machines or overhaued engines: Caution Up to approx. 250 operating hours check the engine oi eve twice every day. Depending on the oad the engine is subjected to, the oi consumption wi drop to the norma eve after approx. 100 to 250 operating hours. Maintenance after 50 operating hours Change engine oi and fiter Check the engine for eaks Retighten the fastening screws on air fiter, exhaust and other attachments. Check screw connections on the machine, retighten as necessary. 77

78 Maintenance X 6.7 Check the fue eve Instrument custer X 6.8 Check the hydrauic oi eve Dipstick mark X 6.9 Check the hydrauic oi fiter ee- Contamination indicament tor X 6.10 Check the cooant eve X 6.11 Check the water separator X 6.12 Check the water eve Water eve gauge X 6.13 Check the emusion eve ony AC-machines X 6.14 Check the chip spreader and cean the spreading beam X 6.15 Check fue ines and camps X 6.16 Service the chip spreader 6.17 Change engine oi and oi fiter X 1 at east 1x per year see foot note X 6.18 Check, cean, repace the combustion air fiter repace min. 1x per year X 6.19 Check the air intake ines X 6.20 Ceaning radiator and hydrauic oi cooer X 6.21 Check, tension, repace the Vbet X 6.22 Check radiator hoses and hose camps X 6.23 Checking, adjusting the scrapers X 78 as required Dipstick mark every 3000 oper. hours Check the engine oi eve every 2000 oper. hours 6.6 every 1000 oper. hours Comment every 500 oper. hours Maintenance work every 250 oper. hours No. every 50 operating hours Maintenance tabe every 10 operating hours, daiy 6.5

79 6.24 Battery service poe grease X 6.26 Drain the fue tank sudge X 6.27 Check and adjust the vave cear- Intake and exhaust ance vave: 0.20 mm on cod engine X 6.28 Check the engine mounts X 6.29 Change hydrauic oi and breath- at east every 2 years er fiter2 X 6.30 Change the hydrauic oi fiter2 at east every 2 years X 6.31 Change the cooant at east every 2 years X 6.32 Repacing the fue ines at east every 2 years X X 6.34 Check the fue injection pump 6.35 Check the tire pressure as required X 6.25 Change the fue fiter 6.33 Check the injection vaves every 3000 oper. hours every 2000 oper. hours every 1000 oper. hours every 500 oper. hours Comment every 250 oper. hours Maintenance work every 50 operating hours No. every 10 operating hours, daiy Maintenance X ony AC-machines X 6.36 Cean the water sprinker system X 6.37 Drain the water sprinker system, maintenance in case of frost X 6.38 Fi the provision tank for the windscreen washer system X 6.39 Tightening torques X 6.40 Engine conservation X 1 2 oi change after 50 and 250 operating hours, then every 250 operating hours Aso after repairs in the hydrauic system. 79

80 Maintenance 80

81 Every 10 operating hours Every 10 operating hou rs 6.6 Check the engine oi eve 6.7 Caution The machine must be in horizonta position. When the engine is warm, shut it down and check the oi eve after five minutes. With a cod engine the oi eve can be checked immediatey. Checking the fue eve Caution Do not drive the fue tank dry, as otherwise the fue system needs to be bed. For quaity and quantity of oi refer to the "tabe of fues and ubricants". Fig. 120 Check the fue eve on fue gauge (i) (Fig. 120) in the instrument custer. Refueing Fig. 119 Pu the dipstick (Fig. 119) out, wipe it off with a int-free, cean coth and reinsert it unti it bottoms. Danger Fire hazard When working on the fue system do not use open fire, do not smoke, do not spi any fue. Pu the dipstick back out. The oi eve must aways be between the "MIN"and "MAX"-marks. Do not refue in cosed rooms. If the oi eve is too ow top up oi immediatey. If the oi eve is too high, determine the cause and drain the oi off. Shut down the engine. Danger Heath hazard Do not inhae any fue fumes. Caution Contaminated fue can cause mafunction or even damage of the engine. If necessary, fi in fue through a funne with screen. Monitor the entire refueing process. For quaity and quantity of fue refer to the "tabe of fues and ubricants". 81

82 Every 10 operating hours Environment 6.8 Check the hydrauic oi eve Catch running out fue, do not et it seep into the ground. Shut down the engine. Caution If, during the daiy inspection of the oi eve the hydrauic oi eve is found to have dropped, check a ines, hoses and components for eaks. In hydrauic systems fied with Panoin HLP Synth. 46 aways use the same oi to top up. With other ester based ois consut the ubrication oi service of the respective oi manufacturer. Cean the area around the fier opening. Remove the fier cap. Fig. 121 Cean the area around the fier opening. Open the fue tank cover (Fig. 121). Top up with fue (diese or winter diese). Screw the fue tank cover back on. Fig. 122 Check the oi eve on the dipstick. The oi eve must be between the "MIN" and "MAX" marks (Fig. 122). If the oi eve is too ow top up hydrauic oi immediatey. For quaity and quantity of oi refer to the tabe of fues and ubricants. 82

83 Every 10 operating hours 6.9 Checking the hydrauic oi fiter eement 6.10 Check the cooant eve i Danger Danger of scading Note If the hydrauic oi is very cod the pin may pop up, you shoud therefore ony check the fiter and press the pin in at operating temperature. Open the cap on the cooant compensation tank ony when the engine is cod. Caution If, during the daiy inspection the cooant eve is found to have dropped, check a ines, hoses and engine for eaks. For quaity of cooant refer to "fues and ubricants". Fig. 123 Check the service indicator 1 (Fig. 123) at operating temperature and with the engine running at maximum speed. If necessary press the pin in. Pin remains pressed in Pin pops out = Hydrauic oi fiter eement o.k. Fig. 124 = Repace the hydrauic oi fiter eement Check the cooant eve in the compensation tank (Fig. 124). To top up unscrew the fier cap and fi in cooant up to the MAX-mark. 83

84 Every 10 operating hours 6.11 Check the water separator Danger Fire hazard When working on the fue system do not use open fire, do not smoke. Do not spi any fue. Shut down the engine Checking the water eve Caution If there is a risk of frost observe the specia service instructions in chapter "water sprinker system, maintenance in case of frost". Make sure that the ventiation bore in the fier cap is free. Danger Heath hazard Do not inhae any fue fumes. i Note The service intervas for the water separator depend on the water content in the fue and can therefore not be determined precisey. After taking the engine into operation you shoud therefore check the water separator every day for signs of water. Fig. 126 Environment Check the water tank fiing eve on the water eve gauge (Fig. 126). Any fue must be caught and disposed of in an environmentay friendy manner. Fig. 127 Open the cap (Fig. 127) and check the water eve. If necessary fi in water through the fier screen and cose the cap again. Fig. 125 Sacken the drain pug (Fig. 125) for a few turns and catch running out fue / water. Tighten the drain pug again and check for eaks, if necessary repace the sea ring. 84

85 Every 10 operating hours 6.13 Checking the emusion eve Checking the chip spreader2 and ceaning the spreading beam Caution Different emusions must not be mixed. If necessary drain off the emusion beforehand. For mixing ratio of water and emusion refer to the specification of the respective manufacturer. Fig. 129 Cean the spreading beam from any dirt (Fig. 129), especiay from asphat. Fig. 128 Unscrew the cover (Fig. 128) and check the emusion eve, fi up if necessary. Caution Make sure that the ventiation bore in the fier cap is free. Fig ony AC-machine Check hydrauic ines (Fig. 130) for eak tightness. Check hydrauic and eectric connections for tight fit. 2 Optiona equipment 85

86 Every 10 operating hours Fig. 131 Caution When ceaning with a steam ceaner do not direct the water jet into the seaing eements of the side profies (Fig. 131). 86

87 Every 50 operating hours Every 50 operating hou rs 6.15 Checking fue ines and camps 6.16 Servicing the chip spreader1 Danger Danger of burning Perform inspection work ony after the engine has cooed down and with the engine stopped. Lubricate the foowing components on the chip spreader: Spreading shaft bearings Drive chain Adjustment ever for chip quantity Screw connections with star handes a movabe parts Caution If fue ines or hose camps are found to be damaged, the corresponding parts must be immediatey repaired or repaced. After repacing ines or hose camps the fue system needs to be bed. Disassembed or new fue ines must be cosed with cean coths on both ends, to make sure that no dirt wi enter into the fue system. Dirt partices can destroy the injection pump. Fig. 132 Check the condition and tight fit of a fue ines (2) (Fig. 132) and hose camps (1). 1 Optiona equipment 87

88 Every 50 operating hours 88

89 Every 250 operating hours Every 250 oper ating hours 6.17 Changing engine oi and oi fiter Danger Danger of scading When draining off hot oi. By hot oi when unscrewing the engine oi fiter. Caution Fig. 134 The oi change at 250 operating hours refers to the use of ois of oi quaity cass API CF, CF-4, CG-4, CH-4 or CI-4 and a fue suphur content of ess than 0.5%. Unscrew the drain pug (Fig. 134) and catch running out oi. Turn the drain pug tighty back in. When using fues with a suphur content higher than 0.5% the oi change intervas must be haved. Drain the engine oi ony when the engine is warm. For quaity and quantity of oi refer to the "tabe of fues and ubricants". Environment Catch running out oi and dispose of environmentay together with the oi fiter cartridge. Fig. 135 Unscrew the fiter cartridge (Fig. 135) using an appropriate fiter wrench. Cean the seaing face on the fiter carrier from any dirt. Fig. 133 Unscrew the oi fier pug (Fig. 133). 89

90 Every 250 operating hours Fig. 136 Fig. 138 Sighty oi the rubber sea on the new fiter cartridge (Fig. 136). Turn the new fiter cartridge on by hand, unti the sea contacts. Tighten the fiter eement for another haf turn. After a short test run check the oi eve once again (Fig. 138), if necessary top up to the top mark (MAX). Fig. 137 Fi in new engine oi (Fig. 137). Tighten the oi fier cap propery. 90

91 Every 250 operating hours 6.18 Checking, ceaning, repacing the combustion air fiter Caution Perform ceaning, maintenance and repair work ony with the engine shut down. Do not start the engine after removing the fiter eement. Do not use gasoine or hot fuids to cean the fiter eement. Fig. 139 After ceaning the fiter eement must be inspected for damage using a torch. Air fiter eements with damaged paper beows or sea ips must be repaced in any case. The main fiter eement must be repaced after 6 times ceaning, but at the atest after one year, irrespective of the operating hours. Each ceaning interva must be marked with a cross on the cover of the fiter eement. Service of the dry air fiter is due when the red piston of the fiter service indicator (Fig. 139) reaches into the transparent window. Caution After ceaning the air fiter press the reset button for the red piston on the fiter service indicator. Ceaning does not make sense if the air fiter eement is covered with a sooty deposit. Use a new fiter eement. Incorrecty handed fiter eements may become ineffective because of damage (e.g.: cracks) and cause engine damage. Open the engine hood. i Note Under very dusty conditions you may have to check the fiter service indicator every day. Fig. 140 Reease the ocking hook (Fig. 140) and take the fiter hood off. Cean fiter hood and dust discharge vave. 91

92 Every 250 operating hours Fig. 141 Carefuy oosen the main fiter eement (Fig. 141). The main fiter eement is ocated directy on the air intake tube, thereby providing a sea on the inside of the fiter cover. Carefuy remove the main fiter eement, in order to reduce the reeased amount of dust. To reease the sea pu the main fiter eement carefuy up, down and sideways or turn it (Fig. 141). Caution Avoid contact between main fiter eement and housing. Fig. 143 Cean the seaing face on the outet tube (Fig. 143). Dust on the outer diameter of the outet tube can impair effective seaing. Check the od main fiter eement. The od main fiter eement can be of hep to discover foreign partices on the seaing face, which coud ead to eaks. A dust strip on the cean air side of the fiter may be a sign for this Eiminate this probem before instaing a new main fiter eement. If the main fiter eement is damaged, the safety eement must be repaced as we. Cean or repace the main fiter eement. i Note We generay recommend to change the fiter. A new fiter eement is far ess expensive than a possibe engine damage. Fig Pu the main fiter eement (Fig. 142) carefuy out of the housing. Examine the main fiter eement thoroughy for damage. Before instaing the new main fiter eement check it for possibe damage from transport, ceaning or incorrect handing. Especiay on the inside of the open end (seaing area). Do not insta damaged fiter eements. If necessary use safety eements.

93 Every 250 operating hours Fig. 144 Fig. 145 Insert the main fiter eement (Fig. 144). The radia seaing area is ocated at the inside of the open fiter edge. This critica seaing area must be under sight tension after the fiter has been instaed. In order to achieve a tight sea appy pressure to the outer edge of the fiter and not to the moveabe centre. Reinsta the fiter hood with the dust discharge vave. i The ength shoud reach down to the bottom of the eement. Bow the main fiter eement out with compressed air (max. 2.1 bar) from inside to outside by moving the tube up and down inside the eement, unti it if free of dust. Examine the main fiter eement with a torch for cracks and hoes in the paper beows. Caution The dust discharge vave must point verticay downwards. Dry ceaning of the main fiter eement Danger Eye injury Note For ceaning purposes fit a tube to the compressed air gun (Fig. 145), the end of which shoud be bent for approx. 90. Caution Do not continue to use a damaged main fiter eement. If in doubt use a new main fiter eement. Wear protective cothing (gogges, goves). 93

94 Every 250 operating hours Changing the safety fiter eement 6.19 Check the air intake ines Caution The safety fiter eement must not be ceaned and shoud not be used again after it has been removed. The safety fiter eement must be repaced: Danger Danger of burning Perform inspection work ony after the engine has cooed down and with the engine stopped. if the main fiter eement is defective, after 6 times ceaning of the main fiter eement, at the atest after 2 years, if the red piston of the fiter service indicator is visibe again after competion of the service work. Remove the housing cover and pu the main fiter eement off. Caution Take care that no contaminants enter into the air intake system, since this coud damage the engine If an air intake hose is damaged, both hose and hose camp must be repaced immediatey. Check the condition and tight fit of a air intake ines and hose camps. Fig. 146 Pu the safety eement (Fig. 146) out by turning it ighty. Push in a new safety fiter eement. Reassembe main fiter eement and cover. 94

95 Every 250 operating hours 6.20 Ceaning radiator and hydrauic oi cooer Danger Danger of injury Perform ceaning work ony with engine stopped and cooed down Caution Dirty operating conditions, particuary ubrication oi and fue deposits on the cooing fins of the engine and the engine oi cooer have an adverse effect on the cooing of the engine. You shoud therefore immediatey sea any oi or fue eaks near cooing fan, cyinder or engine oi cooer and subsequenty cean the cooing fins. Fig. 148 Bow out the air suppy side of the hydrauic oi cooer (Fig. 148). Ceaning with cod ceansing agent Ceaning with compressed air Caution Protect eectrica equipment such as generator, reguator and starter against the direct water jet. In case of oiy dirt spray engine and cooer with a suitabe ceansing agent, e.g. cod ceanser, et it soak in for a whie and spray it off with a strong water jet. Run the engine warm for a whie to avoid corrosion. Fig. 147 Bow the cooing air passages out with compressed air from the air discharge side (Fig. 147). 95

96 Every 250 operating hours 6.21 Checking, tensioning, repacing the V-bet 6.22 Checking radiator hoses and hose camps Danger Danger of burning Perform inspection work ony after the engine has cooed down and with the engine stopped. Caution If a radiator hose is swoen, hardened or cracked, both hose and hose camp must be repaced immediatey. Fig. 149 Checking the V-bet Inspect the entire circumference of the V-bet (1) (Fig. 149) visuay for damage and cracks. Repace a damaged or cracked V-bet immediatey. Check with thumb pressure whether the V-bet can be depressed more than 7 to 9 mm (A) between the V-bet pueys, retighten if necessary. Tightening the V-bet Fig. 150 Sighty sacken the fastening screws (2). Press the generator in direction outward using a ever, unti the correct V-bet tension is reached. Retighten a fastening screws and check the V-bet tension once again. Check the conditon and tight fit of a readiator hoses and hose camps (Fig. 150). Changing the V-bet Sighty sacken the fastening screws (2). Press the generator competey against the engine. Remove the od V-bet. Fit the new V-bet to the V-bet pueys. Tension the V-bet as previousy described. 96

97 Every 250 operating hours 6.23 Checking, adjusting the scrapers Drums Caution Scrapers (2 per drum) must be repaced when worn. Fig. 151 Open the fap, check the scrapers, repace if ncessary (Fig. 151). Whees (AC-machines) Fig. 152 Open the rear fap, check the scrapers, repace if ncessary (Fig. 152). Adjust the scrapers with the screws to a uniform distance of approx. 2 mm from the rubber tires. 97

98 Every 250 operating hours 98

99 Every 500 operating hours not forget to perform reguar open-circuit votage measurements. Every 500 oper ating hours 6.24 Battery service Danger Danger of cauterisation Danger of exposion When working on the battery do not use open fire, do not smoke Caution Exhausted batteries (batteries with formation of suphate on the pates) are not covered under warranty The battery contains acid. Do not et acid come in contact with skin or cothes Wear protective cothing Do not ay any toos on the battery For recharging remove the pugs from the battery to avoid the accumuation of highy exposive gases. Environment Dispose of the od batteries environmentay. i Fig. 153 Note Maintenance free batteries aso need care. Maintenance free ony means that the fuid eve does not need to be checked. Each battery suffers under sef-discharge, which may, in not checked occasionay, even cause damage to the battery as a resut of exhaustive discharge. Disassembe the covering fap of the battery compartment (Fig. 153). The foowing therefore appies for the service ife: Switch off a consumers (e.g. ignition, ight, inside ight, radio). Check open-circuit votage of the battery at reguar intervas. At east once per month. Reference vaues: 12.6 V = fuy charged; 12.3 V = 50% discharged. Fig. 154 Recharge the battery immediatey after an open-circuit votage of V or ess is reached. Do not perform quick charging. The open-circuit votage of the battery occurs approx. 10 hours after the ast charging process or one hour after the ast discharge. After each charging process aow the battery to rest for one hour before taking it into service. For resting periods of more than one month you shoud aways disconnect the battery. Do Cean battery and battery compartment (Fig. 154). Cean battery poes and poe camps and grease them with poe grease (Vaseine). Retighten the poe camps. Check the fastening of the battery. 99

100 Every 500 operating hours Repacing the fue fiter cartridge 6.25 Change the fue fiter Danger Fire hazard When working on the fue system do not use open fire, do not smoke. Do not spi any fue. Danger Heath hazard Do not inhae any fue fumes. Fig. 156 Environment Catch running out fue, do not et it seep into the ground. Sacken and unscrew the fue fiter cartridge (Fig. 156). Cean the seaing face on the fiter carrier from any dirt. Appy a thin fim of fue to the seas and screw the new fiter cartridge on hand-tight. Dispose of the used fue fiter environmentay. Changing the fue pre-ceaner Beeding of the fue system Danger Fire hazard Do not beed the engine whie it is hot, running out fue dripping on the hot exhaust can cause a fire. Fig. 155 Loosen the hose camps (Fig. 155). Pu the fue fiter out of the hoses. Insta the new fue pre-fiter and observe the fow direction (arrow). Fasten the hose camps. Fig Open the beeding screw (Fig. 157) on the top of the injection pump.

101 Every 500 operating hours 6.26 Drain the fue tank sudge Danger Fire hazard When working on the fue system do not use open fire, do not smoke. Do not spi any fue. Danger Heath hazard Fig. 158 Operate the fue ift pump (Fig. 158) unti fue runs out of the beeding screw without air bubbes. Do not inhae any fue fumes. Retighten the beeding screw. Catch running out fue, do not et it seep into the ground. Environment i Note When performing this work the fue tank sha ony hod max. 5 itres of fue, pump off if necessary. Fig. 159 Unscrew the pug (Fig. 159) from underneath the fue tank and et the fue run out. Once a fue has run out screw the oi drain pug back in with a new sea ring. 101

102 Every 500 operating hours 102

103 Every 1000 operating hours Every 1000 operating hours 6.27 Checking, adjusting the vave cearance Caution We recommend to have this work carried out by trained personne or our after saes service. Check and adjust ony when the engine is cod. The first cyinder is the one nearest to the cooing fan side. Vave cearance: Fig. 162 Intake and exhaust vave = 0.20 mm Crankshaft position 1 (Fig. 162) Crank the engine with the starter or a spanner by the V-bet puey unti both vaves on cyinder 1 are overapping. Overapping means: Exhaust vave not yet cosed, intake vave starts to open. Perform the adjustment of the vave by foowing the adjustment diagram "crankshaft position 1", back mark. For contro purposes mark the respective rocker arm with whie chak once the corresponding vave is adjusted. Fig. 160 Remove the vave cover (Fig. 160). Vave adjustment schematic Fig. 163 Crankshaft position 2 (Fig. 163) Turn the crankshaft one revoution (360 ) further. Perform the adjustment of the vave by foowing the adjustment diagram "crankshaft position 2", back mark. Fig. 161 Vave (1) (Fig. 161) white = not adjustabe Vave (2) back = adjustabe I = Intake vave 103

104 Every 1000 operating hours E = Exhaust vave 6.28 Check the engine mounts Check the back vaves (Fig. 162) on cyinders 1, 2 and 3, adjust if necessary. Fig. 165 Fig. 164 Check the gap between rocker arm and vave with a feeer gauge (Fig. 164). If the gap is too wide or too narrow for the feeer gauge, the vave cearance must be adjusted. i Check the fastening of intake and exhaust tubes (Fig. 165) on the cyinder heads for tight fit. Check sockets and camps on the air fiter for tight fit and eak tightness. Check fastening and tightness of the ubrication oi sump. Note Mark checked and adjusted vaves with chak. Insta the cyinder head cover with a new gasket. i Note After a short test run check the engine for eaks. Fig Check the condition and tight fit of the engine piow bocks (Fig. 166).

105 Every 2000 operating hours Every 2000 operating hours 6.29 Changing hydrauic oi and breather fiter i Note See aso the notes on the hydrauic system in the chapter "Genera notes on maintenance". Danger Danger of scading When draining off hot hydrauic oi Fig. 167 Remove the cap from the hydrauic oi tank (Fig. 167). Caution The hydrauic oi must aso be changed after major repairs in the hydrauic system. Perform the oi change when the hydrauic oi is warm. Repace the hydrauic oi fiter eement with every hydrauic oi change. Change the fiter ony after the hydrauic oi change and after the test run. Cean the area round hydrauic oi tank, fier opening and breather fiter. Do not start the engine after draining the hydrauic oi. Do not use any detergents to cean the system. Fig. 168 Use ony int-free ceaning coths. Disconnect bthe eak oi hose from the front right hand vibration motor (Fig. 168), drain off and catch a hydrauic oi. Reconnect the eak oi hose tighty. For quaity and quantity of oi refer to the "tabe of fues and ubricants". When changing from minera oi based hydrauic oi to an ester based bioogicay degradabe oi, you shoud consut the ubrication oi service of the oi manufacturer for detais. Environment Catch running out hydrauic oi and dispose of environmentay. Drive the machine, unti the hydrauic oi has reached operating temperature. Shut down the engine. i Note We recommend to use the fiing and fitering unit with fine fiter to fi the system. This ensures finest fitration of the hydrauic oi, proongs the ifetime of the hydrauic oi fiter and protects the hydrauic system. 105

106 Every 2000 operating hours 6.30 Changing the hydrauic oi fiter Danger Danger of scading Danger of scading by hot oi when unscrewing the oi fiter. Fig. 169 Fi in new hydrauic oi (Fig. 169). Perform a test run and check the system for eaks. Caution If the fiter has to be changed together with the hydrauic oi, the fiter must ony be changed after the oi change and after the test run. Do not use the oi in the fiter bow again. Visibe dirt may be an eary sign for the faiure of system components and indicate the possibe faiure of components. In this case determine the cause and repace or repair the defective components, if necessary. Negigence may cause destruction to the entire hydrauic system. Do not cean or reuse the fiter eement. Apart from the norma oi change intervas, the fiter eement must aso be changed after major repairs in the hydrauic system. Environment Catch running out oi, dispose of oi and fiter eement environmentay. Fig. 170 Check the hydrauic oi eve on the dipstick (Fig. 170). i Note The breather fiter for the hydrauic oi tank is integrated in the fier cap. You shoud therefore repace the compete fier cap. Cose the tank with a new cover. Fig Remove fiter bow (4) (Fig. 171) with fiter eement (3).

107 Every 2000 operating hours Examine the surface of the fiter eement thoroughy for any visibe dirt. Take out the od fiter eement and cean fiter bow and thread. Reassembe the fiter bow with a new fiter eement and new oop rings (1) and (2). Danger of scading After a short test run check the fiter for eaks. Change the cooant ony when the engine is cod Changing the cooant Danger Do not remove the radiator cap when the engine is sti hot. Aways wear goves when handing anti-freeze agent. Caution Aways screw the radiator cap tighty back on (second detent). Aways fi the engine cooing system with an anti-freeze mixture (corrosion protection). Do not use more than 50% anti-freeze. Do not mix different cooants and additives of any other kind. If necessary fush the cooing system 2-3 times with cear water. For cooant quaity refer to the "tabe of fues and ubricants". Environment Catch running out cooant and dispose of environmentay. Fig. 172 Remove the radiator cap (Fig. 172). Disassembe the eft hand side pate from the front frame. 107

108 Every 2000 operating hours Fig. 173 Unscrew the drain pug (Fig. 173). Drain the cooant competey off and coect it. Screw the drain pug back in. Fig. 175 Fi in cooant unti the eve reaches the bottom edge of the fier socket (Fig. 175). Fig. 176 Fig. 174 Open the drain tap (Fig. 174). Drain the cooant competey out of the engine bock and coect it. Cose the drain tap again. Empty the cooant compensation tank. Check the condition of radiator hoses, if necessary repace a radiator hoses. 108 Fi in cooant up to the MAX mark (Fig. 176). For quaity and quantity of cooant refer to the "tabe of fues and ubricants". Reattach the radiator cap and the cap of the compensation tank. Start the diese engine and run it warm to operating temperature. Let the engine coo down and check the cooant eve again, if necessary top up in the compensation tank.

109 Every 2000 operating hours 6.32 Repacing the fue ines 6.33 Check the injection vaves i Danger Fire hazard Note This work must ony be performed by authorized service personne. When working on the fue system do not use open fire, do not smoke. Do not spi any fue. Danger Heath hazard Do not inhae any fue fumes. Caution For safety reasons this work shoud be performed every two years. Hoses consist of rubber or pastic materia and age over the course of time. Environment Catch running out fue, do not et it seep into the ground. Repace a fue hoses, incuding their hose cips. 109

110 Every 2000 operating hours 110

111 Every 3000 operating hours Every 3000 operating hours 6.34 Checking the fue injection pump i Note This work must ony be performed by authorized service personne. 111

112 Every 3000 operating hours 112

113 As required As r equired 6.35 Checking the tire pressure i 6.36 Ceaning the water sprinker system Note Ony AC-machines i Note If there is a risk of frost observe the specia service instructions under "sprinker system, maintenance in case of frost". Fig. 177 Check the tire pressure with a pressure gauge (Fig. 177). Nomina vaue: approx.2.2 bar Fig. 178 i Remove the water tank cover (Fig. 178). Note Ensure equa pressure in a rubber tires Fig. 179 Open the covering fap (Fig. 179) on the right hand side of the rear frame. 113

114 As required Screw the oastic caps back on again. Check the function of the sprinker tubes, if necessary cean or repace the nozzes. Environment Catch and dispose of od emusion environmentay. Empty the emusion tank1. Fig. 180 Take out the drain hose (Fig. 180). Open the drain tap, et a water run out and cose the drain tap again. Fig. 182 Loosen the fitting, take the emusion fiter (Fig. 182) out and cean it. Fush the emusion tank thoroughy. Reinsert the emusion fiter and tighten the fitting. Fig. 181 Unscrew the water hose at the water fiter (Fig. 181). Unscrew the water fiter from the water tank. Unscrew the fiter eement from the cover, cean it and screw it back onto the cover. Fush the water tank out with a strong water jet. Let a water with dirt run out. Screw the cover with the fiter eement back on. Unscrew the pastic caps from the end of the sprinker tube. Fi the water tank with cean water. Activate the sprinker system for a short whie so that a ines are fushed out. Fig. 183 Fi the emusion tank (Fig. 183). Check the function of the sprinker tubes, if necessary cean or repace the nozzes AC-machines

115 As required 6.37 Draining the water sprinker system, maintenance in case of frost Caution If there is a risk of frost the water sprinker system must be competey emptied or fied with an anti-freeze mixture. In this case frost protection measures are of greatest importance in order to avoid freezing of sensitive components ike pump, soenoid vave and water fiter. Fig. 186 Take out the drain hose (Fig. 186), open the drain tap and et a water run out. Draining the water sprinker system Fig. 187 Fig. 184 Remove the water tank cover (Fig. 184). Open the hose couping (Fig. 187) and et the water run out. Fiing the sprinker system with antifreeze mixture Cose drain tap and drain hose. Join the hose coupings together. Fi the water tank with approx. 5 of antifreeze mixture (water and anti-freeze agent). Switch the sprinker system on, unti antifreeze mixture comes running out of the sprinker tubes. Environment Fig. 185 Open the covering fap (Fig. 185) on the right hand side of the rear frame. After the frost period drain off the anti-freeze mixture and dispose of environmentay. 115

116 As required 6.38 Fiing the provision tank for the windscreen washer system Tightening torques for screws with metric unified thread Fig. 189 * Strength casses for screws with untreated, nonubricated surface. Screw quaity designations are stamped on the screw heads. Fig. 188 Check the fuid eve in the tank (Fig. 188), top up if necessary. For winter operation fi in the appropriate amount of ant-freeze agent; refer to the specifications of the manufacturer of the ant-freeze agent. 8.8 = 8G 10.9 = 10K 12.9 = 12K The vaues resut in a 90% utiization of the screw's yied point at a coefficient of friction μ tota = 0,14. Compiance with the tightening torque is checked with torque wrenches. The specified tightening torques do not appy when using MoS2 ubricants. i Note Sef-ocking nuts must aways be repaced once they have been unscrewed. 1 Optiona equipment 116

117 As required 6.40 Engine conservation If the engine is to be shut down for a onger period of time (e.g. over winter), we recommend to appy the foowing conserving measures to avoid corrosion: Cean the engine, incuding the cooing system: With cod ceansing agent and a water jet or, even better, with a steam ceaner. Run the engine warm and shut it down. Drain off the sti hot engine oi and fi in anticorrosion engine oi. Drain off the cooant and fi in system protection agent. Drain the fue from the tank, mix it we with 10% anti-corrosion oi and fi it back in. Run the engine for 10 minutes unti a ines, fiters, pumps and nozzes with this conserving mixture and the new engine oi has been distributed to a parts. Now crank the engine severa times (without ignition) to spray the combustion chambers. Take the V-bets off and spray the grooves of the V-bets with anti-corrosion oi. Remove the anti-corrosion oi before resuming operation. Cose intake and exhaust openings tighty. i Note Depending on the weather conditions these conserving measures wi provide protection for approx. 6 to 12 months. Before taking the engine back into operation a conserving oi must be drained off and repaced by reguar engine oi, see chapter "Fues and Lubricants" according to the API-(MIL)-cassification. Anti-corrosion ois are those that compy with the specification MIL-L B or TL /2 or Nato Code C 640/642. A machine with a conserved engine must be marked by attaching a ceary visibe warning tag. 117

118 As required 118

119 7 Troube shooting 119

120 Troube shooting 7.1 Genera notes The foowing work must ony be performed by professionay trained personne or by our customer service. Pease observe stricty the safety reguations in the corresponding section of these operating and maintenance instructions. Mafunctions are frequenty caused by incorrect operation of the machine or insufficient maintenance. Whenever a faut occurs you shoud therefore thoroughy read these instruction on correct operation and maintenance. If you cannot ocate the cause of a faut or rectify it yoursef by foowing the troube shooting chart, you shoud contact our customer service department. 120

121 Troube shooting 7.2 Engine Fauts Possibe cause Remedy The engine does not start Fue tank empty Fi the tank Fue fiter cogged,in winter due to paraffin separation Change the fiter Use winter fue Fue ines eaking Check a ine connections for eakages and tighten the fittings. Trave ever not in "0"-position Move the trave ever to "0"-position Battery discharged or not connected Charge the battery, check the termina camps Operating error see chapter "Starting the engine" Incorrect vave cearance Adjust the vave cearance Lack of oi Top up engine oi Emergency stop switch is engaged. Emergency stop switch is unocked. Battery power too ow Have the battery inspected Battery camps oose or oxidized, causing the starter to turn too sowy Cean the termina camps, tighten them and cover them with acid free grease Especiay during winter: the use of too viscous engine oi Use engine oi suitabe for the ambient temperature Insufficient fue suppy, cogging of the fue system due to paraffin separation in winter Change the fue fiter Check the ine connections for eaks and tighten the fittings. Use winter fue in the cod season. Incorrect vave cearance Adjust the vave cearance Injection vaves or injection pump defective Have examined by a speciaist Air fiter cartridge dirty Cean, change if necessary Excessive pay in the throtte cabe Adjust the throtte cabe, change it if necessary Engine oi eve too high Drain the oi to the upper dipstick mark Poor fue quaity Use specified fue Air fiter dirty Cean, change if necessary Poor compression due to burned or broken compression rings or incorrect vave cearance Have compression rings and pistons examined by a speciaist, adjust the vave cearance Injection vave defective Have examined by a speciaist The engine starts poory and works irreguary with poor power Engine oses power and speed, excessive exhaust smoke 121

122 Troube shooting Fauts Possibe cause Remedy Engine overheats, shut down immediatey Radiator excessivey soied Cean the cooing fins Cooant eve to ow Top up cooant.danger Ony when the engine is cod Injection vave defective Have examined by a speciaist Engine oi eve too ow Top up engine oi to the upper dipstick mark Fiing capacity of the injection pump not correcty adjusted Have adjusted by a speciaist Lack of cooing air at the cooing air bower Cean the cooing air duct V-bet oose or broken Tension or repace the V-bet Air fiter cartridge dirty Cean, change if necessary Leakages in the ubrication system, oi eve too ow Check fittings on oi ines, ubrication oi fiter for eaks, tighten the fittings if necessary. Top up ubrication oi up to the upper mark on the dipstick. Engine oi of wrong SAE-cass Change the engine oi. The generator does not charge the battery, because generator or reguator is defective Have examined by a speciaist Engine oi pressure too ow, shut down immediatey The charge contro ight ights during operation 122

123 8 Disposa 123

124 Disposa 8.1 Fina shut-down of machine If the machine can no onger be used and needs to be finay shut down you must carry out the foowing work and have the machine disassembed by an officiay recognized speciaist workshop. Danger Danger of cauterisation Danger of exposion When working on the battery do not use open fire, do not smoke The battery contains acid. Do not et acid come in contact with skin or cothes Wear protective cothing Remove the batteries and dispose of in compiance with ega reguations. Environment Catch a fues and ubricants, do not et them seep into the ground and dispose of in compiance with ega reguations. Empty the fue tank. Drain the hydrauic oi tank. Drain cooant from engine and cooing system. Drain the ubrication oi from the engine. Danger Danger of exposion Parts that previousy contained combustibe fuids must not be cut with a cutting torch. 124

125