070 Double Drum TRAINING

DOUBLE DRUM COMPACTOR TRAINING MANUAL
TRAINING MANUAL
FOR SMALL TANDEM ROLLERS
DV201, DV202, DV203, DV204
CASE Corporation
© 7 / 2005
SEPTEMBER 26, 2005
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We preserve the right for changes at pictures and data for improving the manual’s quality. Overprint and copying of
any kind and also individual paragraphs is conditioned by our written approval only.
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CONTENT ............................................................................................................................... 3
1. MACHINE DESCRIPTION .................................................................................................. 6
2. TECHNICAL DATA........................................................................................................... 10
3. INDIVIDUAL GROUPS ROLLER...................................................................................... 18

THE FRONT AND REAR DRUM.....................................................................................................................18
THE FRONT FRAME .......................................................................................................................................26
THE REAR FRAME .........................................................................................................................................28
THE JOINT CONNECTION .............................................................................................................................30
FRONT AND REAR BRACKET ......................................................................................................................34
SCRAPERS OF THE DRUMS .........................................................................................................................36
SPRINKLING ...................................................................................................................................................38
ENGINE DEUTZ...............................................................................................................................................40
COOLING OF THE HYDRAULIC OIL .............................................................................................................44
PLATFORM......................................................................................................................................................46
HYDRAULICS..................................................................................................................................................49
ELECTRICAL INSTALLATION .......................................................................................................................79
4. CONTROL OF THE ROLLER........................................................................................... 99

INSTRUMENTS AND CONTROLS .................................................................................................................99
CONTROLLING BASIC FUNCTIONS OF THE ROLLER ............................................................................109
MACHINE TRANSPORT ...............................................................................................................................115
SPECIAL CONDITIONS OF THE ROLLER USE .........................................................................................121
SAFETY REGULATIONS ..............................................................................................................................123
FILLING SPECIFICATIONS ..........................................................................................................................125
5. MAINTENANCE.............................................................................................................. 130
INDIVIDUAL OPERATIONS OF MAINTENANCE ........................................................................................132
TROUBLESHOOTING...................................................................................................................................142
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1. MACHINE DESCRIPTION
Machine description
CASE Model DV201, DV202 & DV204 rollers are all tandem vibration rollers with articu-
lated frames and two smooth drums. Both drums are hydrostatic drive and vibration. The
vibration of the rear drum may be switched on and off. All functions of the rollers are
controlled by hydrostatic motors. The frames are designed to allow for soil compaction
close to walls and curbs on both sides of the rollers. Their small dimensions and turning
radius make the rollers suitable for work in limited areas. The operator's station permits
perfect visibility of both rims of the drums.
Area of use
The rollers are intended to perform small size compaction in road construction, such as
local roads, cycling paths, sidewalks, parking areas, and garage entries, and in general
civil engineering work on smaller industrial areas. The rollers are particularly suited for
compaction of asphalt mixtures up to a finished depth of 120 mm (4 ¾ in), however, they
may also be used for compacting hydraulically bonded mixtures up to a finished depth of
150 mm (6 in), mixed soils up to 200 mm (8 in), or sandy and gravel materials up to 300
mm (12 in). The rollers are not suitable for compacting rock-fill and clay soils.
The rollers have been designed for operation to CSN IEC 721-2-1(038900); WT, WDr,
MWDr, namely mild, warm and dry, or hot and dry climate, with limited temperature
range of -15° C (5° F) to + 45° C (113° F).
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1 - Front frame 12 - Fuel tank

2 - Rear frame 13 - Hydraulic oil tank
3 - Articulated joint 14 - Sprinkling water tank front and rear
4 - Front and rear forks 15 - Dash Panel
5 - Front and rear drum 16 - Hood
6 - Engine 17 - Sprinkling pump
7 - Hydraulic pump for travel 18 - Sprinkling heads for the drums
8 - Tandem hydraulic pump for vibration and power 19 - Scrapers for the drums
steering 20 - Battery
9 - Hydraulic oil cooler 21 - Protective ROPS frame
10 - Engine air filter 22 - Travel hydraulic motor
11 - Exhaust 23 - Vibration hydraulic motor
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Dimensions
in mm (in) A D H1 K1 L1 L2
1715 738 2660 310 2453 2640
DV201 (67.5) (29.06) (104.72) (12.2) (96.6) (104)
1715 738 2660 310 2453 2640
DV202 (67.5) (29.06) (104.72) (12.2) (96.6) (104)
1715 746 2660 310 2461 2640
DV204 (67.5) (29.4) (104.72) (12.2) (96.89) (104)
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Dimensions
in mm (in) S B1 H2 K2 O W1
12 1090 1825 590 45 1000
DV201 (0.47) (42.9) (71.85) (23.22) (1.77) (39.37)
12 1290 1825 590 45 1200
DV202 (0.47) (50.79) (71.85) (23.22) (1.77) (47.24)
16 1396 1825 590 48 1300
DV204 (0.63) (54.96) (71.85) (23.22) (1.89) (51.18)
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2. TECHNICAL DATA
Weights
DV201 DV202
Working weight with ROPS due to EN 500-1 kg (lb) 2520 (5550) 2790 (6145)
front drum kg (lb) 1185 (2610) 1320 (2907)
rear drum kg (lb) 1335 (2940) 1470 (3238)
Static linear load of the front drum kg/cm (lb/in) 11.8 (66.2) 11.0 (61.6)
Static linear load of the rear drum kg/cm (lb/in) 13.3 (74.6) 12.2 (68.6)
Working weight with ROPS due to ISO 6016 kg (lb) 2645 (5826) 2915 (6420)
Load of the front drum kg (lb) 1220 (2687) 1355 (2985)
Load of the rear drum kg (lb) 1425 (3139) 1560 (3435)
DV203 DV204
Working weight with ROPS due to EN 500-1 kg (lb) 3055 (6730) 3335 (7346)
front drum kg (lb) 1520 (3350) 1660 (3656)
rear drum kg (lb) 1535 (3380) 1675 (3690)
Working weight with ROPS due to ISO 6016 kg (lb) 3200 (7048) 3480 (7665)
Load of the front drum kg (lb) 1565 (3448) 1705 (3755)
Load of the rear drum kg (lb) 1635 (3600) 1775 (3910)
The weight data can differ from above mentioned data according to the further customers’ requirements for the roller’s equip-
ment and accessories.
Note: Operation weight to EN 500-1 = CECE
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Traveling
DV201/DV202 DV204
The travel speed smoothly regulated in booth directions
1st range - working km/h (MPH) 7.5 (4.7) 5.3 (3.3)
2nd range - transport km/h (MPH) 13.6 (8.5) 10 (6.2)
Steering angle ±° 33 33
Front drum oscillation at the vertical level ±° 10 10
Theoretical roller’s gradeability % 40 40
Side static stability ° 30 30
Vibration
DV201 DV202
Drive hydrostatic
Vibration exciter one-level, circle undirected vibration
Frequency Hz 53/62 53/62
(VPM) (3180/3720) (3180/3720)
Nominal amplitude mm (in) 0.47 (0.0185) 0.47 (0.0185)
Centrifugal force at one drum kN (lb) 20.8/28.5 23.8/32.5
(lb) (4580/6277) (5242/7159)
DV204
Drive hydrostatic
Vibration exciter one-level, circle undirected vibration
Frequency Hz 53/62 53/62
(VPM) (3180/3720) (3180/3720)
Nominal amplitude mm (in) 0.47 (0.0185) 0.45 (0.0177)
Centrifugal force at one drum kN (lb) 25.5/34.9 29.4/40.3
(lb) (5617/7687) (6476/8877)
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Engine
DV201 / DV202
Manufacturer DEUTZ AG
Type F2L 1011F, air-cooled, in-line diesel
Number of cylinders 2
Bore mm (in) 91 (3.58)
Stroke mm (in) 105 (4.13)
Displacement cm3 (cu in) 1366 (83.3)
Engine output due to ISO 3046/1, DIN 6271 kW (HP) 20 (26.8)
Rated speed min-1 (RPM) 2400/2800
Max. torque Nm (ft lb) 80 (59)
Specific fuel consumption under nominal output l/h (gal US/h) 3 (0.8)
Fuel filter DEUTZ 0118 0815 EZ 8941-23
Oil filter DEUTZ 0117 4482
Air filter DONALDSON G 06-5498
Air filter element DONALDSON P82-2768
Starter BOSCH 12 V/2.3 kW
Engine cooling system Cylinders cooled by engine lubrication oil, built
in oil cooler. Cylinder heads cooled by air.
DV204
Manufacturer DEUTZ AG
Type F3L 1011F, air-cooled, in-line diesel
Number of cylinders 3
Bore mm (in) 91 (3.58)
Stroke mm (in) 105 (4.13)
Displacement cm3 (cu in) 2049 (125)
Engine output due to ISO 3046/1, DIN 6271 kW (HP) 27.5 (36.9)
Rated speed min-1 (RPM) 2400/2800
Max. torque Nm (ft lb) 113 (83.4)
Specific fuel consumption under nominal output l/h (gal US/h) 3.5 (0.9)
Fuel filter DEUTZ 0118 0815 EZ 8941-23
Oil filter DEUTZ 0117 4482
Air filter DONALDSON G 06-5498
Air filter element DONALDSON P82-2768
Starter BOSCH 12 V/2.3 kW
Engine cooling system Cylinders cooled by engine lubrication oil, built
in oil cooler. Cylinder heads cooled by air.
Engine fulfills requirements of 99/68/EC
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Brakes
DV201 / DV202
Service brake travel hydrostatic set
Parking and emergency brake gear brakes built to the travel hydro engines
controlled by springs with hydraulic brake-
release
Brake-releasing pressure MPa (PSI) 1.7 (247)
DV204
Service brake travel hydrostatic set
Parking and emergency brake lamellas brakes built to the travel hydro engines
controlled by springs with hydraulic brake-
release
Brake-releasing pressure MPa (PSI) 1.7 (247)
Steering
Hydraulic power steering one hydraulic cylinder

Gear hydro pumps of steering Second part of tandem pump
BOSCH HY/ZFFS 11/5.5 R
Power steering unit REXROTH LAGC 100
Safety pressure MPa (PSI) 19 (2755)
Hydraulic cylinder PHM 63/32/160
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Hydrostatic travel drive
DV201 / DV202
Variable displacement pump of travel
with mechanical control HYDROMATIK A10VG28
Speed min (RPM)
-1
2400/2800
Drums drive hydromotors POCLAIN MK04
Range of working speed min-1 (RPM) 0 - 98
Maximal working pressure MPa (psi) 35 (5075)
Maximal torque Nm (lb-ft) 2275 (1680)
DV204
Variable displacement pump of travel
with mechanical control HYDROMATIK A10VG28
Speed min (RPM)
-1
2400/2800
Drums drive hydromotors REXROTH MCR05S
Range of working speed min-1 (RPM) 0 - 72
Maximal working pressure MPa (psi) 35 (5075)
Maximal torque Nm (lb-ft) 3146 (2320)
Hydrostatic vibration drive
Gear hydro pump of the vibration First part of tandem pump BOSCH HY/ZFFS
11/5.5 R
Speed min-1 (RPM) 2400/2800
Safety pressure MPa (psi) 24 (3480)
Hydromotors of the vibration BOSCH HY/MZFS 8 cm3
Rated speed min-1 (RPM) 3720
Cooling hydraulic oil
Oil cooler NISSENS 151199N1

Filter element of hydraulic oil ARGO V3.0520-06
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Hydraulic tank
Suction basket ARGO AS080-01

Filling cap ARGO LE.0817-01
Fills
DV201 / DV202 DV204

Enginel (gal US) 6.5 (1.7) 6.5 (1.7)
Fuel l (gal US) 67 (17.7) 72 (19)
Hydraulic system l (gal US) 38 (10.0) 38 (10.0)
Vibration drum l (gal US) 2x1.8 (2x0.48) 2x1.8 (2x0.48)
Front sprinkling tank l (gal US) 53 (14) 67 (17.7)
Rear sprinkling tank l (gal US) 150 (39.6) 160 (42.3)
Sprinkling
Water pump SHURFLO 8000-043-235

Water filter JABSCO 36400-0000
Electrical installation
Electric set voltage V 12

Accumulator capacity Ah 72
Grounded - pole
Safety device
Emergency brake Turning on optically signalized

Battery disconnector Disconnecting the el. installation
Warning beacon Safety optical signalization (optional equipment)
Protective frame ROPS (tipping optional)

The construction of protective frame ROPS meets the international standards SAE J 1040, AS 2294, ISO 3471
DV201 / DV202 DV204

for roller's weight max. kg (lb) 2900 (6390) 3800 (8370)
Protective frame weight kg (lb) 65 (143) 70 (154)
to the roller's frame is fasten M20x55 (8G) - 6 pcs. M20x55 (8G) - 6 pcs.
Tightening moment Nm (lb-ft) 314 (232) 314 (232)
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Hygienic parameters
Noise:
The acoustic pressure level influencing the driver when driving under vibrations:
LpA = 88 dB(A) (measured due to the EN 11 204 on the sand base)
The acoustic pressure level influencing the driver when driving without vibrations:
LpA = 87 dB(A) (measured due to the EN 11 204 on the sand base)
Guaranteed sound power level:

LWA = 108 dB(A) (measured due to the Directive 2000/14/EC, EN ISO 3744 on the elas-
tic material, stopped rollers with vibration)
Vibrations:
Vibrations acceleration nominal effective value:
- transferred to the body aw < 0.5 ms-2 (vector sum)
(measured due to the EN 1032 when driving under the vibrations on the sand base)
- transferred to the hands aw < 2.5 ms-2 (vector sum)

(measured due to the ISO 5349 when driving under the
vibrations on the sand base)
Options
Warning beacon
Back-up alarm
Direction lights, brake lights, tail lights
Rear view mirror
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3. INDIVIDUAL ROLLER GROUPS
THE FRONT AND REAR DRUM
The drum is welded from steel plates, the surface is machined. Roller bearings with the vibra-
tor shaft and two eccentrics are located in the lids of the drums. The shaft is driven through a
flex coupling by the vibration hydraulic motor.
The bearings are lubricated by oil splash.
The drum is attached and turns in the bearings of the right lid and of the hydraulic motor. The
drum is spring-mounted on the frame of the roller on both sides by rubberized metal pieces.
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1A DRUM
19
1B DRUM
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1-2 ECCENTRIC
21
22
23
24
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THE FRONT FRAME
The front frame is welded. The fuel tank is part of the frame. The front of the frame contains
the plastic water tank, hydraulic oil tank, and the battery with the switch. The middle section
houses the engine, hydraulic aggregates, and components.
The entire front frame is covered by a folding plastic hood.
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50 FRONT FRAME
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THE REAR FRAME
The frame is welded. A platform and a plastic water tank are mounted to the frame flexibly.
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60 REAR FRAME
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THE ARTICULATION JOINT CONNECTION
The articulation joint connects the front and rear frame of the roller. It has a vertical and a hori-
zontal pin, both located in bearings that allow for the turning of the frames in horizontal and
vertical planes.
When loading the rollers by a crane, it is possible to fix the joint against movement in either
plane.
From the back, a bracket for mounting the hydraulic steering cylinder is attached to the joint .
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65 Joint
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33
FRONT AND REAR BRACKET
The drums are attached flexibly to the front and rear frame by bracket. The hydraulic travel motor is mounted on the left
bracket; the damper plate is attached flexibly by rubber mounting metal pieces to the right bracket.
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70 BRACKETS
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SCRAPERS OF THE DRUMS
The scrapers clean the surface of the drums. They are adjustable in their holders and have
replaceable plastic wiper blades.
Plastic pipes for sprinkling the drums are installed above the scrapers, with jet-heads that can
be disassembled and cleaned.
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55 SCRAPER
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SPRINKLING
The sprinklers wet the drums when working

on asphalt roads. The roller has two inter-
connected water tanks.
One tank is mounted on the front frame, the
other on the rear frame. The level of water
may be checked through the front transpar-
ent tank, since they are joined vessels.
The sprinkling system consists of a filter,
pump, reverse valve, drain valve, filter
closing valve, valve regulating the amount
of water to the jets, and sprinkling pipes
with jets mounted on the front and rear
frame.
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94 SPRINKLING
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Engine DEUTZ
The rollers use Deutz F2L 1011F engines

on rollers DV201 and DV202, and Deutz
F3L 1011F engine for the DV204 roller.
These are air-cooled in-line Diesel engines.
The cylinders are oil cooled. Oil is cooled in
turn in the oil radiator. Cylinder heads are
air-cooled.
The engine is flexibly mounted in the front
frame of the roller by rubberized metal
pieces.
A flex coupling is mounted on the flywheel,
through which, the travel pump, REXROTH
HYDRAULIC is driven.
Two gear pumps, BOSCH-REXROTH, are
mounted on the side of the engine in tan-
dem. The first pump provides oil under
pressure for the vibration system, the other
for steering.
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103 ENGINE DEUTZ
39
40
43
COOLING OF THE HYDRAULIC OIL
The oil cooler, NISSENS, is inserted in the return path of the hydraulic system to maintain the
working temperature level of the hydraulic oil.
The cooling block with a one-way valve is inserted before the radiator. The cooler is by-passed
when the oil temperature is low.
44
123 COOLING
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PLATFORM
The platform sits on the rear frame on a damping system that separates the driver’s seat from
vibrations produced by the drums.
The platform supports the driver’s seat that can be moved forward, backwards, and sideways
on the DV204. An Operator’s Manual storage box is in the back of the seat.
The water tank is located below the seat.
The dashboard houses the steering wheel, the controllers, and the instrument panel with con-
trol instruments.
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150 PLATFORM
47
185 CONTROL
48
HYDRAULICS
Hydraulic system consist of three basic circuits:

- Hydraulic of travel
- Hydraulic of vibration
- Hydraulic of steering
The Hydraulic pump drive consist of two geared hydraulic pumps in tandem, attached to the
engine, and one travel regulating hydraulic pump with a tilting plate and mechanical control.
The first section of the tandem pump drives vibration, the other controls steering.
The steering loop includes power steering unit, REXROTH LAGC 100, and a linear hydraulic
cylinder.
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Legend
1 Pump of travel Bosch Rexroth
2 Pump of vibration and steering Bosch Rexroth
4 Hydromotor of the travel Poclain
5 Hydromotor of vibration Bosch Rexroth
7 Hydromotor
10 Power steering unit Bosch Rexroth
12 Filling socket Hytos
13 Suction filter Hytos
14 Main Filter Hytos
15 Control Block of vibration Hytos
17 Oil cooler Nissens
18 Cube cooler Hytos
19 Switch of temperature VDO
20 Switch 17 bar (250 psi) Hytos
21 Ball valve
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51
300 HYDRAULIC FRONT
52
310 HYDRAULIC REAR
53
HYDRAULIC OF DRIVE
The drive pump is driven by the engine through a mechanical flex coupling, CENTAFLEX. The
closed circuit includes two hydraulic motors with a negative, spring applied brake.
The drive pump circuit contains 2 safety valves adjusted for max. safety pressure of 330 bar
(4785 psi), a supplementary pressure valve adjusted to 22 bar (320 psi), flush-valve, hydraulic
control of the swash plate, and the brake solenoid.
HYDRAULIC OF DRIVE
NON-ACTIVATED TRAVEL
If travel is not activated, the entire travel loop is filled with control pressure from the steering
pump over the pressure filter.
In the travel pump circuit, oil flows first to the safety valve, adjusted to 22 bar (320 psi). De-
pending on the engine speed, the pressure is measured between 22 and 24 bar (320 and 350
psi).
After the safety valve, oil flows to the high-pressure valves, the brake solenoid, and through
the main loop to the flush valve, travel hydraulic motors, and the short circuit ball valve. Excess
lubrication oil drains over the safety valve into the return circuit.
54
55
HYDRAULIC OF DRIVE
ACTIVATED TRAVEL
The pump distributor is mechanically activated from the travel lever. If all conditions for travel
have been satisfied, the brake solenoid is activated automatically (by moving the travel lever to
travel position), which connects control pressure to the distributor of travel pump control.
In line with the direction of the move of the distributor, the supplementary pressure (which at
time is the control pressure) reaches the control of the tilting plate of the pump, and tilts the
plate.
The pump starts working and delivers pressure oil into one of the pressure branches to flow to
the safety high-pressure valve (330 bar) (4785 psi), the flush valve, both of the hydraulic mo-
tors for travel, and the ball valve. The pressure oil starts turning the hydraulic motors of travel
When the brake solenoid is activated the supplementary pressure is distributed also to the
brakes of the travel hydraulic motors, where the pressure oil overcomes the springs and the
brakes of the hydraulic motors are off.
Furthermore, a pressure switch is inserted in the brake loop, adjusted to 17 bar, that controls
the brake indicator. The pressure disconnects the switch and turns the indicator and brake
lights off.
The gate of the flush valve is tilted from the main branch by the operating pressure, and con-
nects the flow from the loop with the complementary pressure to the by-pass valve, which is
adjusted to a flow of 6 liters per minute, and from there the superfluous oil flows back to the
tank.
A temperature sensor is connected onto the return branch that closes at 85° C (185° F) the
control indicator of oil overheating and an audible warning sound. When the travel lever is
placed into reverse, the same process takes place also in the other working branch.
Should pressure in the working branch exceed the safety pressure of 330 bar (4785 psi), the
safety high-pressure valve lets oil flow into the supplementary branch, and from there through
the return branch into the tank.
The ball valve connected into the main operating loop interconnects the pressure branches
and is there in case of a machine defect, when it is required to be towed. By opening the valve
the branches are short-circuited between the travel pump and hydraulic motors. With the me-
chanical brakes off, the roller may be towed.
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LINEAR VALVES – DESCRIPTION OF CONSTRUCTION AND FUNCTION
Linear valves VPP2-04 are used as safety or by-pass valves used in hydraulic loops that work
with wide ranges of through-flows and pressures.
The valve consists of housing (1), cone with damping piston (2), and spring (3). The pressure
is adjusted manually by the screw with internal hex (4). The spring presses the cone into its
seat (5) and keeps the valve closed. Should the pressure in channel P increase above the
value set by the spring, the cone lifts up and bypasses the fluid from channel P to channel T.
59
HYDRAULIC OF VIBRATION
The vibration is provided by the gear pump (the first section of the tandem mounted on the
side of engine). The inlet hose comes directly from the hydraulic tank through the internal filter
(grade 100 micron). The pressure oil flows from the pump to the series connection to the front
and rear vibration hydraulic motors. The solenoid distributor in the circuit provides bypass of oil
while the vibration is switched off and provides distribution of the pressure oil either to the front
hydraulic motor or to both simultaneously. The safety valve in the circuit limits working pres-
sure to 240 bar (3480 psi).
HYDRAULIC OF VIBRATION - NOT ACTIVATED VIBRATION
Not activated vibration

Oil is forced from the hydraulic tank by air pressure to the second section of the double-pump,
which is attached to the engine, through the internal filter of 100 microns filtering grade.
Oil is being pushed up through the line to the vibration hydraulic motor and simultaneously
through the pressure loop to the vibration block.
The vibration block consists of a solenoid distributor and a safety valve. The safety valve is
adjusted to the top pressure of 240 bar (3480 psi).
When the solenoid is not activated, the pressure oil passes freely through the drain and back
to the tank. No pressure is present in the loop and the hydraulic motor does not turn.
60
61
HYDRAULIC OF VIBRATION - VIBRATION OF THE FRONT DRUM
Vibration of the front drum
The pressure oil flows to the vibration hydraulic motor and the vibration block in a similar fash-
ion as above (non-activated vibration). Now, when the solenoid is activated, the piston in the
distributor moves and the pressure branch is connected up to its end in the vibration block
(point A1). Pressure increases and the hydraulic motor starts turning.
Oil drains from the hydraulic motor over a one-way valve into the distributor and from there
through the drainpipe to the tank.
Lubrication drain oil flows from the hydraulic motor body through a separate branch directly to
the tank.
Should the hydraulic motor be blocked and the pressure went over 240 bar (3480 psi), the
safety valve opens and the pressure oil goes into the draining branch.
62
63
HYDRAULIC OF VIBRATION - VIBRATION OF BOTH DRUMS
Vibration of both drums

Inlet and pressure delivery are similar to those of preceding cases, however the other side of
the distributor is activated. This way the pressure branch is connected through the distributor
to the one-way valve to its rear part. The way further up is closed.
Pressure oil passing into the hydraulic motor of the front drum which turns in the front drum,
the oil flow continues to the hydraulic motor of the rear drum and turns it as well.
Oil cannot go through the one-way valve (0.5 bar) [7.25 psi] since it is being held by the dis-
tributor pressure from its back side.
If the pressure exceeds the safety pressure of 240 bar (3480 psi), the safety valve opens the
way to the drain. Lubrication drain oil from both motors goes directly to the tank.
64
65
HYDRAULIC OF STEERING
The power for steering is provided by the gear pump, (the second section of the tandem). The
inlet pipe comes directly from the hydraulic tank through the interior filter (grade 100 micron) to
the gear pump. From here the pressure oil flows to the steering unit. Its safety valve limits
working pressure to 190 bar (2755 psi). Steering of the roller is provided by the steering cylin-
der fixed on the steering joint. Return oil from the steering unit flows through a pressure filter
(grade 10 micron) to the drive pump. From here it is distributed as the charge pressure to the
drive system. At the same time it serves as the control pressure for releasing the brakes on the
drive hydraulic motors.
The return branches from the drive and vibration circuit are led to the one-way valve. From
here the oil (cold oil) flows directly to the hydraulic tank or through the hydraulic oil radiator
(warm oil) to the hydraulic tank.
Leaks from the vibration and drive hydraulic motors flows directly to the hydraulic tank.
When measuring pressure in the steering circuit, it is necessary to consider that the ad-
justed pressure in the steering circuit will be increased by the supplementary pressure.
Therefore top pressure of about 215 bar (3120 psi) will be reached. Maximum measuring
pressure also depends on the temperature of the oil and the speed of the engine.
Maximum supplementary pressure measuring on the pump can increased about 2 bar (30
psi). It is dependent upon the temperature of the oil and the speed of the engine.
HYDRAULIC OF STEERING -
NON-ACTIVATED STEERING
Oil is forced from the tank by air pressure to the first section of the gear pump and delivered
into the power steering, where it moves over the one-way valve to the safety valve adjusted to
190 bar (2755 psi), and continues to the distributing section. If steering is not activated, it
passes through the distribution, fills the entire steering loop including the steering cylinder, and
continues to the hydraulic filter of 10 microns grade, and the hydraulic pump for travel, as the
charge pressure.
The power steering circuit also contains two shock valves adjusted to 240 bar (3480 psi) pres-
sure, which protect the steering cylinder from being damaged from an external force. The
pressure filter of hydraulic oil is protected by a by-pass valve (7 bar) [100 psi] and an indicator
of filter contamination.
66
67
HYDRAULIC OF STEERING - STEERING ACTIVATION
Turning the steering wheel activates also the steering, and the pressure oil is distributed over
the distributor of power steering into one or the other pressure branches, which leads into the
steering cylinder.
Conductors that are not pressurized for operation have only supplementary pressure (22 – 24
bar) [320 – 350 psi], and the oil continues to the hydraulic filter, into the hydraulic pump for
travel.
The distribution of power steering works on the proportional basis, e.g., the faster you turn the
steering wheel, the faster you steer.
In the limit steering position, when the steering cylinder reaches the minimum or the maximum
position, the pressure increases to the value preset on the safety valve (190 bar) [2755 psi].
Superfluous oil bypasses into the supplementary loop. The test point is located past the steer-
ing pump. During measurement one has to consider that the preset pressure will increase by
the safety pressure in the control loop. The measured pressure will be about 215 bar (3120
psi), (190 bar plus 24 bar, 2755 psi plus 350 psi).
68
69
FLUSHING AND DRAIN
The travel pump is flushed by oil that flows through the safety valve of the control pressure into
the pump case and from there through the radiator block to the tank.
The radiator block includes the one-way valve with flow either directly to he hydraulic tank
(when the oil is cold) or through the radiator to the tank. The temperature gradient is calculated
so that at 60° C (140° F) oil temperature all oil flows through the radiator.
Vibration and travel hydraulic motors leak directly into the tank, since the pressures may not
increase in the hydraulic motors casing (max. 1 bar) [max. 15 psi]. That is why oil may not flow
through the one-way valve of the block (1.5 bar) [22 psi], or the radiator.
70
71
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72
350 A HYDRAULIC OF DRIVING SET
73
350 B HYDRAULIC OF DRIVING SET
74
350 C HYDRAULIC OF DRIVING SET
75
HYDRAULIC OIL TANK
The hydraulic tank is located under the hood in the front section of the front frame. The filling
throat is located on the lid of the tank.
Two level marks are on its side.
Hydraulic oil level may not drop below the lower mark of the indicator. In the tank there is suc-
tion screen with a cleaning capacity of 100 microns only.
76
370 HYDRAULIC TANK
77
570 FRAME ROPS
78
575 FRAME ROPS
79
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80
ELECTRICAL INSTALLATION
403 ELECTRICAL INSTALLATION
81
SCHEME OF THE ELECTRICAL INSTALLATION
Legend
R1 Glow plug
A1 Interrupter of direction lights (optional) R2 Potentiometer of sprinkling drums
A2 Brake timer R3 Resistors
E1,2 Front outline lights (optional) S1 Key switch
E3,4 Tail lights (optional) S2 Headlights switch
E5 Car make lighting (optional) S3 Switch of rear headlights
E6,7 Front headlights S4 Switch of emergency brake (optional)
E8,9 Rear headlights S5 Push button of horn
E10 Safety beacon (optional) S6 Switch of hazard warning lights
E11,14 Front direction lights (optional) S7 Change over switch of direction lights (optional)
E12,13 Rear direction lights (optional) S8 Push button of emergency brake
E15,16 Brake lights (optional) S9 Position switch of back-up alarm
F1-9 Fuses S10 Parking brake push button
G1 Battery S11 Position switch of seat
G2 Alternator S12 Inductive switch of neutral (in travel control)
H1 Horn S13 Over pressure switch of pump sprinkling drums
H2 Indicator of direction lights (optional) S14 Switch of vibration (at grip of travel control)
H3 Back-up alarm (optional) S15 Switch of vibration – manual l/s automatic
H4 Indicator of sprinkling drum S16 Inductive switch of vibration
H5 Indicator of vibration pre selection S17 Switch vibration – front drum/both drums
H6 Indicator of overheating engine oil S18 Overheating of engine oil switch
H7 Acoustic signal of trouble S19 Overheating of hydraulic fluid switch
H8 Indicator of overheating hydraulic oil S20 Pressure switch of brake
H9 Indicator of brake S21 Pressure switch of engine lubrication
H10 Indicator of charging V1,2 Blocking diodes
H11 Indicator of engine lubrication X1 Socket of safety beacon or hand lamp
K1-3 Auxiliary relay X2-19 Connectors
M1 Starter Y1 Electromagnetic valve of engine STOP
M2 Pump of sprinkling Y2 Electromagnetic valve of brake
P1 Hour counter Y3 Electromagnetic valve of front drum vibration
Q1 Battery disconnector Y4 Electromagnetic valve of both drums vibration
82
83
84
85
Figure no. 1
1. Battery breaker ON
After breaker (Q1) was switched on we get the voltage to the engine starter (M1) and alter-
nator (G2).
Over fuse (F9) voltage appears on key switch (S1) and over fuses (F1 – F4) to headlights
switch (S2), rear lights switch (S3), beacon switch (S4), horn push-button (S5), and emer-
gency lights switch (S6).
Marked in blue.
2. Key switch in position 1

With key switch in position 1 voltage appears on fuses (F5 – F8)
From fuse (F5) to emergency brake switch (S8), the engine stop solenoid (Y1), position
switch of backup horn (S9), brake switch (S10) and universal brake timer (A2), seat position
switch (S11), neutral proximity switch (S12), vibration switch (S14), relay (K2), relay (K3),
and brake lights.
From fuse (F6) to overpressure switch of the sprinkling pump (S13), motor of sprinkling
pump (M2), and universal timer of the brake (A2),
From fuse (F7) to control lights (H6, H8, H9, H10, and H11), alternator (G2), safety switches
(S18, and S19), and pressure switches (S20 and S21).
Marked in red.

Voltage appears on glow-plug (R1) - heating is turned on.
Marked in violet.

Voltage appears on relay (K1) and then on starter (M1) – the engine is being started, si-
multaneously heating of the glow plug (R1).
Marked in green.
86
87
Figure no. 2
1. After the engine has started

Same wiring as in Fig. 1 point 2), except that after starting, polarity on alternator changes,
chassis is disconnected, and from D+ we get positive voltage. Thus the charging indicator is
turned off, the oil pressure in the engine loop disconnects the pressure switch (S21), and
thus, indicator H11 is also turned off. The increased pressure in the hydraulic system dis-
connects the pressure switch (S20) and turns indicator (H9) off – brakes of the travel hy-
draulic motors are off because of hydraulic oil pressure.
Marked red.
2. The roller starts moving - backwards

For moving the roller, the driver must sit in his seat and activate the seat switch (S11); volt-
age appears in brakes timer (A2).
For the move of the travel control lever out of neutral, the proximity switch (S12) in the travel
lever is on, voltage appears on the timer switch (A2), then on relays (K1) and (K3). Relay
(K3) disconnects the connection to the brake lights (E15 and E16), (K1) disconnects the
starter.
Together with the movement of the reverse control lever, the position switch (S9) of the
back-up horn (H3) is turned on.
Marked in blue.
88
89
Figure no. 3
1. Key switch in position 1, engine running

Key switch position 1, distribution same as in preceding case, except that by the move of
the travel control lever to neutral the proximity neutral switch is disconnected and thus, volt-
age to relay (K3) that connects brake lights (E15, E16) is off.
Marked red.
2. Parking brake switch activated

By activating parking brake switch (S10) voltage to (A2) – contact 6 is off. The control indi-
cator switch (S10) is connected to chassis and goes on.
A2 activates the connection of brake magnet (Y2) to chassis (A2 contact 10 and 11). The
roller brakes.
Marked in blue.
3. Activation of headlights switch

By activating the headlight switch the front lights (E1, E2, E6, and E7), rear lights (E3, E4),
and license plate light (E5) are on. At the same time the control indicator goes on in switch
(S2).
Marked in violet.
90
91
Figure no. 4
1. The roller is moving, key switch position 1

Marked red.
2. Manual switching on vibration

Select the position for manual operation of vibration by switch (S15). The travel control lever
doesn’t switch off when stopped.
By activating the push button switch (S14) in the travel control lever the control indicator
(H5) goes on – voltage is applied through (S15) to (S17), where in line with the preset se-
lection voltage is applied to the vibration solenoid of the front drum (Y3) or (Y4) for both
drums vibration.
Marked in green.
3. Automatic vibration on
Switch (S15) in the automatic position - contacts 3-4 are closed.
Activating (S14) turns on indicator (H5) and voltage appears through (S15) on the proximity
switch of vibration (in the travel control lever); from there current moves to relay (K2), the
relay closes and allows current to (S17), and from there to solenoid (Y3) or (Y4) as preset.
Marked in violet.
4. Sprinkling activation
Sprinkling is activated by the cycling switch (R2). After switching to one of the cycling posi-
tions unit (A2) connects contacts 9 with 10 and 11 (chassis), indicator (H4) goes on, and the
sprinkling pump starts working. After 1.5 sec. Connection to chassis (A2) goes off and
sprinkling is terminated
The time of pump stoppage may be regulated continually by the cycling switch (R2) be-
tween 1.5 sec. to 20 sec.
By moving the travel control lever to position D, sprinkling may be initiated even without the
roller moving.
Marked in blue.
92
93
Figure no. 5
1. Engine oil overheating
Engine oil overheating is powered through fuse (F7). By activating switch (S18) when the
engine oil overheats, connection is to the chassis. Control indicator on the dashboard (H6)
goes on, and at the same time the horn (H7) sounds.
Marked in violet.
2. Overheating of hydraulic oil
When the hydraulic oil overheats the temperature switch (S19) is on – the circuit is con-
nected to the chassis. The control indicator (H8) on the dashboard goes on, and at the
same time the warning horn sounds (H7).
Marked in green.
94
95
ACTION A2 – UNIVERSAL BRAKE TIMER
Starting functions are preset, S11 is open, starting possible, travel impossible (by control
lever).
S11 closed, S10 closed, starting possible, travel impossible (by control lever).
During travel S10 closed, brake is not activated until the control lever is moved to neutral.
Thereafter sudden stop is experienced (do not use too often, overwhelms the brake.)
Lever in travel position, the roller is stopped over S10. The roller will not moved even with
S10 open; the travel control lever must be in neutral – release brake – start moving.
Travel – the driver stands up. The roller continues moving until the travel control lever is
moved to neutral. The roller brakes after one second.
During normal operation the roller doesn’t brake when the lever is moved to neutral.
When the lever is moved to position D, sprinkling may be cycled while the roller is standing
still.
96
TRAVEL CONTROL
97
412 INDICATOR LIGHT
98
421 HEADLIGHTS
99
100
4. CONTROL OF THE ROLLER
INSTRUMENTS AND CONTROLS
Symbol table - legend:

12 - Engine lubrication indicator
1- Travel controller 13 - Indicator engine overheating
2- Working speed pre-set 14 - Indicator hydraulic fluid overheating
3- Key switch 15 - Switch + head lights indicator (options)
4- Stop button - emergency brake 16 - Switch + back lights indicator (options)
5- Engine hours counter 17 - Vibration switch of front drum and vibration of both
6- Switch + directions indicator (options) drums
7- Switch + indicator of the beacon (options) 18 - Indicator of vibration
8- Switch + indicator of the warning lights (options) 19 - Sprinkling cycling device
9- Horn switch 20 - Sprinkling run indicator
10 - Recharge indicator 21 - Battery disconnector
11 - Switch + indicator parking brake + indicator emer- 22 -Vibration control (hand - automatic)
gency brake
101
Instruments and controls - legend:
Legend:
1 – steering wheel
2 – travel controllers
3 – vibration switch (on/off)
4 – accelerator controller
5 – key switch
6 – STOP emergency brake button
7 – horn button
8 – parking brake switch
9 – turn indicator control (options)
10 – switch for selection of vibration drums
11 – vibration switch (manual - automatic)
12 – switch + pilot lamp for front lights (options)
13 - switch + pilot lamp for rear lights (options)
14 – storage battery charge pilot lamp
15 – engine overheating pilot lamp
16 – hydraulic fluid overheat warning lamp
17 – brake pilot lamp
18 – engine lubrication pilot lamp
19 – sprinkling function pilot lamp
20 – vibrations ON pilot lamp
21 – indicator lamp for turn indicator (options)
22 – switch + pilot lamp of warning lights (options)
23 – switch + pilot lamp of the flashing beacon (options)
24 – wiper-speed switch for sprinkling
25 – fuse box
26 – seat
28 – socket for the inspection lamp and flashing beacon
29 – 50 A heating fuse
30 – hourmeter
31 – master switch
102
103
Steering Wheel (1) It is used for setting diesel engine speed in

The steering wheel serves to steer the the range of idling rate (approximately 900
roller. Turning the wheel to right causes RPM and maximum rate. The accelerator
articulation of the roller to right and oppo- controller is coupled using a cable with the
site. speed lever of the fuel injection pump. If
vibration is used, the controller is arrested
in two positions (cutouts in the cam plate)
Travel controller (2) according to the required vibration rate in
Direction and speed are controlled by this Hz (VPM = vibration per minute).
device. If it is in its neutral position (”0”), the
brake is on and the roller can be started.
Key switch (5)
When the roller has been started you must
The switch has five positions, i. e., ”P”, ”0”,
draw the controller towards yourself and
”I”, ”II”, and ”III”. ”P” position is not func-
change the position from ”0 to D” – travel-
tional.
ling position.
”0” position = ENGINE STOP
Controller position F1 = the roller goes for-
ward at working speed. ”I” position = all appliances are con-
Controller position B1 = the roller goes nected
backward at working speed. ”II” position = engine heating is ON – in
Controller position F2 = the roller goes for- cold weather it is necessary to hold the
ward at travelling speed. ignition key in this position for about one
minute
Controller position B2 = the roller goes
backward at travelling speed. ”III” position = ENGINE START.
The vibration switch (ON/OFF) (3) is in Emergency brake button (6)

the controller handle and by means of it you In the event of any defect – the roller can-
can switch on or off vibrations during com- not be stopped by switching positions of the
paction. travelling controller (2) – it is necessary to
use the emergency brake button. After
pushing the button the brake is applied and
the engine switches off. Pilot lamp (18) is
Pay attention to the following in-
ON. The brake is released by turning the
formation:
button in the direction of the arrow.
Travelling speed corresponds to
the amount of controller deflection
Only use the STOP button
in the speed mode chosen.
as an emergency brake!
The controller is fixed at the set po-
If the switch of the emer-
sition.
gency brake is in the
The travel controller serves also as pushed down position,
a service brake of the roller. the engine cannot be
started.
Accelerator controller (4)
104
Warning horn push button (7)

The horn sounds when the push button is
depressed.
Parking brake switch (8)

It is used for brake activation – the function
is indicated with (17) pilot lamp.
After shifting the travel controller to the
neutral position (the roller is braked after 2
sec.) the switch is on and the brakes are
applied immediately.
It should be used when the brakes

must be applied immediately (e.g.
when working on a slope). You
must release the brake using the
switch before starting.
Never apply the parking

brake when the roller is
running!
Change-over switch of direction lights

(9)
- left direction lights turned on
- turned off
- right direction lights turned on
105
NOTE - on all control switches below,

the first statement indicates function in
the forward or away position.
Switch and indicator of front headlights (12)

(options)
- Off
- On
Headlights are switched on as signaled by
the light in the switch.
Selector of vibrating drums (10) Switch and indicator of rear lights (13)
- the roller vibrates with the front drum (options)
only
- Off
- the roller vibrates with both drums
- On
Rear lights are switched on as signaled by
the light in the switch.
Vibration switch (11)
”MAN” position = manual vibration switching

(ON/OFF) has been selected in
the range of operating and trav-
elling speed – the roller can
vibrate on the spot.
”AUT”position = automatic vibration switch-
ing (ON/OFF) has been se-
lected in the range of operating
speed – when the roller stops
the vibration goes OFF auto-
matically.
Never vibrate on the spot

with vibration ON for
longer than 30 seconds.
If you want to activate vi-
bration, switch 3 on the
travelling controller must
be ON.
106
Engine lubrication pilot lamp (18)

It indicates sufficient oil pressure in the lu-
brication system of the engine. After
switching the key to ”1” position the lamp
must go ON and after starting it goes OFF.
If the lamp goes ON when the en-

gine is running, insufficient lubrica-
tion of the engine is indicated.
When the lamp goes ON

while the engine is run-
Battery charging indicator (14) ning, stop the engine im-
The indicator signals correct battery- mediately!
charging condition. When the ignition key
(5) is turned to "1" the indicator lights up
and goes off after starting. If not, look for
defect. Sprinkling operation indicator (19)
The indicator signals drum sprinkling. The
sprinkling pump is on.
Engine overheating warning indicator
(15)
When the engine temperature reaches the Vibration indicator (20)
highest allowable level, the engine over- The indicator signals vibration on. Vibration
heating pilot lamp goes ON, an audible is turned on or off with the switch in the
warning is given. travel controller.
Hydraulic fluid heater warning indicator Indicator of direction lights (21) (op-
(16) tions)
When the fluid temperature reaches the
highest allowable level the fluid overheating This indicator starts blinking when the di-
warm lamp goes ON, an audible warning is rection lights are turned on.
given.
Check direction lights.

Brake indicator (17)
The lit up indicator signals that the brake is
on.
107
Sprinkler cycling (24)

The cycles of sprinkling are adjusted con-
tinually by turning from the 0 to the right.
Automatic function
Sprinkling is turned off automatically when
the travel control is moved to position ”0”
The roller sprinkles when standing still,
when the travel control is in position “D”.
Switch + pilot lamp of warning lights (22)

(options)
- off
- warning light on (indicator in the
switch)
Switch & pilot lamp of the flashing bea-

con (23)
(options)
- off
- warning beacon on, signaled by indi-
cator in the switch.
Beacon to place on the frame ROPS to
connect to plug (28).
108
Driver's seat with safety switch (26)

It is adjustable and furnished with an iner-
tia-reel safety belt and seat switch.
Fuse box (25)

The box contains fuses.
F2 - 10 A - rear lights
F1 - 10 A - front headlights The operator must use
F2 - 10 A - rear lights the safety belt (1) when
F3 - 10 A - plug of service lamp (warn- working!
ing beacon)
F4 - 7.5 A (15 A) - horn, direction
lights,
F5 - 10 A - STOP engine, back up
alarm, el. magnet of brake
F6 - 15 A - sprinkling of drum
F7 - 7.5 A - lamp control
F8 - reserve
Replace fuses with same

type fuses only!
109
Seat switch function: Sliding seat lengthwise - by lifting lever (1)

the seat may be moved forwards and back.
The driver must sit on his seat be-
fore the roller is started.
The driver may drive (reverse) the roller

even if he gets up during travelling.
Seat adjustment elements

Backrest angle adjustment - by pushing
lever (1) the backrest folds as needed.
Sliding seat sideways - by pressing lever (1)

the seat may be moved left or right.
Seat firmness adjustment - by pressing

lever (1) the firmness of the backrest is ad-
justed to the driver's weight between 50 -
130 kg (110 - 266 lb) in steps of 10 kg (22
lb).
110
Box (27)
The operation manual and service docu-
mentation are in the locker located on the
Engine heating fuse (29)
rear side of the seat.
This 50 A fuse secures the whole electrical
circuit.
Operating hours counter (30)

The counter shows number of engine oper-
ating hours. The counter starts counting
hours after the charging indicator went off.
The recorded time is not dependent of the
engine's speed.
Battery breaker (31)

The service lamp plug and warning bea- The breaker connects or disconnects elec-
con (28) trical wiring of the roller.
The plug (12V) connects the service lamp 0 disconnect
and the warning beacon. I connect
111
The starting procedure:

CONTROLLING BASIC FUNCTIONS
OF THE ROLLER Switch on the storage battery master
switch (1).
Controlling basic functions of the roller
Starting the engine
It is necessary to check
the amount of oil in the
engine and hydraulic
tank, the amount of fuel
in the fuel tank, and the
amount of water in the
water tanks every day be-
fore starting the engine.
Make sure that no engine
components are loose,
worn or missing. Shift the travelling controller (2) to ”0”
neutral position (the engine can be
The engine may be
started only in the neutral position).
started from the driver’s
post only.
Before starting the engine

use the horn and make
sure that nobody can be
endangered by starting
the engine.
112
Insert the ignition key into the key switch If the engine does not start even after
(5) and turn it to the ”I” position, the bat- three attempts, look for a defect.
tery charge (14) and engine lubrication After starting the engine reduce the
(18) pilot lamps will go ON as well as the speed gradually and check if the pilot
brake light (17). lamps indicate the correct functioning of
Place the accelerator controller (4) ap- the engine.
proximately in the middle. After starting the engine, let it run without
Switch the key into the suspended ”II” any load at an increased rate – 1300-
position and hold it there for about one 1500 RPM
minute (preheating) (this step can be Do not use full load until the engine
omitted if the engine is warm or in the warms up (for about 3 to 5 minutes).
case of a high ambient temperature).
Rapid increase or decrease in RPM is
inadmissible.
The roller must be with

released brakes before
starting – using the
”STOP” button. The travel
controller must be in the
”0” position.
When starting the engine
with the auxiliary power
supply, connect the grips
plus (+) to plus (+) and
minus (-) to minus (-).
Always connect the “mi-
nus” as the last one and
disconnect as the first
one.
Watch out for the starting
Switch the key into the ”III” position and voltage of the auxiliary
the engine will be cranked (hold the key power supply (for 12 V).
in this position until the engine starts). Is prohibited to check if
Do not try to start the engine for a longer the wire is live by spark-
period of time than 15 seconds. If it does ing by the roller ground.
not start, wait about 30 seconds and re-
peat the process.
When starting for the second and subse-
quent times, shift the accelerator con-
troller to maximum fuel supply.
113
Travel forward and reverse
Warn using the horn be- Direction and speed selection

fore running the roller
and wait for a sufficient Switch OFF vibration using ”3” switch,
time, so the possible per- (20) pilot lamp goes OFF.
sonnel can leave the
Set the necessary speed to approxi-
dangerous space (space
mately 1800 RPM.
under the roller) !
Draw the controller (2) towards yourself
Check if the space in the from 0 to ”D” position.
front and in the back of
the roller is free of per- Controller position F1 = the roller goes
sons ! forward at working speed.
backward at working speed.
Controller position F2 = the roller goes
forward at travelling speed.
backward at travelling speed.
The parking brake must be

switched OFF using switch ”8” be-
fore the roller starts moving.
114
Travelling with vibration Position II of the accelerator controller –

frequency of 62 Hz - engine speed 2800
Choose, using the vibrating drums se- RPM.
lector (10), if vibration should be done
using the front drum only or using both
drums simultaneously.
Shift the vibration switch (11) to the
”AUT” or ”MAN” position.
”AUT” position = the roller vibrates in the
operating speed mode. If the roller does
not run, vibration automatically goes
OFF.
”MAN” position = the roller vibrates inde-
pendently of the speed selected even
though the roller stays on the spot.
Never use vibration for
longer than 30 seconds
Put the roller into motion and switch on
when the roller stays on
the vibration using the vibration switch
the spot as the vibrator
(3). The drums will start vibrating, pilot
bearings could be dam-
lamp (20) will light up. Vibration can be
aged. Never start vibra-
interrupted by pressing the vibration
tion on hard (frozen, con-
switch (3) again.
crete) ground.
The accelerator controller must al-

ways be set to position I or II when
vibration is ON.
Choose one position in the accelerator

controller cam plate (4) for the appropri-
ate rate of vibrator frequency.
Position I of the accelerator controller –
frequency of 53 Hz - engine speed 2400
RPM.
115
Stopping the roller and the engine
Turn vibration off.

Shift travel lever to zero.
Switch off all accessories, such as sprin-
kling, lights, etc.
Lower engine speed.
Stop the engine by turning the key to "0".
Let a hot engine run idle for about 1 to 2
minutes at 1000 rpm. The roller applies
brakes automatically thereafter.
Shutting down the roller
Remove key (1) from the key switch.
Place the roller on a flat surface with suf-
ficient load-carrying capacity
If the lubrication indicator lights up Switch off the battery breaker
during travel, stop the engine im-
Clean the roller, the scrapers, etc.
mediately, find the defect and repair
it. Inspect the roller and repair defects
caused by its operation.
Check that the accessories are properly
stored.
In case of emergency,
particularly on a slope, Wedge the drums with blocks.
stop the roller immedi- Make sure that there is no danger of
ately by pressing the landslides, flooding, etc.
parking brake switch after Lock the hood.
the travel lever was Close and lock the lid (2) over the dash-
shifted to neutral. board to protect it against vandals.
After removing the key close the lid Stop the roller on a flat
on the key switch. and firm ground.
Check that the parking
spot is in no danger by
forces of nature (land-
slide, flood, etc.).
116
Stopping the roller in an emergency

The running-in period
In case of defect, stop the roller by
pressing the emergency brake push During the running-in period (60 hours) use
button. The roller and the engine stop. 1st degree vibration only, 53 Hz (VPM). The
Release brakes by turning push button number of revolutions should not exceed 70
(6) in the direction of the arrow. % of the maximum value. The longer the
running-in period under reduced load, the
Before starting the engine, move the
longer the life of engine components, and
travel controller (2) to "0".
lower costs on maintenance and operation
can be expected.
The roller may not be
used, if the emergency Attention!
brake doesn't operate
The engine may not be run in with pro-
properly.
longed runs at low loads, less than half,, or
at low speed. The piston rings will not be
properly adapted with resulting increased
use of oil and smoke emission. After 60
hours, the engine is properly run in and
may be fully loaded.
117
This Page is Blank.
118
In some countries the roller may move

MACHINE TRANSPORT on its own, if the roller is equipped with
directional signals. Please check your lo-
Moving the roller on the site cal ordinance.
The roller moves on its own over the site SAFETY REGULATIONS
outside public roads. Observe safety regu-
lations applicable to specific sites.
The transport roller must be for
transport the roller during the
During times of low visi- loading and unloading locked and
bility the roller must have mechanically secured against non-
its headlights turned on. desirable move using the locks.
When running on the transporting
device and running out are all per-
Moving the roller on public roads sonnel obliged to get out of it ex-
cept the roller driver, to prevent the
The basic modification of the roller is not accidents if the roller falls down.
equipped for moving on its own on public The worker vectoring the roller on
roads, and its travel there is forbidden. the transporting device must stand
The roller may be moved loaded on a still on one place out of the roller
truck of suitable carrying capacity. The and out of the transporting device a
elevation of the platform must be such so be in sight of the driver (in a visual
that the total height including the roller is contact) during the whole period of
not more than 4 meters. The roller must the running on and out.
be properly fastened to the carrier vehi-
The worker vectoring the roller
cle. The binding points are following:
must communicate with the driver
front and rear fastening eyes at the side
using the specified communicating
signs.
When transporting the roller (on the
platform) there can’t be any per-
sonnel nor on the platform, neither
on the roller.
The roller must be on the platform
properly hanged and mechanically
secured against shifting to all direc-
tions and also against turn over.
The tires must be blocked using the
chocks.
Before undergoing the under-
plates of the drum frame.
passes, bridges, tunnels, elevated
traces, check their height.
119
Loading the roller
To load the roller on a vehicle use loading turned, and fixed again with bolt (1). For
ramps or cranes. loading the roller with a crane see illustra-
tion.
For loading by the crane the roller has
hooks installed on its frame.
Prior to lifting the flexible hinge must be
secured against unwanted turning by mov-
ing the securing rod (B) into the holder (2)
on the rear frame of the roller and fixing it
with pin (A) and split pin.
DV201
The locking insert (2) fixed to the hinge by

one bolt (1) is removed,
120
DV202
DV203
DV204
Learn about your national laws and

regulations related to operation of
cranes; these must be kept when
loading and unloading the roller. The
rigging means must also conform to
the respective regulations.
For rigging, use only the designated
hooking circles (pins).
Use only the crane and the rigging
means of sufficient payload.
The rigging can be done only by a li-
censed rigger.
Do not enter under the suspended
items.
121
Towing the roller
In case of a defect, the roller can be towed Releasing brakes of the Rexroth DV204
for a certain, necessary distance. Attach the hydraulic motor of travel:
ropes to the towing eyelets on both sides of Remove two bolts (1) on the face of the
the front or rear chassis. hydraulic motor marked by an arrow.
Two holes with M10 thread in the piston of

the brake become obvious.
Release the brakes on both of the hydraulic

motors on both drums and short circuit the
hydraulic loop of travel to prevent the drums
from skidding.
122
Releasing the brakes of the hydraulic

Screw fully either 2 bolts (3) with washers motor of travel Poclain DV201/DV202:
(4), into the two holes in the piston of the
brake (2), evenly one after the other,
Remove two plugs (1), on the face of the
hydraulic motor.
or two bolts (3) with washers (4).
Push both bolts (2) inside against the

pressure of spring (3) and screw both
evenly and fully in with torque 35 Nm.
123
Short-circuit hydraulic loop of travel Nobody may be on the

roller that is being towed
Move lever 1 to OFF. with a non-functioning
engine.
It is necessary to main-
tain the minimal deviation
from the direct towing
angle. Maximum devia-
tion is possible within
30°.
Smooth and constant
movement must be main-
tained in towing. Do not
exceed towing speed by
more than 2 km/hour (1.2
mph) and do not tow for
more than 300 m (2 tenths
Towing the roller General
of a mile)
Safety Instructions
The towing vehicle
should correspond by its
Before you release the size to the damaged
brakes, block both drums roller. It must have suffi-
against any spontaneous cient towing power,
movement of the roller. weight and braking effect.
When towing the roller, When towing down hill,
check, that the brakes do an additional vehicle
not get warm because of should be attached to the
insufficient releasing. rear end of the roller. This
When the brakes of hy- way it is possible to pre-
dromotors are released, vent an inadvertent
and the hydraulic circuit movement of the dam-
short-circuited, no brak- aged roller.
ing system is available!
These are general re-
All the service, emer-
quirements for a safe
gency and parking brakes
towing of the roller under
are out of operation!
normal conditions. Any
Do not start the engine possibly different situa-
during towing. tion that could occur
For towing, use a tow bar during towing must be
of sufficient capacity, 1.5 anticipated.
times stronger than the When towing is com-
weight of the towed pleted, return the roller
roller. Do not use a chain into its original condition.
for towing!
124
If there is a need to work

Steps for returning the roller to its origi- with the roller under the
nal condition conditions where the per-
sonnel can be exposed to
the increased vibration,
When finished with tow- the supervisor is obliged
ing, wedge both drums to to change the working
prevent spontaneous process to avoid the
movement. threat to the driver’s
health.
Apply brake by removing two bolts and Long-term work in the vi-
inserting original bolts M100 in Rexroth bration-stroke mode is
hydraulic motors on roller DV204. not allowed. The roller
Apply brake by releasing two bolts and could be damaged in ex-
inserting plugs in Poclain hydraulic mo- treme situations.
tors on roller DV201/DV202
Slide back the lever for short-circuiting Operating the roller under more severe
the hydraulic loop and safeguard with weather conditions
washer against remove of lever.
Machine operation at low temperatures
SPECIAL CONDITIONS OF THE
ROLLER USE Compacting in winter depends on the con-
tent of minute particles and water in the
Travel with vibration on the compacted compacted soil. With the temperature drop-
and hard materials ping below freezing, the ground becomes
firmer and more difficult to be compacted.
By travel with the roller while vibrating,
there could occur a loss of the tread contact If it becomes necessary to work at tem-
with the compacted material, (so called vi- peratures below 0° C (32° F), it is possible
bro impact), due to a high ratio of the base to compact dry soil and gravel or do fast
material compaction or due to travel on compacting of unfrozen materials before
hard materials. That condition is realized by the ground freezes solid.
transferring the vibration to the roller frame
and to the driver's post. Particularly we can
Preparations of the roller for work at low
remove the effects by increasing the travel
temperatures:
speed or by changing the vibration values
of the roller, (using a lower amplitude). The · Change oil for oil recommended for the
increasing vibration transferred to the specific range of low ambient tempera-
driver's post can occur also with the in- tures.
creased ratio of base compacted material. · Use hydraulic oil of corresponding kinetic
viscosity
· Use winter fuel
· Check charge of the battery
125
This Page is Blank
126
For good starting at low temperatures the If the engine at the high altitudes (over
battery must be fully charged. By warming 1500m / 4920ft) smokes black smoke,
up the battery to 20 °C (68 °F), by taking it contact the engine manufacturer’s service,
out and storing it in a warm room, the limit to provide the adjustment of the injection
temperature for starting is lowered by 4 to pump due to these conditions.
5° C (7 to 9 F).
The roller may be used only after the fluids The engine output is affected by the
have been warmed up to working tem- environment in which the roller
perature. works.
Machinery working at higher tempera- Work in a dusty environment

tures and humidity
If the environment is very dusty, reduce the
At higher temperature and humidity, the interval for cleaning the air filter and change
engine power drops. As these factors are the elements more frequently; clean the
not mutually dependent, their effects on the engine and hydraulics cooler more often
engine power can be approximately de- too.
scribed as follows:
Compaction near to construction or un-
· Every 10° C (18° F) of increased tem- derground utility pipes and cables
perature causes the power drop up to 4
% (at constant humidity).
If there is a need to compact near the un-
· Every 10 % of increased relative humid- derground pipes and cables, judge the vi-
ity causes the power drop up to 2 % (at brations influence affected by the roller
constant temperature). work to the constructions or underground
pipes and cables, to avoid damaging them.
Machinery working at Higher altitude
At increasing altitudes the engine power The manufacturer is not

drops because of lower air pressure and responsible for the dam-
thus lower specific weight of the intake air. ages done by using the
roller near to other con-
Altitude (m) (ft) Power de-rating % struction or underground
pipes and cables!
0 0 0
500 (1640) 3
1000 (3281) 6
1500 (4921) 10
2000 (6562) 15
2500 (8202) 21
3000 (9843) 28
127
SAFETY REGULATIONS
Prohibited Activities
It is prohibited
to work with the roller in such a place, where the driver
can’t see from the driver’s post and where there could
to use the roller after consuming some spirits or nar-
exist the danger for other personnel and property, until
cotics.
sufficient work safety is reached by other means for
to use of the roller, when its activity may endanger its example, by means of signals given by adequately
technical shape, safety (health or life) of the people, trained person.
property or materials or eventually the traffic and its
to work with the roller in the protective area of high-
fluency.
voltage wiring and transformer stations.
to start and use the roller if there are some personnel
to run across the power cables, if they are not suffi-
within the reach of the roller - with exception of training
ciently protected against mechanical damage.
provided by authorized instructor.
to work with the roller at a low visibility and at night,
to use the roller, if any of its safety installation are
until the working area and the job site is sufficiently il-
dismantled or damaged (emergency or working brake,
luminated.
safety beacon etc.).
to leave the driver’s post when the roller is running.
to travel and compact within such an incline, where
there is a danger of instability of the roller (turnover). to get in or get out when the roller is travelling, jumping
The mean static stability of the roller is degraded by from the roller.
the dynamical effects of travel.
to sit on the external parts of the roller when it is run-
to travel and compact within such an incline, where ning.
there is danger of a soil flow down with the roller, or the
to leave the unsecured roller - to leave the roller with-
adhesion lost and an uncontrollable skid.
out the appropriate secure against its misuse.
to drive the roller in another way than as specified in
to defeat the operation of any safety, protective and
the driver’s manual.
securing systems or to change their operational fea-
to adjust accelerator controller during driving roller. tures.
to travel and compact within such a range from edges to use the roller, when there is a leak of fuel, engine oil,
of slopes and heaps according the weighting of the coolant or hydraulic fluid.
earth, where there is a danger of soil flow down or drop
to start the engine in another way then described in the
the roadside with the roller.
manual.
to travel and compact within such a range from edges
to place on the driver’s post any other kind of things
of slopes, walls and heaps, where is danger of soil flow
than personal needs (i.e. tools, instruments).
down and burying the roller.
to put the material and next parts on the roller.
to compact using the vibration in such distance from
the buildings and objects and the installations where to remove the impurities from the roller while it is run-
there can be a danger of their damage in the case of ning.
the vibrations transfer.
to make the maintenance, cleaning and repairs, until
to manipulate the roller if the driver’s post is not prop- the roller is secured against the self-move and acci-
erly tighten. dental running, and until the contact of the worker with
moving parts of the roller is eliminated.
to manipulate the roller if the side engine space cover
is opened. to touch the moving parts of the roller with the body or
with equipment and tools handed.
to carry and transport personnel on the roller.
to smoke and manipulate with open flames when in-
to work with the roller, if another rollers or other trans-
specting the fuel or refueling, when changing, filling the
port means are within the threat reach of it, with ex-
oil, lubricating the roller, and during the accumulator
ception of these working with collaboration with the
check and refilling.
roller.
to carry the rags full of flammables or flammables in
open vessels on the roller (in an engine space, or in
the cab).
128
to run the engine in a closed building.
129
Viscosity
FILLING SPECIFICATIONS The oil viscosity changes with the tem-
Engine oil
perature. The viscosity class, SAE (Society
The use of a quality engine lubricating oil and proper
of automotive engineers), the ambient tem-
exchange interval are inportant for the engine life- perature and the use of the roller working
cycle. conditions affect the oil lubricating ability.
Quality To use the engine at lower temperatures
The oils are divided on the output class and quality doesn’t cause the engine damage, it can
class. They are specified due to the API (American only cause difficult engine starts.
Petroleum Institute) and CCMC (Committee of
COMMON Market Automobile Constructors). The use of the engine at the upper tem-
Permitted oils: perature limit causes a decrease in the oil
API CF-4 CG-4 CH-4
lubricating abilities.
CCMC D5 It is recommended to use the universal
ACEA E1-E3/96 E4-98 wide-scope oil to prevent the oil changeing
because of the ambient temperature
changes.
Diagram of Viscosity
All-year recommended oil is SAE 15W-40
due to the diagram.
For easier engine starting under tempera-
tures slightly over 0° C (32° F) is possible to
use the SAE 10W-30 oil due to the dia-
gram.
Conditions of the oil exchange

Regularly change the oil in intervals ac-
cording to the table after 500 engine hours.
If we don’t reach the oil exchange interval
within one year, change the oil irrespec-
tively to the number of engine hours after 1
year.
Oil exchange interval is influenced by the
sulfur amount in the weight % in diesel oil.
130
The dependence of the temperature to the

Fuel added kerosene amount shows the dia-
gram.
As an engine fuel is used the diesel oil : Sufficient anti-freeze quality we can reach
CEN EN 590 or DIN/EN 590 (proposal) also by adding the additive to the fuel for
improving the liquidity (fuel additives).
DIN 51 601
BS 2869 (1998) : A1 and A2 Do the mixing only in the
ASTM D 975-88: 1-D and 2-D tank. Fill first the tank with
VV-F-800C : DF-A, DF-1 and DF-2 determined mount of kero-
sene, then replenish with
NATO code F-54 and F-75
the fuel.
The mixtures of winter fuels
Common fuel for the diesel engines con- are equally flammable as
tains the sulfate amount under 0.5% of the gas itself – keep the fire
weight, when using the fuel with larger sul- regulations !
fate amount 0.5 – 1 % it is necessary to
decrease the oil exchange intervals to one
half.
Diagram of Mixing
It is strictly required to use
above specified brands of
diesel fuel only. Usage of
different fuel (like Bio-fuels,
or Light heating oils of any
kind) is strictly
PROHIBITED.
Winter fuel
Under lower temperatures under +5 °C (41
°F) by the common diesel fuel the causes
the separation of paraffins in the roller fuel
system. Separated paraffins can cause the
faults even disable the roller’s operations.
In that case , under ambient temperatures
under +5 °C (41 °F) use the winter diesel
fuel.
The diesel fuel is usually changed by the
distributors due to the year season.
When using the summer diesel fuel under
temperatures near the 0 °C (32 °F) mix to
the diesel fuel the kerosene for improving
the lower-temperature qualities.
131
During operation of the roller it is necessary

Hydraulic Oil to avoid mechanical contamination (wear,
dust etc.). Oil must not exceed 17/14 con-
tamination class (according to ISO 4406).
Operating fluid must be checked by taking
samples in regular intervals - see the table.
When taking samples it is necessary to fol-
low rules specified by PANOLIN Company
laboratory. The best solution is to have di-
rectly the PANOLIN Company take the
sample.
! NOTE !
When filling biologically fast-
degradable oils, mixing with up to 2%
of the total tank content is allowed.
Move from mineral oils to synthetic

Such a change must be made according to
VDMA 24´569.
When filling older rollers with PANOLIN
HLP Synth product the residual limit of min-
eral oils must not exceed 8% of the total fill.
Synthetic hydraulic oil

The hydraulic system may be filled with
synthetic oil under the following condi-
tions:
PANOLIN - HLP Synth 15/22/32/68 is fully
synthetic, high-performance oil classified
according to VDMA 24´568 directive into
HESS class. It complies with DIN 51524
parts 2 and 3. The requirements for aging
resistance are exceeded several times. In
case of leakage oil is completely degraded
by microorganisms present in water and
soil.
132
This Page is Blank
133
! NOTE !
Water content (condensation water) in Lubricating grease
oil must not exceed 0.1%.
Mixing PANOLIN HLP Synth oil with For the roller lubrication is necessary to use
other biologically degradable oils (non- the plastic lubricant with content of lithium
saturated synthetic esters or plant oils) due to the regulation NLGI-2 according to
is not allowed! the lubrication schedule table.
Always contact the manufacturer or

PANOLIN Company to consult any
moves to different type of oil or mixing
with other types of oils!
FLUIDS
* NLGI - National Lubricating Grease Institute
134
134
135
INDIVIDUAL OPERATIONS OF
MAINTENANCE
Change of the oil and engine oil filter
Drain the oil after finishing work or after

decreasing the temperature to 60° C
(140° F), or with the engine turned on
(when driving the roller) wait until the oil
temperature reaches the 60° C (140° F).
Place the roller in a horizontal position on
a flat, solid base.
Turn the engine off.
Prepare a convenient vessel with a ca- Clean the contact area for the filter seal.
pacity of approximately 7 liters (2 gal.). Slightly lubricate the rubber filter gasket
Remove the outlet plug (1) and let the oil with oil and screw it on, properly tighten.
flow out.
Clean the area round the oil filter’s head. Check the stud and clean the contact
Remove the filter (1). area for the seal.
Mount the plug back. Tightening moment
50 Nm (37 ft lb).
136
Fill the engine with clean engine oil by Catch the out flowing oil,
the filling neck (2). The whole content is don’t let it sink in to the
6.5 liter (1.72 gal US) of oil. ground.
Dispose of the oil according
to valid regulations.
Used filters store in the in-
dividual container and ma-
nipulate with them such
way to prevent the pollution
of the environment.
Start the engine and let it run under in-

creased speed for 2-3 minutes.
Stop the engine, wait for 5 min. to let the
oil flow down to the engine pan. Then
check the proper oil level – if necessary,
replenish to upper guideline of the gauge
(1).
Check the tightness.
Change oil and filter in a

new engine or after (Gen-
eral Overhaul) after 50 &
150 Operating hours.
Change the oil always after
1 year even if the exchange
interval hasn’t been
reached of 500 work-out
engine hours.
Use recommended oils.
Use recommended filters
only. Don’t over-tighten the
filter, it can cause the stud
and gasket damage.
When removing the hot oil,
watch out for possibility of
being burned.
137
Exchange of fuel filter Use the recommended origi-

nal filters only.
Position the roller on a horizontal, solid, Don’t over-tighten the filters,
flat surface. it can cause damage to the
Stop the engine. stud and gasket.
Raise the hood and remove the left en- Used filters store in the indi-
gine cover vidual container and ma-
Remove the fuel filter (1) – catch the out nipulate with them such way
flowing fuel. to prevent the pollution of
Clear the filter holder sealing area. the environment.
Slightly lubricate the rubber gasket of the
new filter with fuel oil and fill it with diesel
fuel.
Screw in the filter by hand to contact with
the gasket and then tighten a half turn
more.
Check the tightness !
When changing, operate due

to the ecological instructions
and the hygienic principles!
Keep the fire regulations!
Do the change on ventilated
spaces without danger of
rise the fire.
Prevent the fuel outflow into
the ground.
When working, don’t smoke
and use open fire flames.
138
Replacing oil and filter in the hydraulic

Cleaning the filter of fuel pump
system
The roller must be level on firm and Drain oil when warm – not hot – below
straight ground. 50° C (122° F).
Stop the engine, raise the hood and dis-
Place the roller on a flat, firm and hori-
connect electrical wiring.
zontal base.
Remove lid (1) with strainer.
Stop the engine.
Clean thoroughly and open the hydraulic
tank lock.
Remove the draining plug of the oil tank
(1), catch the oil in a ready vessel. The
content is 38 liters (10 US gallons).
Remove the filter container (2) with the
filter cartridge using a 36mm wrench;
take the cartridge out.
Clean the filter thoroughly – check the
“O” ring seal (3).
Clean the bottom of the seating area of
the filtration block.
Insert a new cartridge in the filter housing
Wash the strainer (2) in clean fuel, and and reinstall. Tighten using torque 40+10
replace if needed. Nm (30+7 lb ft).
Replace seal rings (3) if needed. Insert draining plug.
Reinstall and check tightness.
139
Remove the cover (2). Remove the suc-

tion strainer (14). Wash the suction
strainer in gasoline and blow the strainer
with pressure air from inside.
Check the condition of the suction
strainer; replace the strainer in case of
damaged filter part. Check the inside of
the tank. Carefully clean the bottom and
flush it with new oil if there are any impu-
rities at the bottom. Mount the strainer to
the suction pipe.
Reassemble the cover. Lubricate the O-
ring with clean oil. For dismantled the
entire upper cover, use a new Teflon
sealing strip (13).
140
Start the engine, adjust the speed to

Filling hydraulic system 1200 rpm and test all functions until all
Fill with equipment, with filter density 3- loops are full.
10 µm. Add oil to level MAX, close the tank.
Fill through filler neck (1) with specified Start the engine, adjust the speed to
type of new oil, to maximum of about 38 1200 rpm and test all functions of the
liters (10 US gallons). roller.
Check for leaks – add oil if necessary.
Attention!
If the roller is filled in a dif-
ferent manner (manual fill-
ing and can), change inter-
vals must be halved (1000
hours or 1 year).
Use this filling process only
in emergency – it is not
recommended by the
manufacturer.
141
Oil change in the vibrator
Change the oil when the oil is warm.

Position the roller on a horizontal, solid,
flat surface.
Turn the carriages in such a way as to
set the outlet plug (1) to the lowest posi-
tion.
Stop the engine. Watch out for the burn ups

Place the appropriate vessel under the when out flowing the hot oil.
outlet plug. Attend to ecology !!!
Unscrew both plugs and let the oil flow
out.
Turn the drum with plug (1) to the top
position.
Through the filling hole fill 1.8 liter (2 qts
US) of recommended engine oil.
Check level of oil often, by removing the
check plug (2).
Mount the plug.
142
Test posts
The vibration testing spot is provided with a

quick coupler. On other inspection points
the quick couplers must be first installed
according to the table and illustrations.
* - The roller (the drum) must be wedged

against movement
** - On a still standing roller travel must not
be activated.
***- It is measured when vibration has been
started
**** - It is measured when steering is
blocked (limit position of drums) – its
value with filling pressure.
Notice
When measuring on outputs 1 or 2 of the
travel pump, the short-circuiting loop must
be disconnected. The ball valve of short-
circuiting must be closed.
143
Cleaning and replacement of air filter

cartridges Release the clip and remove the lid.
Place the roller on a flat, horizontal sur-

face.
Stop the engine, lift the hood.
If the pressure indicator (1), becomes
red, it is necessary to clean or replace
the cartridge, at least after 1 year of op-
erations.
Remove the main cartridge.
Remove dust filter and clean.
Clean the inside of the filter – not with

compressed air.
Install dust valve.
Install cleaned or new cartridge. Make
sure that it sits tight.
Thereafter, zero out the indicator by
pressing the button on its housing.
144
Remove the old cartridge very carefully.

Cleaning of the cartridge: Clean the inside of the filter housing in a
Use only dry cleaning with compressed manner that would not deposit dust in-
air. Pressure may not exceed 5 bar (72 side the inlet pipe to the engine.
PSI). Apply air at an angle from inside Clean the seating surface for the seal in
out. the filter housing.
Inspect traces of dust in the old cartridge
that indicate its tightness inside the filter
housing.
Press the seal on the new cartridge to
see its flexibility.
Make sure that the seal sits tight.
Check connections and pipes to see if
tight.
Forbidden procedures!
Never use damaged car-
tridge.
Do not remove cartridge
The cartridge may be cleaned no more just for its inspection.
than 5 times before being replaced by a
Do not judge soiled car-
new one. It must be also replaced after
tridge by its looks only.
one year of use.
Do not leave the filter open
Note each cleaning on the lid.
longer than absolutely nec-
If the cartridge is soiled by carbon parti- essary.
cles, it must be replaced, since cleaning
is not possible. Do not use filter with a
damaged lid of housing.
After cleaning, check that the cartridge
has not been damaged (use light). If Do not clean the cartridge
damaged, it must be replaced. We rec- by knocking on it.
ommend that at least one spare cartridge Use only original approved
is on hand. A damaged cartridge is not cartridge.
effective and may cause damage to the
Do not clean using fluid
engine.
cleaner.
Correct procedures for the replacement
of the cartridge:
145
TROUBLESHOOTING ENGINE
More frequent defects are mostly the results of incorrect operation of the roller. Therefore, in case of any troubles
reread instructions of the operation and maintenance manual. If not able to specify the cause of the trouble using
the following chart, contact customer service of the manufacturer or an expert. If you are not qualified in the field
of electrical and hydraulic systems or trained in the service of this roller, do not carry out any repairs of hydraulic
system.
146
147
TROUBLESHOOTING:
1/ Oil leaking under the lid of the vibrator

2/ Oil leaking between damper plate and vibrator lid
3/ Vibrator doesn‘t work, hydraulics OK
4/ The roller engine cannot be started
5a/ The roller doesn‘t vibrate - automatic position - wiring
5b/ Continuation hydraulics
6/ The roller doesn‘t vibrate position manual - wiring
7/ Both drums do not vibrate
8/ Steering is defective, the wheel gets stuck
9/ Steering does not work in difficult terrain
10/ Steering goes to one side
11/ The roller doesn‘t move engine runs - wiring
12/ The roller doesn‘t move - the engine runs - hydraulics
13/ The roller moves in one direction, or has decreased pulling power in one direction
14/ Hydraulic oil foams
15/ Oil level decrease in hydraulic tank
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164

070 Double Drum TRAINING

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DOUBLE DRUM COMPACTOR TRAINING MANUAL

SEPTEMBER 26, 2005

1. MACHINE DESCRIPTION .................................................................................................. 6

3. INDIVIDUAL GROUPS ROLLER...................................................................................... 18

4. CONTROL OF THE ROLLER........................................................................................... 99

This Page is Blank

1 - Front frame 12 - Fuel tank

Note: Operation weight to EN 500-1 = CECE

Engine fulfills requirements of 99/68/EC

Hydraulic power steering one hydraulic cylinder

Hydrostatic travel drive

Hydrostatic vibration drive

Cooling hydraulic oil

Oil cooler NISSENS 151199N1

Suction basket ARGO AS080-01

DV201 / DV202 DV204

Water pump SHURFLO 8000-043-235

Electric set voltage V 12

Emergency brake Turning on optically signalized

Protective frame ROPS (tipping optional)

DV201 / DV202 DV204

This Page is Blank

Guaranteed sound power level:

- transferred to the hands aw < 2.5 ms-2 (vector sum)

3. INDIVIDUAL ROLLER GROUPS

THE FRONT AND REAR DRUM

THE FRONT FRAME

THE REAR FRAME

THE ARTICULATION JOINT CONNECTION

This Page is Blank

FRONT AND REAR BRACKET

SCRAPERS OF THE DRUMS

The sprinklers wet the drums when working

The rollers use Deutz F2L 1011F engines

103 ENGINE DEUTZ

COOLING OF THE HYDRAULIC OIL

The water tank is located below the seat.

Hydraulic system consist of three basic circuits:

300 HYDRAULIC FRONT

310 HYDRAULIC REAR

This Page is Blank

LINEAR VALVES – DESCRIPTION OF CONSTRUCTION AND FUNCTION

HYDRAULIC OF VIBRATION - NOT ACTIVATED VIBRATION

Not activated vibration

HYDRAULIC OF VIBRATION - VIBRATION OF THE FRONT DRUM

Vibration of the front drum

HYDRAULIC OF VIBRATION - VIBRATION OF BOTH DRUMS

Vibration of both drums

HYDRAULIC OF STEERING - STEERING ACTIVATION

FLUSHING AND DRAIN

This Page is Blank

350 A HYDRAULIC OF DRIVING SET

350 B HYDRAULIC OF DRIVING SET

350 C HYDRAULIC OF DRIVING SET

HYDRAULIC OIL TANK

370 HYDRAULIC TANK

570 FRAME ROPS

575 FRAME ROPS

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403 ELECTRICAL INSTALLATION