Box 504, SE-371 23 Karlskrona, SwedenTelephone +46 455 30 60 00

Telefax +46 455 30 60 30Web www.dynapac.com

DYNAPACCA 152

M152EN2

MAINTENANCE

19ILF015WO1

Reservation for alterations.Printed in Sweden

Vibratory RollerCA 152

MaintenanceM152EN2, May 2001

Diesel engine:CA 152: Cummins 4BT 3.9C

These instructions apply from:CA 152 PIN (S/N) *64X20704*

The CA 152 is one of Svedala Dynapacs light vibratory rollers. It is available in D(smooth drum) and PD (padfoot) versions respectively. The PD version has its greatest

range of application on cohesive material and disintegrated rock.

All types of base courses and sub-bases can be compacted, and the interchangeable drums, from D toPD and vice versa, provide even greater versatility in the choice of application.

This manual describes the cab and safety-related accessories.Other accessories, such as the compaction meter, tachograph and CCS/RA field

computer, are described in separate instructions.

KEEP

THIS

MANU

AL FO

R

FUTU

RE R

EFER

ENCE

2 CA 152 M152EN2

Read through the entire manual beforestarting any maintenance operations.Ensure good ventilation (air extraction) if thediesel engine is run indoors.If the engine covers gas struts aredisengaged and the cover is raised to itsupper position, block the cover so that itcannot fall down accidentally.

It is important that the roller is maintained correctly toensure proper function. It should be kept clean so that anyleakage, loose bolts and loose connections can bediscovered in time.Make a habit of walking round the roller to check it everyday before starting the first shift including under themachine. This is often the easiest way of discovering anyleakage.

SPARE A THOUGHT FOR THEENVIRONMENT! Do not let oil, fuel and otherenvironmentally hazardous substances contami-nate the environment.

This manual contains instructions for periodic attentionwhich should normally be carried out by the roller operator.

There are additional instructions relating to thediesel engine, for which the manufacturersinstructions are detailed in the engine manual.This is found under a separate flap in the rollersproduct binder.

CONTENTS

GENERAL

Safety instruction Personal Safety

Special caution Machine or componentdamage

WARNING SYMBOLS

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of itsconstituents are known to the Stateof California to cause cancer, birthdefects, and other reproductiveharm.

CAUTION

CAUTION

WARNING

WARNING

WARNING

WARNING

PageLubricants and symbols ................................................... 3Technical specifications ............................................... 4, 5Maintenance schedule ..................................................... 6Maintenance measures ................................................ 7, 8Every 10 operating hours (daily) ................................. 9-11Every 50 operating hours (weekly) ........................... 12-14Every 250 operating hours (monthly) ........................ 15-18Every 500 operating hours (every three months) .... 19, 20Every 1000 operating hours (every six months) ....... 21-23Every 2000 operating hours (every year) ................. 24-26Long-term storage .......................................................... 27Special instructions ........................................................ 28Electrical system, fuses ........................................... 29, 30

3CA 152 M152EN2

LUBRICANTS AND SYMBOLS

ENGINE OIL Shell Rimula SAE 15W/40 or equivalentambient air temperature API Service CF-4/SG, (CD/CE)-10C +50C (14F - 122F)HYDRAULIC FLUIDambient air temperature Shell Tellus Oil TX68 or equivalent-10C +40C (14F - 104F)ambient air temperature Shell Tellus Oil T100 or equivalentabove +40C (above 104F)BIODEGRADABLE Shell Naturelle HF-E46HYDRAULIC FLUID When it leaves the factory, the machine may be filled

with biologically degradable fluid. The same type offluid must be used when changing or topping off.

TRANSMISSION OILambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5-15C +40C (5F - 104F)ambient air temperature Shell Spirax HD85W/140 or equivalentabove +40C (above 104F)DRUM OILambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5-15C +40C (5F - 104F)ambient air temperature Shell Spirax HD85W/140 or equivalentabove +40C (above 104F)GREASE SKF LGHB2 (NLGI Class 2) or equivalent for

articulated joint. Shell Retinax LX2 or equivalentfor other lubrication points.

FUEL See the engine manual

COOLANT Shell Anti-Freeze 402 or equivalentmixed 50/50 with water Anti-freeze protection down to about -35C (-31F).50/50

Always use high-quality lubricants, in the quantities specified. Excessgrease or oil can promote overheating, resulting in premature wear.

When driving in extremely high or low ambient tempe-ratures, other lubricants areneeded. Refer to the chapter entitled Special Instructions or contact Svedala Dynapac.

Engine, oil level Tire pressure

Engine, oil filter Air filter

Hydraulic fluid tank, level Battery

Hydraulic fluid filter Recycling

Transmission, oil level Fuel filter

Drum, oil level Coolant, level

Oil for lubrication

CAUTION

CAUTION

4 CA 152 M152EN2

TECHNICAL SPECIFICATIONS

Weights & dimensions CA152 CA152D CA152PD

Operating mass with ROPS, EN500, kg (lbs) 7200 7300 7700(15,876) (16,096) (16,978)

Operating mass without ROPS, kg (lbs) 6870 6970 7370(15,148) (15,368) (16,250)

Operating mass with cab, kg (lbs) 7420 7520 7920(16,361) (16,581) (17,463)

Length, standard-equipped roller, mm (in) 4776 4776 4871(188) (188) (192)

Width, standard-equipped roller, mm (in) 1852 1852 1852(73) (73) (73)

Height, with ROPS, mm (in) 2774 2774 2815(109) (109) (111)

Height, without ROPS, mm (in) 2050 2050 2065(81) (81) (81)

Height, with cab, mm (in) 2815 2815 2857(111) (111) (116)

Height, with AC and hazard beacon, mm (in) 3115 3115 3157(123) (123) (124)

Vibration data CA152 CA152D CA152PD

Static linear load kg/cm (pli) 21,5 (120.4) 22,1 (123.76) -Amplitude (High) mm (in) 1,7 (0.07) 1,7 (0.07) 1,7 (0.07)Amplitude (Low) mm (in) 0,8 (0.03) 0,8 (0.03) 0,85 (0.03)Frequency (High amplitude) Hz (vpm) 29 (1740) 29 (1740) 29 (1740)Frequency (Low amplitude) Hz (vpm) 40 (2400) 40 (2400) 40 (2400)Centrifugal force(High amplitude) kN (lb) 100 (22,500) 100 (22,500) 124 (27,900)Centrifugal force(Low amplitude) kN (lb) 94 (21,150) 94 (21,150) 118 (26,550)

Tires (all-weather)Tire dimensions ............................. 420/70 B24 (Std type) 14,9-24T461 8 ply (Tractor type)Tire pressure ................................. 110 kPa (1,1 kp/cm2) (16 psi) 180 kPa (1,8 kp/cm2) (26 psi)

Electrical system

Battery ........................................... 12 V, 170 AhAlternator ....................................... 14 V, 95 AFuses ............................................ See under heading Electrical System

Fluid volumes Litres (gal or qts)Rear axle: Differential ....................................................6 l (6.3 qts) Planetary gears ............................................0,75 l (0.8 qts) /each sideDrum ............................................................10,5 l (11.1 qts)Hydraulic reservoir .......................................52 l (13.7 gal)Oil in hydraulic system .................................18 l (4.8 gal)Lubrication oil, diesel engine ........................10 l (10.6 qts)Coolant, diesel engine ..................................20 l (21.1 qts)Fuel tank ....................................................225 l (59.4 gal)

The tires can be optionally filled with fluid, (extra weight up to 350 kg/tire,770 lbs/tire). When servicing, bear this extra weight in mind.

WARNING

5CA 152 M152EN2

Tightening torque

Hydraulic system

Bolt dimension: M20 (P/N 50 02 26)Strength category: 8.8Tightening torque: 330 Nm (243 lbf.ft)

(for Dacromet treated)

ROPS

Opening pressure, MPa (psi)

Drive system 38,0 (5,500)Charge system 2,0 (290)Vibration system 33,0 (4,800)Steering system 18,0 (2,600)Brake disengagement 1,4 (200)

TECHNICAL SPECIFICATIONSTightening torque in Nm (lbf.ft) for oiled, brightgalvanized bolts tightened with a torque wrench.

M STRENGTH CLASS thread 8.8 10.9 12.9

M6 8,4 (6.2) 12 (8.9) 14,6 (10.8)M8 21 (15.5) 28 (20.7) 34 (21.1)M10 40 (15.5) 56 (41.3) 68 (25.1)M12 70 (51.6) 98 (72.3) 117 (86.3)M16 169 (124.7) 240 (177) 290 (213.9)M20 330 (243.4) 470 (346.7) 560 (413.1)M24 570 (420.4) 800 (590.1) 960 (708.1)M30 1130 (833.5) 1580 (1165.4) 1900 (1401.4)M36 1960 (1445.7) 2800 (2065.3)

CAUTION

ROPS bolts must always be tightened dry.

Measured with vibration switched ON and on afoam-rubber mat, standard roller.

Noise levels with vibration switched OFF (dB(A)).Measured on hard surface, standard roller.

Operators station, (with cab) LpA: 82 dB(A)Operators station, (without cab) LpA: 79 dB(A)Seven metres from the machine: LpA: 79 dB (A)

Noise level Operator's station(ISO 6394)

Vibration Operator's station(ISO 2631)

Vibration on the operators seat is 0,07 m/s2 withoutcabin. Vibration on the operators seat is 0,19 m/s2with cabin. The limit value is 0,5 m/s2.

6 CA 152 M152EN2

MAINTENANCE SCHEDULE

1. Radiator grille2. Oil level, diesel engine3. Fuel filter4. Air filter5. Engine cover, hinges6. Hydraulic fluid tank, sightglass7. Bleeding filter8. Hydraulic fluid filters (2 filters)9. Drainage, hydraulic fluid reservoir10. Hydraulic fluid, filler11. Fuse-box12. Roller oil, filling, 2 fillers13. Roller gearbox

14. Scrapers15. Roller oil, level plugs, 2 pcs.16. Rubber elements and attachment

screws17. Steering joint18. Steering cylinder19. Flywheel casing, hydraulic pumps20. Wheel nuts21. Tires, pressure22. Rear axle, differential23. Rear axle, planetary gears, 2 pcs.24. Rear axle suspension, 2 sides25. Oil filter, diesel engine

26. Drainage, fuel tank27. Diesel engine mountings, 4 pcs.28. Feed pump, fuel29. Diesel fuel, filler30. Battery31. Radiator32. Hydraulic fluid cooler33. Drive belts, cooling, alternator34. Steering chain35. Seat bearing34. Steering chain37. Forward/Reverse lever38. Fresh air filter (with cab)

1 2 3 4 5 6 7 8 9 10 37 11 12 13

26 25 24 23 22 21 20 19 36 35 34 18 17 16 15

14

33

32

31

30

29

28

27

Fig. 1 Service and maintenance points

7CA 152 M152EN2

Periodic maintenance shall be carried out at thespecified intervals, that is to say either every day,every week etc., or after the specified number ofoperating hours, whichever comes first.

Always first remove all exterior dirt beforefilling up fluids etc., and before checking oiland fuel levels, and also when lubricating withgrease or oil.

The engine manual specifies additional ser-vice/maintenance instructions which relate tothe diesel engine.

MAINTENANCE MEASURES

Item. in Measure See page Commentsfig. 1

Before the days first start14 Check scraper setting 91 Check for free circulation of cooling air 10

31 Check coolant level 10 See engine manual2 Check diesel engine oil level 10 See engine manual

29 Top up fuel tank 116 Check fluid level in hydraulic tank 11

Check brakes 11

Every 10 operating hours (daily)

Item. in Measure See page Commentsfig. 1

Check that hoses and couplings are not leaking7 Clean the filter element of the air cleaner 12 Replace as required

17 Lubricate steering joint 1318 Lubricate the steering cylinder brackets 1320 Check the wheel-nuts are tightened 1421 Check tire pressure 14

- Inspect the air conditioning 14 Optional- Lubricate the strike-off blade bearings. 14 Optional

After the first 50 hours of operation change all the oil filters andlubricating oils, but not the hydraulic fluid.

Every 50 operating hours (weekly)

CAUTION

CAUTION

CAUTION

8 CA 152 M152EN2

MAINTENANCE MEASURE

Item. in Measure See page Commentsfig. 1

23 Check the oil level in rear axle/planetary gearing1515 Check the oil level in drum 1532 Clean the radiators 16

20, 24 Inspect and tighten bolted joints 16 Applies only to new andrepaired components

16 Inspect rubber elements and bolted joints 1725 Change engine oil and oil filter 17 See engine manual30 Inspect the battery 18

Inspect the air conditioning 18 Optional

Every 250 operating hours (monthly)

Item. in Measure See page Commentsfig. 1

8 Change the hydraulic fluid filters 219 Drain condensate from hydraulic tank 21

26 Drain condensate from fuel tank 224 Replace air cleaner main filter 22

22 Change oil in rear axle differential 2223 Change oil in rear axle planetary gears 2338 Replace the fresh air filter in the cab 23 Optional

Check diesel engine valve clearance See engine manual33 Check belt tension for drive belt system See engine manual

Every 1000 operating hours (every six months)

Item. in Measure See page Commentsfig. 1

9, 10 Change fluid in hydraulic tank 2412, 15 Change oil in roller 24

37 Lubricate Forward/Reverse control 25Overhaul air conditioning 25 Optional

Every 2000 operating hours (every year)

Item. in Measure See page Commentsfig. 1

3 Replace fuel filter See engine manual5 Lubricate controls and joints 193 Replace fuel pre-filter 19

36 Lubricate the steering chain 20 Optional35 Lubricate the seat bearing 20 Optional7 Check bleeder filter on hydraulic tank 21

Every 500 operating hours (every three months)

9CA 152 M152EN2

EVERY 10 OPERATING HOURS (daily)

Never work under the roller with the enginerunning. Park on a level surface. Block thewheels securely.

It is important to consider movement of thedrum when the machine turns, ie, the scraperscan be damaged or wear of the drum mayincrease if adjustment is made closer than thevalues stated.

If necessary, adjust distance to the drum as follows:the scraper is integrated with the beam.Loosen the four screws (2) on the frame side, then ad-just the beam to about 20 mm (0.8 in) from the drum.Tighten the screws.

Scrapers Check/Adjust

Fig. 2 Scrapers1. Scraper beam2. Screws

1

2

Soft scrapers (Optional)Loosen the screws (2) and adjust to light contactagainst the drum. Tighten the screws.

2 1 1 2

Fig. 4 Scrapers1. Scraper blade2. Screws

Fig. 3 Scrapers1. Scraper blade2. Screws

CA 152 PDLoosen the four screws (2) on the frame side, then ad-just the beam to about 25 mm (1 in) between the teethand the drum.Tighten the screws.1

2

CAUTION

WARNING

10 CA 152 M152EN2

Diesel engine Check oil level

Fig. 7 Engine compartment1. Oil dipstick

Park the machine on a level surface. Theengine should be switched off and theparking brake engaged during all inspectionand adjustment operations on the machine,unless otherwise stated.

Watch out for contact with hot engineparts and the hot radiator when the oildipstick is being removed. There is a riskof burn injuries.

The dipstick is located on the engines right side.

Pull up the dipstick (1) and check that the oil level isbetween the upper and lower marks. For further details,refer to the engine manual.

1

EVERY 10 OPERATING HOURS (daily)

Check that the diesel engine has free circulation ofcooling air through the grille in the enginecompartment.

Press the button on the hood lock (1) to open, and raisethe engine hood to its fully open position. Ensure thatthe red safety catch on the left gas-spring is engaged.

If the engine covers gas struts are disen-gaged and the cover is raised to its upperposition, block the cover so that it cannotfall down accidentally.

Air circulation Check

Fig. 5 Grille1. Hood lock

1

Fig. 6 Radiator1. Max. level2. Min. level3. Filler cap

1 32

Coolant level CheckCheck that level of the coolant is between the max. andmin. marks.

Danger of scalding. Take great caution ifthe radiator cap must be opened while theengine is hot. Wear protective gloves andgoggles.

Fill with a mixture of 50% water and 50% anti freeze.See lubricant specification and in the engine manual.

Flush the system every other year andchange the coolant. Ensure also that air canflow unrestricted through the radiator.

WARNING

CAUTION

WARNING

WARNING

WARNING

11CA 152 M152EN2

EVERY 10 OPERATING HOURS (daily)

Refuel daily, before starting to work. Screw off the lock-able tank cap (1) and fill with diesel fuel to the loweredge of the filler pipe.

Stop the engine. Short the refuelling nozzleby holding it pressed against the filler pipe(1) while filling the tank.

See the engine manual with regard to quality of diesel fuel.

The tank holds 225 litres (59.4 gal).1Fig. 8 Fuel tank

1. Tank cap

Fuel tank Filling

Hydraulic reservoir Check fluid level

Brake function Check

Fig. 10 Control panel1. Reserve-/parking brake knob2. Forward/reverse lever

Fig. 9 Hydraulic fluid reservoir1. Sight glass2. Filler pipe

Check operation of the brakes as follows:

Drive the roller slowly forward.

Push the reserve/parking brake knob (1); the warninglamp on the instrument panel should light and the rollershould stop.

After testing the brakes, set the forward/reverse lever(2) in neutral.Pull up the reserve-/parking brake knob.

The roller is now ready for operation.

Position the roller on a level surface and check that thesight glass reading (1) is between the max. min.marks. Top off with hydraulic fluid according to the lu-bricant specification if the level is too low.

WARNING

1 2

1

2

WARNING

12 CA 152 M152EN2

Replace or clean the air cleaners main filter ifthe warning lamp on the instrument panellights up when the diesel engine is operatingat full speed.

Undo the three locking braces (1). Then pull off thecover (2) and pull out the main filter (3).Do not remove the safety filter (4).

If the main filter is to be cleaned, compressed air atmax. 5 bar (72 lbs/sq in) pressure should be used.Blow up and down along the paper creases on the in-side of the filter.

Hold the nozzle at least 23 cm (0.8-1.2 in) away fromthe paper creases so that the paper does not tear un-der the pressure of air.

Use protective goggles when working withcompressed air.

Dry the inside of the cover (2) and filter housing (5).Check that the hose clamps between the filterhousing and inlet hose are tightened and thatthey do not leak. Check the entire length of thehose all the way to the engine.

Once the main filter has been cleaned a maxi-mum of 5 times, it must be replaced.

EVERY 50 OPERATING HOURS (weekly)

Main filter Cleaning withcompressed air

Fig. 12 Main filter

2 3

Fig. 11 Air cleaner1. Locking braces2. Cover3. Main filter4. Safety filter5. Filter housing

1 4 5

Air cleaner Check/clean

Fig. 13 Air filter4. Safety filter

Safety filter Replacement

4Replace the safety filter with a new one at every 5threplacement or cleaning of the main filter. The safetyfilter cannot be cleaned.

When replacing the safety filter (4), pull out the old filterfrom its holder, insert a new one and refit the aircleaner in the reverse order to the instructions given inthe figure above.

WARNING

CAUTION

CAUTION

CAUTION

13CA 152 M152EN2

EVERY 50 OPERATING HOURS (weekly)Steering joint and steeringcylinder Lubrication

Fig. 14 Steering joint, left side

Place the roller on a level surface. Switch theengine off and push in the reserve/parkingbrake knob for all checking and adjustmentson the roller, unless otherwise specified.

Allow no one to get near the steering jointwhen the engine is running. Danger ofbeing crushed when steering is operated.Push the reserve/parking brake knob be-fore lubricating.

Turn the steering wheel fully to the right to gain accessto all six lubricating nipples on the left side.

Use grease recommended in Lubricant Speci-fication on page 3.

Wipe all the nipples clean from dirt and grease.

Lubricate each nipple (1) with five strokes of the greasegun. Make sure that grease penetrates the bearings.

If grease does not penetrate through the bearings, itmay be necessary to relieve the load on the articulatedjoint with a hydraulic jack and then repeat the greasingprocess.

Steering joint Lubrication

Steering cylinder Lubrication

Fig. 16 Steering cylinder, left side2. Lubricating nipples, cylinder brackets (x2)

Fig. 15 Steering joint, left side1. Lubricating nipples,

steering joint (x4)

Wipe nipples clean from dirt and grease.

Lubricate each nipple (2) with three strokes of the grease gun.Allow a little grease to remain on the nipples aftergreasing. This will prevent contaminants from enteringthe nipples.

1

1

2

CAUTION

WARNING

WARNING

14 CA 152 M152EN2

Tires tire pressureWheel nuts tightening

EVERY 50 OPERATING HOURS (weekly)

Fig. 17 Wheels1. Air valve2. Wheel nut

1

2

Check the tire pressures using a pressure gauge.

If the tires are filled with fluid, the air valve (1) must bein the 12 oclock position during pumping.

The relevant tire pressures are given under the headingSpecifications.

Check both tires.

When changing the tires it is important thatboth of them have the same rolling radius. Thisis necessary to ensure proper functioning ofthe anti-slip in the rear axle.

Check the tightening torque of the wheel nuts (2) at 470Nm (350 lbf.ft). Check both wheels and all the nuts.(Applies only to new machine or recently fitted wheels.)

Check the safety manual that accompaniesthe roller before filling the tires with air.

CAUTION

WARNING

Remove the rubber plug in the condenser hood whilethe unit is operating and make sure through the sightglass (1) that no bubbles are visible on the dryer filter. Ifbubbles are visible through the sight glass, it is a signthat the refrigerant level is too low. If so, stop the unit.The unit may be damaged if it is run with insufficientrefrigerant.

Clean the condenser element free from dust as required.

Air conditioning (Optional) Inspection

Fig. 18 Air conditioning1. Sight glass

1

Always lower the blade to the groundbefore leaving or parking the roller.

Make sure that nobody is in the way whenoperating the blade.

Lower the blade.

Wipe the nipples clean from grease and dirt, three oneach side of the machine.

Grease each nipple (1) with four strokes of the greasegun. Ensure that grease penetrates the bearings.

Fig. 19 Strike-off blade1. Lubricant nipples

1

Strike-off blade (Optional) Lubrication WARNING

WARNING

15CA 152 M152EN2

Drum Checking the oil level

EVERY 250 OPERATING HOURS (monthly)Rear axle differential Check oil level

Never work under the roller with the engi-ne running. Park on a level surface. Blockthe wheels securely.

Wipe clean and remove the level plug (1) and checkthat the oil level reaches the lower edge of the plughole. Top off with oil to the right level if the level is low.Use transmission oil according to the lubricantspecification.

Position the roller with the level plug (1) in the planetarygears at 9 oclock.

Wipe clean and remove the level plug (1) and checkthat the oil level reaches the lower edge of the plughole. Top off with oil to the right level if the level is low.Use transmission oil according to the lubricantspecification.

Clean and screw in the plug.

Check the oil level in the same way in the rear axlesother planetary gear.

1

Fig. 20 Oil level check differential housing1. Oil level/Filler plug

Rear axle planetary gears Check oil level

Fig. 21 Oil level check planetary gear1. Oil level/Filler plug

1

WARNING

Fig. 22 Right side of drum1. Filling plug2. Number plate3. Sight glass

Position the roller on a flat surface so that the filler plug(1) and number plate (2) on the right side of the drumare straight up.

Oil level should reach up to the sight glass (3).Top off as required through the filler plug (1) halfway onthe sight glass.

Clean the magnetic filler plug (1) from any metal parti-cles before refitting it.

See lubricant specification for the right grade of oil.

Do not overfill with oil, risk of overheating.

3

2

1

CAUTION

16 CA 152 M152EN2

EVERY 250 OPERATING HOURS (monthly)

Fig. 23 Radiator1. Water cooler2. Hydraulic fluid cooler

Radiator Check/clean

1

2

Place the roller on a level surface. Switchthe engine off and push in the reserve/parking brake knob for all checking andadjustments on the roller, unless otherwisespecified.

Check that air can flow freely through the radiators (1)and (2).A dirty radiator should be blown clean with compressedair, or alternatively cleaned with a high-pressure washer.

Blow or wash the cooler in the opposite direction to thatof the cooling air.

Be careful when using a high-pressure washer do not place the nozzle too close to theradiator.

Use protective goggles when working withcompressed air or a high-pressure washer.

WARNING

CAUTION

WARNING

Bolted joints Checking tightening torque

Fig. 24 Right side of machine1. Steering pump2. Rear axle3. Engine suspension4. Wheel nuts

Steering pump against engine (1) 38 Nm (28 lbf.ft).Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.Engine suspension (3). Check that all M12 bolts (x20)are tightened, 78 Nm (57 lbf.ft).Wheel nuts (4). Check that all nuts are tightened, 470Nm (347 lbf.ft), oiled.(The above applies to new or replaced componentsonly.)

32

1

4

17CA 152 M152EN2

EVERY 250 OPERATING HOURS (monthly)

Check all the rubber elements (1), and replace them all ifmore than 25% of the elements on the same side of theroller have cracks deeper than 1015 mm (0.4-0.6 in).Use a knife blade or other pointed tool when carryingout this check.

Check also that the screw fasteners (2) are tightened.

Fig. 25 Roller, vibration side1. Rubber element2. Screw fasteners

Rubber elements and screwfasteners Check

Fig. 26 Left side of engine1. Drain plug2. Oil filter

Diesel engine Changing the filter and oil

Position the roller on a level surface. Stopthe engine and apply the parking brake/reserve brake.

The oil drain plug (1) located in a mount on the rear axleis most easily accessible from underneath the engine.Drain the oil while the engine is warm. Place a recepta-cle for at least 15 litres under the drain plug.

Danger of being scalded when draining offhot oil. Protect your hands.

Change the engine oil filter (2) at the same opportun-ity. See also the engine manual.2 1

1

2

WARNING

WARNING

Dispose of the drained oil and filter in anapproved manner.

18 CA 152 M152EN2

Battery Check electrolyte level

Make sure there are no naked flames in thevicinity when checking the electrolyte level.An explosive gas is formed in the batteryduring the charging process.

Lift up the engine compartment cover and undo thequick-release screws (1).Raise the battery cover (2).Dry the upper face of the battery.

Use protective goggles. The battery con-tains corrosive acid. In the event of con-tact, rinse with water.

Remove the cell covers and check that the fluid levelis about 10 mm (0.4 in) above the plates. Check thelevel in all the cells. If the level is lower, top up to thecorrect level with distilled water. If the ambient airtemperature is below freezing point, the engine shouldbe run for a while after the distilled water is added,otherwise there is a risk that the water might freeze.

Check that the ventilation holes in the cell covers arenot blocked, then refit the covers.

The cable terminals must be properly tightened andclean. Corroded cable connections should be cleanedand greased with alkaline Vaseline.

When removing the battery, always undo thenegative cable first.When fitting the battery, always connect thepositive cable first.

Dispose of the old battery in the approvedenvironmentally suitable manner batteriescontain toxic lead.

When carrying out electrical welding onthe machine, disconnect the batterysnegative cable and then all the electricalconnections leading to the alternator.

Fig. 27 Battery box1. Quick-release screws2. Battery cover3. Battery

Battery cell

Fig. 28 Electrolyte level in battery1. Cell cover2. Electrolyte level3. Plate

EVERY 250 OPERATING HOURS (monthly)

WARNING

WARNING

WARNING

CAUTION

Inspect refrigerant hoses and connections and makesure that there are no signs of oil film that could indicateleakage of refrigerant.

Air conditioning (Optional) Inspection

Fig. 29 Air conditioning

1 2 3 1

12

3

10 mm(0.4 in)

19CA 152 M152EN2

EVERY 500 OPERATING HOURS (every three months)

Fig. 30 Engine hood1. Hinge

Controls and movingjoints Lubrication

1 Place the roller on a level surface. Switchthe engine off and push in the reserve/parking brake knob for all checking andadjustments on the roller, unless otherwisespecified.

Lubricate engine hood hinges (1) and the slide rails ofthe operators seat with grease, other joints andcontrols with oil. Lubricate the cab hinges with grease.See lubricant specification.

Fig. 31 Engine1. Fuel pre-filter2. Hose clamps

Fuel pre-filter Replacement

Loosen the hose clamps (2) and remove the pre-filter(1). Fit the new filter, taking care to fit in the direction offlow. The arrow is to point away from the tank.

12 2

Discard the pre-filter (1) in a safe manner, it isof the expendable type and cannot be cleaned.

Start the engine and check that the pre-filter does notleak.

Make sure there is adequate ventilation(extraction) if the diesel engine is run in-doors. Risk of carbon monoxide poisoning.

WARNING

WARNING

20 CA 152 M152EN2

EVERY 500 HOURS OF OPERATION (Every three months)

Optional on rollers without cab

Remember that the chain is a vital part of thesteering mechanism.

Clean and lubricate the chain (1) between the seatbearing and steering valve with grease. The chain isaccessible underneath the platform.

It is not necessary to remove the chain.

Adjust the chain as follows if it has slackened so thatsize a is less than 30 mm (1.2 in): Loosen the nuts (4)and adjust the mount (5) backwards with the adjustingnut (3) until size a is 50 mm (2 in).

Steering chain andSeat bearing Lubrication

Fig. 32 Underneath operators position1. Steering chain2. Chain-tightening device3. Adjusting nut4. Nuts5. Control valve mount

a

1

2

4

5

3

CAUTION

4

5

6

3

21

7

Seat bearing Lubrication

Fig. 33 Seat bearing1. Lubrication nipple2. Cogwheel3. Steering chain4. Adjusting screw5. Cover6. Slide rails7. Slew interlock

Remember that the chain is a vital part of thesteering mechanism.

Remove the cover (5) to gain access to the lubricationnipple (1).Lubricate the slew bearing of the operators seat withthree strokes of a hand-operated grease gun.

Lubricate the seat locking latch (7), accessible frombelow.

Also grease the slide rails of the seat (6).If the seat begins to bind when resetting, itneeds to be lubricated more often.

Clean and grease the chain (3) between the seat andthe steering column.If the chain becomes slack on the cogwheel (2), loosenthe screws (4) and move the steering column forward,tighten the screws and check the tension of the chain.

CAUTION

CAUTION

Optional on rollers without cab

21CA 152 M152EN2

EVERY 1000 OPERATING HOURS (every six months)

Fig. 36 Hydraulic tank, underside1. Drainage tap2. Plug

1

2

Hydraulic tank Drainage

Fig. 35 Engine compartment1. Hydraulic fluid filters (x2)

Fig. 34 Hydraulic fluid tank1. Filler cover/bleeder filter3. Sight glass

3

2

1

Hydraulic fluid filter Change

Condensate in the hydraulic reservoir is removed viathe drainage tap (1).Drainage should be performed when the roller has beenstanding for a long period of time, for example over-night. Drain as follows:Remove the plug (2).Place a container under the tap.Open the tap (1) and let any trapped condensate run out.Shut the drainage tap.Refit the plug.

Place the roller on a level surface. Switchthe engine off and push in the reserve/parking brake knob for all checking andadjustments on the roller, unless otherwisespecified.

Undo the cover/bleeder filter (2) on top of the reservoirso that over-pressure inside the reservoir can be elimi-nated.Check that the bleeder filter (2) is not blocked airshould flow freely through the cover in both directions.If there is a blockage in either direction, clean the filterwith a little diesel oil and blow through with compressedair until the blockage disappears, or replace the coverwith a new one.

Always use protective goggles when work-ing with compressed air.

Clean thoroughly around the oil filters.

Remove the oil filters (1) and dispose of themin an approved manner. They are single-usefilters and cannot be cleaned.Check that the old sealing rings do not remainstuck on the filter holders, otherwise this mightgive rise to oil leakage between the old andnew seals.

Clean the filter holder sealing surfaces thoroughly.Apply a thin film of hydraulic fluid on the seals of thenew filter. Screw on the filter by hand.

First tighten the filter until its seal is in contactwith the filter attachment. Then turn an addi-tional half revolution. Do not over-tighten thefilter as this might damage the seal.

Start the engine and ensure that there is no leakage ofhydraulic fluid from the filters. Check level of fluid in thesight glass (3) and top up as required.

Make sure there is adequate ventilation(extraction) if the diesel engine is run in-doors. Risk of carbon monoxide poisoning

WARNING

CAUTION

WARNING

CAUTION

WARNING

22 CA 152 M152EN2

EVERY 1000 OPERATING HOURS (every six months)

Fig. 37 Fuel tank1. Drainage plug

Fuel tank Drainage

1

2 3

Fig. 38 Air cleaner1. Locking braces2. Cover3. Main filter4. Backup filter5. Filter housing

1 4 5

Air filter Replacement

Fig. 39 Rear axle1. Oil level/Filler plug2. Drainage plugs

Rear axle differential Oil change

12

2

Side view of rearaxle (transmissionpipe)

Water and sediment in the fuel tank are removed viathe drainage plug in the bottom of the fuel tank.

Be very careful during draining. Do not dropthe plug or else all the fuel will flow out.

Drainage should be performed when the roller has beenstanding for a long period of time, for example over-night. The fuel level should be as low as possible.

The roller should preferably have been standing withthis side somewhat lower, so that water and sedimentwill gather near the drainage plug (1). Drain as follows:Place a container under the plug (1).Undo the plug and drain off the water and sediment untilonly clean diesel fuel appears through the plug opening.Refit the plug.

Replace the main filter (3) of the air cleaner even if ithas not yet been cleaned five times, see under 50hours for filter replacement.

Never work under the roller with the enginerunning. Park on a level surface and blockthe wheels securely.

Wipe clean and remove the level/filler plug (1) and allfive drain plugs (2) and drain the oil into a suitablereceptacle. The volume is almost 8 litres (8.45 qts).

Save the oil and deposit it in an approvedmanner.

Refit the drainage plugs and top up with fresh oil until thecorrect level is reached. Refit the oil-level/filler plug. Usetransmission oil, see the lubrication specification.

Dont forget to drain the oil from the rear axles transmis-sion pipe.

WARNING

CAUTION

23CA 152 M152EN2

1

Fig. 41 Planetary gear/filling position1. Plug

Position the roller with the plug (1) at its lowest position.Wipe clean, unscrew the plug (1) and drain the oil into asuitable receptacle. The volume is about 2 litres (2.1 qts).

Save the oil and deposit it in an approvedmanner.

Position the roller with the plug at 9 oclock.

Fill with oil to lower edge of level hole. Use transmis-sion oil. See lubricant specification.

Clean the plug and screw back in.

Change the oil in the same way as the other planetarygears of the rear axle.

Rear axle planetary gears Oil change

Fig. 40 Planetary gear/drainage position1. Plug

1

EVERY 1000 OPERATING HOURS (every six months)

Fig. 42 Cab1. Fresh air filter2. Screw (x2)

Fresh air filter ReplacementLoosen the two screws (2) at the rear of the cab roof.Take down the whole holder and remove the filterinsert.

Replace with a new filter.

It may be necessary to replace the filter more often ifthe machine is used in a dusty environment.

12 2

24 CA 152 M152EN2

Place the roller on a level surface so that the drain plug(1) is straight down and place a receptacle that will holdat least 15 liters under the plug.

Save the oil and deposit it in an approvedmanner.

Clean and unscrew the plug (1). Allow all of the oil todrain off. Fill with oil according to Drumchecking theoil level.

There is danger of being scalded whendraining hot oil. Protect your hands.

Fig. 43 Hydraulic tank, underside1. Drainage tap2. Plug

EVERY 2000 OPERATING HOURS (every year)

1

2

Hydraulic tank Fluid change

3

1

Drum Changing the Oil

Fig. 44 Drum, right side1. Drain/Filler plug2. Number plate3. Sight glass

2

Place the roller on a level surface. Switch theengine off and push in the reserve/parkingbrake knob for all checking and adjustmentson the roller, unless otherwise specified.Danger of being burned when draining hotoil. Protect your hands.

Obtain a container for collecting the used fluid. The con-tainer should have a volume of at least 60 litres (16 gal).A suitable container may be an empty oil drum or sim-ilar item which is placed beside the roller. The fluid thenruns in a hose from the drainage plug (1) to the oildrum, after the plug (2) has been removed and the tapopened.

Save the oil and deposit it in an approvedmanner.

Fill up with fresh hydraulic fluid as per the instructionsunder the heading Hydraulic reservoir Check fluidlevel.Replace the hydraulic fluid filters at the same time.

Start the diesel engine and operate the various hydrau-lic functions.

Make sure there is adequate ventilation(extraction) if the diesel engine is runindoors.(Risk of carbon monoxide poisoning)

Check the fluid level and top up if necessary.

WARNING

WARNING

WARNING

WARNING

25CA 152 M152EN2

EVERY 2000 OPERATING HOURS (every year)Forward/Reverse lever Lubrication

Fig. 45 Forward/Reverse lever1. Screw2. Plate3. Cam disk

1 2 3

Unscrew the screws (1) and remove the plate (2).Grease the contact surface of the cam disc (3).Refit the plate (2) with the screws (1).

Inspect the steering joint to detect any damage orcracks.

Check and correct any loose bolts.

Check also for any stiffness and play.

Steering joint Check

Fig. 46 Steering joint

26 CA 152 M152EN2

Regular inspection and maintenance are necessary toensure satisfactory long-term operation.Lift off the fiberglass cover (1) and then screw loose thetwo covers (2) from the unit.Clean the condenser unit and the condenser elementsfree from dust using compressed air.

The air jet could damage the flanges of theelements if it is too powerful.

Wear protective goggles when workingwith compressed air.

Inspect the fastening of the condenser element.Clean the cooler unit and the cooling elements free fromdust using compressed air.Inspect and shield the systems hoses against chafing.Inspect the fastening of the compressor motor andhydraulic motor, and also the clearance of connectingcollars between the compressor and the hydraulicmotor. The axial clearance should be about 45 mm(0.16-0.20 in) and the radial clearance about 1 mm (0.04 in).Make sure that drainage from the cooling unit is unob-structed so that no condensation accumulates insidethe unit.Inspect suspension of the rubber dampers for the con-denser unit. Check that they are not cracked and showno sign of damage.The unit should be run at least five minutes every week,if possible, to ensure lubrication of rubber gaskets in thesystem.

The air unit should not be run when the outdoortemperature is below 0C (32F).

Inspect the sight glass on the unit (1), above the dryerfilter in the condenser. Bubbles should only be visible onstarting and stopping the compressor. An authorizedservice company should be consulted for service ifmany bubbles or milky fluid are observed.

The compressor will be damaged if the unitis run with too little refrigerant.

Do not disconnect the hose coupling.

The cooling system is pressurized.Incorrect handling can result in seriouspersonal injuries.The system contains pressurized refriger-ant. Releasing refrigerants into the air isprohibited. The refrigerant circuit may onlybe repaired by an authorized company.

EVERY 2000 HOURS OF OPERATION (Yearly)

Fig. 47 Air conditioning1. Fiberglass cover2. Cover3. Sight glass

3

1 2

Air conditioning (Optional) Overhaul

WARNING

WARNING

WARNING

WARNING

WARNING

CAUTION

CAUTION

27CA 152 M152EN2

LONG-TERM STORAGEFor long-term storage (longer than one month),the following instructions should be followed.

These instructions apply for storage lasting upto 6 months.

Before re-commissioning the roller, the pointsmarked with an asterisk * must be restored.

Fig. 48 Protecting the roller from theelements

* See the manufacturers instructions in the engineinstruction manual, which is supplied together withthe roller.

* Remove the battery from the roller, clean itsexterior, check its electrolyte level and recharge itonce a month.

* Cover the air cleaner or its opening with plastic ortape, and cover also the exhaust pipes opening.This is done so as to prevent moisture frompenetrating into the engine.

Fill the fuel tank completely to prevent condensation.

Drain off any condensation water and fill the hydrau-lic reservoir to the upper mark.

Lubricate the steering joint bearings and the steeringcylinders two bearings with grease.Grease the steering cylinders piston withconservation grease.Grease also the engine compartment covers hin-ges, the seat slide rails, the engine-speed controland the forward/reverse control mechanism.

Check that tire pressure is 110 kPa (1,1 kp/cm2),(16 psi).

* Place the instrument cover on the steering column.Cover the entire machine with a tarpaulin, whichshould hand some way off the ground. If possible,store the roller indoors, preferably in a building with auniform temperature.

Diesel engine

Battery

Air cleaner, exhaust pipe

Covers, tarpaulin

Fuel tank

Tires (All-weather)

Steering cylinder, hinges etc.

Hydraulic reservoir

CAUTION

28 CA 152 M152EN2

SPECIAL INSTRUCTIONS

Standard lubricants and otherrecommended oils

Upon delivery from the factory, the various systemsand components are filled with the oils specified seelubricant specification and they can be used at ambienttemperatures from -10C to +40C (14F - 104F).

A maximum temperature of +35C (95F)applies for biological hydraulic fluid.

When operating in hotter ambient temperatures, but upto max. +50C (122F), the following instructions apply:The diesel engine can handle this temperature with thestandard oil, but the following oils must be used in theother components:Hydraulic system with mineral fluid: Shell Tellus TX100or corresponding.Other components using transmission oil:Shell Spirax HD 85W/140 or corresponding.

The temperature limits apply for a roller with standardfeatures.

Rollers with extra equipment such as noise suppress-ers etc. may require additional attention at the uppertemperatures.

When washing the machine, do not direct thejet of water directly at the fuel or hydraulic fluidtank covers. This is particularly importantwhen using a high-pressure washing unit.

Do not spray water directly on electric components orthe instrument panel. Put a plastic bag over the fillercap of the fuel tank and secure with a rubber band.This will prevent water from entering the venting hole inthe filler cap. This could otherwise cause operationaldisturbance, for example, a clogged filter.

If there is a fire in or on the machine, it is best to use anABE-class fire extinguisher. However, a BE-class CO2extinguisher is also suitable.

If the roller is equipped with a protective structure(ROPS, Roll Over Protective Structure), or protectivecab, never subject the structure or cab to welding ordrilling. Never attempt to repair a damaged structure orcab; they must be replaced with new ones.

When an auxiliary starter battery is used, alwaysconnect the positive terminal on the auxiliary battery tothe positive terminal on the rollers battery, andnegative to negative.

Higher ambient temperaturemax. +50C (122F)

Temperatures

High-pressure washing

Extinguishing fires

ROPS, protective cab

Starting assistance

CAUTION

CAUTION

29CA 152 M152EN2

ELECTRICAL SYSTEM, FUSES

The electrical regulating and control system isprotected against overload by 27 fuses and 12 relays.The number depends on how much extra equipment isfitted on the machine.

The four fuse boxes (1,2,3,4) and the relays arelocated behind the lower instrument plate, which can beremoved by turning the four quick-screws (5) a -turn.The machine is equipped with a 12 V electrical systemand an alternator.

Connect the battery to the correct polarity( to ground). The cable between batteryand alternator must not be disconnectedwhen the engine is running.

Fig. 49 Instrument panel1,2,3,4. Fuse boxes

5. Quick-screws6. Relays

5 3 4 5

Fuses and relays

5 1 2 5

Fuses on the machine

Fig. 50 Fuse box, left side (1)7.5A 1. Brake valve, starter relay, hourmeter7.5A 2. VBS relay7.5A 3. Indicating panel7.5A 4. Horn7.5A 5. Low/High speed/Strike-off blade3A 6. Reversing alarm

Fuse box, left side (2)7.5A 1. Instrumentation3A 2. Compaction meter7.5A 3. Hazard beacon7.5A 4. Anti-spin20A 5. Air cond.20A 6. Air cond.

The figure shows the rating and function of the differentfuses.

All fuses are flat pin fuses.

The tachograph and memory for the radio are protectedat the battery master disconnect switch by a 0,5A and3A fuse, respectively.

Fuse box, right side (3)20A 1. Working lights, left20A 2. Working lights, right, instrument illumination7.5A 3. Headlight, left7.5A 4. Headlight, right, instrument illumination*

5. 6.

Fuse box, right side (4)10A 1. Hazard beacon10A 2. Direction indicators, main fuse7.5A 3. Position light, left, front and rear5A 4. Position light, right, front and rear5A 5. Direction indicator, left, front, rear and side5A 6. Direction indicator, right, front, rear and side

* When driving lights are fitted

6

WARNING

= Optional

30 CA 152 M152EN2

Main fuses

Fig. 52 Engine compartment1. Main fuses2. Fuel solenoid relay3. Starter relay

There are four main fuses (1). These are locatedbehind the battery master disconnect switch. The threescrews need to be unscrewed to remove the plasticcover.

The fuses are of the flat pin type.

The fuel solenoid relay (2) and the starter relay (3) arealso fitted here.

Supply, standard 30 A (Green)Supply, cab 50 A (Red)Supply, lighting 40 A (Orange)Supply, AC 30 A (Green)

ELECTRICAL SYSTEM, FUSES

Fuses in the cab

Fig. 51 Fuse box overhead in cab15A 1. Rear cab working light15A 2. Front cab working light. Radio10A 3. Cab interior lighting20A 4. Heater/fresh air fan10A 5. Rear screen wiper/screen-wash10A 6. Front screen wiper/screen-wash

The electric system in the cab is equipped with its ownfuse box, located overhead at the front right part of thecab.The figure shows the ampere rating and function of thedifferent fuses. All fuses are of the flat pin type.

1 2 3

K2 VBS relayK3 Main relayK4 Horn relayK5 Hourmeter relayK6 Fuel level relayK7 Reverse alarm relayK8 Lights relayK9 Direction indicator relayK10 Brakes relayK11 Air cond. relay

Relays

Fig. 53 Instrument panel

= Optional

Lubricants and symbols Technical specifications Maintenance schedule Maintenance measures Every 10 operating hours (daily) Every 50 operating hours (weekly) Every 250 operating hours (monthly) Every 500 operating hours (every three months) Every 1000 operating hours (every six months) Every 2000 operating hours (every year) Long-term storage Special instructions Electrical system, fuses