DYNAPAC

CA 150
MAINTENANCE
M150EN2

Box 504, SE-371 23 Karlskrona, Sweden

Phone: +46 455 30 60 00, Fax: +46 455 30 60 30
www.dynapac.com

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 ILF015WO1 19

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 Vibratory Roller
CA 150

Maintenance
M150EN2, August 2002
Diesel engine:
CA 150: Cummins 4BT 3.3C

These instructions apply from:

CA 150 PIN (S/N) *73X20150*

R
FO
L
A E
U NC
N
A RE
M E
IS E F
TH R
P E
R
EE T U
K U
F

CA 150 is Dynapac’s light vibratory soil compactor. Available in D (smooth drum) and
PD (padfoot) versions. The PD version has its widest range of application on cohesive
material and rockfill materials.

All types of supporting and reinforcement courses can be compacted, and the
interchangeable drums, ie, D to PD and vice versa, give enhanced versatility in the
choice of application.

This manual describes the cab and safety-related accessories. Other accessories,
such as the compaction meter, etc. are described in separate instructions.

Reservation for alterations.

Printed in Sweden

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 CONTENTS

Page
Lubricants and symbols ................................................... 3
Technical specifications ............................................... 4-6
Maintenance schedule ..................................................... 7
Maintenance Measure .................................................. 8, 9
Every 10 operating hours (daily) ............................... 10-13
Every 50 operating hours (weekly) ........................... 14-16
Every 250 operating hours (monthly) ........................ 17-20
Every 500 operating hours (every three months) .......... 21
Every 1000 operating hours (every six months) ....... 22-24
Every 2000 operating hours (every year) ................ 25, 26
Long-term storage .......................................................... 27
Special instructions ........................................................ 28
Electrical system, fuses ........................................... 29, 30

WARNING SYMBOLS
WARNING

Safety instruction – Personal Safety

CAUTION

Special caution – Machine or component damage

GENERAL
WARNING
Read through the entire manual before
starting any maintenance operations.
WARNING

Ensure good ventilation (air extraction) if the

diesel engine is run indoors.
It is important that the roller is maintained correctly to
ensure proper function. It should be kept clean so that any
leakage, loose bolts and loose connections can be
discovered in time.
Make a habit of walking round the roller to check it every
day before starting the first shift – including under the
machine. This is often the easiest way of discovering any
leakage.
SPARE A THOUGHT FOR THE
ENVIRONMENT! Do not let oil, fuel and other
environmentally hazardous substances contami-
nate the environment. CALIFORNIA
This manual contains instructions for periodic attention Proposition 65 Warning
which should normally be carried out by the roller operator.
CAUTION
There are additional instructions relating to the Diesel engine exhaust and some of its
diesel engine, for which the manufacturer’s constituents are known to the State of
instructions are detailed in the engine manual. California to cause cancer, birth defects,
This is found under a separate flap in the roller’s and other reproductive harm.
product binder.

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 LUBRICANTS AND SYMBOLS
CAUTION
Always use high-quality lubricants, in the quantities specified. Excess grease or oil can
promote overheating, resulting in premature wear.

ENGINE OIL Shell Universal SAE 15W/40 or equivalent

API Service CF-4/SG, (CD/CE)

HYDRAULIC FLUID
ambient air temperature Shell Tellus Oil TX68 or equivalent
-10°C – +40°C (14°F - 104°F)
ambient air temperature Shell Tellus Oil TX100 or equivalent
above +40°C (above 104°F)
BIODEGRADABLE Shell Naturelle HF-E46
HYDRAULIC FLUID When it leaves the factory, the machine may be filled
with biologically degradable fluid. The same type of
fluid must be used when changing or topping off.
TRANSMISSION OIL
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
ambient air temperature Shell Spirax HD85W/140 or equivalent
above +40°C (above 104°F)
DRUM OIL
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
ambient air temperature Shell Spirax HD85W/140 or equivalent
above +40°C (above 104°F)
GREASE SKF LGHB2 (NLGI Class 2) or equivalent for
articulated joint. Shell Retinax LX2 or equivalent
for other lubrication points.
FUEL See the engine manual

50 COOLANT Shell Anti-Freeze 402 or equivalent

/50
mixed 50/50 with water Anti-freeze protection down to about -35°C (-31°F).

CAUTION
When driving in extremely high or low ambient tempe-ratures, other lubricants are needed.
Refer to the chapter entitled “Special Instructions” or contact 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

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 TECHNICAL SPECIFICATIONS

Weight and sizes CA150 CA150D CA150PD CA150P

Operating mass with ROPS, EN500, kg (lbs) 6930 (15,300) 7130 (15,700) 7430 (16,400) 7230 (16,000)
Operating mass without ROPS, kg (lbs) . 6600 (14,600) 6800 (15,000) 7100 (15,700) 6900 (15,200)
Operating mass with cab, kg (lbs) ........... 7150 (15,800) 7350 (16,200) 7650 (16,900) 7450 (16,400)
Length, standard-equipped roller, mm (in) 4776 (188) 4776 (188) 4871 (192) 4871 (192)
Width, standard-equipped roller, mm (in) . 1852 (73) 1852 (73) 1852 (73) 1852 (73)
Height, with ROPS, mm (in) .................. 2784 (110) 2784 (110) 2825 (111) 2825 (111)
Height, with silencer, mm (in) ................ 2525 (99) 2525 (99) 2540 (100) 2540 (100)
Height, with cab, mm (in) ....................... 2815 (111) 2815 (111) 2857 (112) 2857 (112)

Fluid volumes (Liters) (gal or qts)

Rear axle:
• Differential ................................................. 7,0 (7.4 qts)
• Planetary gearing ...................................... 0,8/side (0.8 qts) /each side
Drum oil ....................................................... 10,5 (11.1 qts)
Hydraulic reservoir ...................................... 52 (13.7 gal)
Fluid in hydraulic system (D, PD) ............... 18,0 (4.8 gal)
Lubricating oil, Diesel engine ....................... 8,0 (8.5) qts)
Coolant, Diesel engine ................................ 12,5 (13.2 qts)
Fuel tank ..................................................... 225 (59.4 gal)

Electrical system

Battery ......................................................... 12 V, 170 Ah

Alternator ..................................................... 14 V, 60A
Fuses .......................................................... See under main heading: Electrical system

Tires

Tire size ...................................................... 420/70 B24 (Std type) 14,9-24T461 8 ply (Tractor type)
Air pressure ................................................ 110 kPa (1,1 kp/cm2) (16 psi)
WARNING
As extra equipment, the tires can be filled with liquid (extra weight up to 350 kg/tire)
(770 lbs/tire). Remember this extra weight when you perform service.

Compaction data CA150 CA150D CA150PD/P

Static linear load ......................... kg/cm (pli) 21,2 (118.7) 21,7 (121.5) –
Amplitude (High) .............................. mm (in) 1,7 (0.067) 1,7 (0.067) 1,7 (0.067)
Amplitude (Low) .............................. mm (in) 0,8 (0.031) 0,8 (0.031) 0,8 (0.031)
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)

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 TECHNICAL SPECIFICATIONS
Tightening torque Tightening torque in Nm (lbf.ft) for oiled, bright
galvanized 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 ROPS bolts must always be tightened dry.

Bolt dimension: M20 (P/N 50 02 26)

Strength category: 8.8
Tightening torque: 330 Nm (243 lbf.ft)
(for Dacromet treated)

Hydraulic system Opening pressure, MPa (psi)

Drive system ........................ 38,0 (5,500)

Charge system ....................... 2,0 (290)
Vibration system ................... 33,0 (4,800)
Steering system ................... 17,5 (2,540)
Brake disengagement ............ 1,4 (200)

CA 150 M150EN2 5

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 TECHNICAL SPECIFICATIONS

Vibrations - Drivers seat The vibration values are measured in conformance

(ISO 2631) with the driving mode described in EU directive
2000/14/EC on EU equipped machines, on soft
polymer material with vibration switched ON and
the operator’s seat in transport mode.

Operator’s station, vibration, hand/arm (steering

wheel/lever):
Below limit value.
Limit value: <2.5 m/s2.
Operator’s station, vibration, entire body (operator’s
seat):
Below limit value.
Limit value: <0.5 m/s2.

CAUTION
Vibration levels may vary when driving on
different courses and with different seat
positions.

Acoustic values
The acoustic values are measured in conformance with EU directive
2000/14/EC on EU-equipped machines, on soft polymer material
with vibration switched ON and the operator’s seat in transport
mode.

Model Guaranteed Acoustic Acoustic

acoustic pressure level, pressure level,
power level operator’s ear operator’s ear
dB(A) Lw(A) (platform) (cab) dB(A)
dB(A) Lp(A) Lp(A)

CA 150 107 89 90

CAUTION
Noise level can vary when driving on different
courses and with different seat positions.

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 MAINTENANCE SCHEDULE

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

32

31

30

29
13

28 27 26 25 24 23 22 21 20 19 18 17 16 15 14

Fig. 1 Service and maintenance points

1. Radiator grille 12. Drum oil, filling 23. Rear axle, planetary gearing, x2
2. Fuel filter, initial fuel filter 13. Scrapers 24. Rear axle suspension, two sides
3. Drive belts, cooling, alternator 14. Drum oil, level plug, x1 25. Feed pump, fuel
4. Oil level, diesel engine 15. Rubber elements and fastening screws 26. Oil filter, diesel engine
5. Air filter 16. Steering joint 27. Draining, fuel tank
6. Hydraulic reservoir, sight glass 17. Steering cylinder, x1 28. Engine suspension, x4
7. Breather filter 18. Hydraulic filter, x1 29. Diesel fuel, filling
8. Drain, hydraulic reservoir 19. Flywheel casing, hydraulic pumps 30. Battery
9. Hydraulic fluid, filling 20. Wheel nuts 31. Radiator
10. Forward/reverse lever 21. Tire pressure 32. Hydraulic fluid cooler
11. Fuse box 22. Rear axle, differential

CA 150 M150EN2 7

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 MAINTENANCE MEASURES

Periodic maintenance shall be carried out at the

specified intervals, that is to say either every day,
every week etc., or after the specified number of opera-
ting hours, whichever comes first.

CAUTION Always first remove all exterior dirt before

filling up fluids etc., and before checking oil
and fuel levels, and also when lubricating with
grease or oil.
CAUTION
The engine manual specifies additional ser-
vice/maintenance instructions which relate to
the diesel engine.

Every 10 operating hours (daily)

Item. in Measure See page Comments
fig. 1

Before the day’s first start

13 Check scraper setting 10
1 Check for free circulation of cooling air 11
31 Check coolant level 11 See engine manual
4 Check diesel engine oil level 12 See engine manual
29 Top up fuel tank 12
6 Check fluid level in hydraulic tank 12
Check brakes 13

Every 50 operating hours (weekly)

Item. in Measure See page Comments
fig. 1

Check that hoses and couplings are not leaking

7 Clean the filter element of the air cleaner 14 Replace as required
16 Lubricate steering joint 15
17 Lubricate the steering cylinder brackets 15
20 Check the wheel-nuts are tightened 16
21 Check tire pressure 16

CAUTION

After the first 50 hours of operation,

change only the drum oil and all the oil filters.

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 MAINTENANCE MEASURE

Every 250 operating hours (monthly)

Item. in Measure See page Comments
fig. 1

23 Check the oil level in rear axle/planetary gearing17

14 Check the oil level in drum 17
32 Clean the radiators 18
20, 24 Inspect and tighten bolted joints 18 Applies only to new and
repaired components
15 Inspect rubber elements and bolted joints 18
26 Change engine oil and oil filter 19 See engine manual
30 Inspect the battery 19, 20

Every 500 operating hours (every three months)

Item. in Measure See page Comments
fig. 1

2 Replace fuel filter See engine manual

2 Clean the initial fuel filter 21
7 Check bleeder filter on hydraulic tank 22

Every 1000 operating hours (every six months)

Item. in Measure See page Comments
fig. 1

18 Change the hydraulic fluid filters 22

27 Drain condensate from fuel tank 23
5 Replace air cleaner main filter 23
8 Drain condensate from hydraulic tank 24
22 Change oil in rear axle differential 24
24 Change oil in rear axle planetary gears 24
Check diesel engine valve clearance See engine manual
3 Check belt tension for drive belt system See engine manual

Every 2000 operating hours (every year)

Item. in Measure See page Comments
fig. 1

8, 9 Change fluid in hydraulic tank 25

12 Change oil in roller 25
10 Lubricate Forward/Reverse control 26

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 EVERY 10 OPERATING HOURS (Daily)

Scrapers
– Check/Adjust
WARNING Never work under the roller with the engine
running. Park on a level surface. Block the
wheels securely.

CAUTION It is important to consider movement of the

drum when the machine turns, ie, the scrapers
can be damaged or wear of the drum may
increase if adjustment is made closer than the
1
values stated.
2
If necessary, adjust distance to the drum as follows:
the scraper is integrated with the beam.
Fig. 2 Scrapers Loosen the four screws (2) on the frame side, then ad-
1. Scraper beam just the beam to about 20 mm (0.8 in) from the drum.
2. Screws Tighten the screws.

CA 150 PD/P
Loosen the four screws (2) on the frame side, then ad-
just the beam to about 25 mm (1 in) between the teeth
and the drum.
1 Tighten the screws.

Fig. 3 Scrapers
1. Scraper blade
2. Screws

Soft scrapers (Optional)

Loosen the screws (2) and adjust to light contact
against the drum. Tighten the screws.

2 1 1 2

Fig. 4 Scrapers
1. Scraper blade
2. Screws

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 EVERY 10 OPERATING HOURS (Daily)

Air circulation – Check

Check that the diesel engine has free circulation of
cooling air through the grille in the engine compartment.

Open the cover (1) fully upward. Make sure that the red
safety catch on the right side is latched.

Fig. 5 Grille
1. Cover

Coolant level – Check

Check that level of the coolant is between the max. and
1 3
min. marks.
2
WARNING Danger of scalding. Take great caution if
the radiator cap must be opened while the
engine is hot. Wear protective gloves and
goggles.

Fill with a mixture of 50% water and 50% anti freeze.

See lubricant specification and in the engine manual.
CAUTION
Flush the system every other year and
Fig. 6 Radiator change the coolant. Ensure also that air can
1. Max. level flow unrestricted through the radiator.
2. Min. level
3. Filler cap

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 EVERY 10 OPERATING HOURS (Daily)

Diesel engine
– Check oil level
WARNING Park the machine on a level surface. The
1 engine should be switched off and the
parking brake engaged during all inspec-
tion and adjustment operations on the
machine, unless otherwise stated.

WARNING Watch out for contact with hot engine

parts and the hot radiator when the oil
dipstick is being removed. There is a risk
of burn injuries.

The dipstick is on the left-hand side of the engine.

Pull up the dipstick (1) and check that the oil level is
Fig. 7 Engine compartment
between the upper and lower marks. For further details,
1. Oil dipstick refer to the engine manual.

Fuel tank – Filling

Refuel every day. Top off to the lower edge of the filler
pipe. Use diesel fuel in accordance with the engine
manufacturer’s specifications.
2
WARNING Stop the diesel engine. Short (press) the
filler gun against a non-insulated part of
the roller before refueling, and against the
filler pipe (1) while refueling is in progress.

1 The fuel tank holds 225 litres (59,4 gal).

CAUTION Check that there is no sediment or water in the

Fig. 8 Fuel tank fuel pre-filter (2).
1. Filler pipe
Clean the pre-filter if required, see under "500
2. Initial fuel filter
hours of operation".

Hydraulic reservoir
– Check fluid level
Position the roller on a level surface and check that the
2 sight glass reading (1) is between the max. – min.
marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.

1
Fig. 9 Hydraulic fluid reservoir
1. Sight glass
2. Filler pipe

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 EVERY 10 OPERATING HOURS (Daily)

Brake function – Check

WARNING
3 Check operation of the brakes as follows:
1

Drive the roller slowly forward.

Push the reserve/parking brake knob (1); the warning

lamp (3) on the instrument panel should light and the
roller should 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.

Fig. 10 Control panel

1. Reserve-/parking brake knob
2. Forward/reverse lever
3. Warning lamp

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 EVERY 50 OPERATING HOURS (Weekly)

Air cleaner
– Check/clean
CAUTION Replace or clean the air cleaner’s main filter if
2 3 the warning lamp on the instrument panel lights
up when the diesel engine is operating at full
speed.

Undo the three locking braces (1). Then pull off the
cover (2) and pull out the main filter (3).

Do not remove the safety filter (4).

1 4 5

Fig. 11 Air cleaner

1. Locking braces
2. Cover
3. Main filter
4. Safety filter
5. Filter housing

Main filter – Cleaning with

compressed air
If the main filter is to be cleaned, compressed air at
max. 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 2–3 cm (0.8-1.2 in) away from

the paper creases so that the paper does not tear un-
der the pressure of air.
WARNING
Use protective goggles when working with
compressed air.

Fig. 12 Main filter Dry the inside of the cover (2) and filter housing (5).
CAUTION
Check that the hose clamps between the filter
housing and inlet hose are tightened and that
they do not leak. Check the entire length of the
hose all the way to the engine.
CAUTION
Once the main filter has been cleaned a maxi-
Safety filter – Replacement mum of 5 times, it must be replaced.
Replace the safety filter with a new one at every 5th
4 replacement or cleaning of the main filter. The safety fil-
ter cannot be cleaned.

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

Fig. 13 Air filter

4. Safety filter

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 EVERY 50 OPERATING HOURS (Weekly)

Steering joint and steering

cylinder – Lubrication
WARNING
Place the roller on a level surface. Switch the
engine off and push in the reserve/parking
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
WARNING
Allow no one to get near the steering joint
when the engine is running. Danger of
being crushed when steering is operated.
Push the reserve/parking brake knob be-
fore lubricating.

Turn the steering wheel fully to the right to gain access

Fig. 14 Steering joint, left side to all six lubricating nipples on the left side.
CAUTION
Steering joint – Lubrication Use grease recommended in Lubricant Speci-
fication.
1
Wipe all the nipples clean from dirt and grease.

Lubricate each nipple (1) with five strokes of the grease

gun. Make sure that grease penetrates the bearings.

If grease does not penetrate through the bearings, it

may be necessary to relieve the load on the articulated
joint with a hydraulic jack and then repeat the greasing
process.

Fig. 15 Steering joint, left side

1. Lubricating nipples,
steering joint (x4)

Steering cylinder
– Lubrication
2 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 after

greasing. This will prevent contaminants from entering
the nipples.

Fig. 16 Steering cylinder, left side

2. Lubricating nipples, cylinder
brackets (x2)

CA 150 M150EN2 15

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 EVERY 50 OPERATING HOURS (Weekly)

Tires – tire pressure

Wheel nuts – tightening
Check the tire pressures using a pressure gauge.

If the tires are filled with fluid, the air valve (1) must be
in the “12 o’clock” position during pumping.

The relevant tire pressures are given under the heading

“Specifications”.

Check both tires.

1 CAUTION
When changing the tires it is important that
2 both of them have the same rolling radius. This
is necessary to ensure proper functioning of
the anti-slip in the rear axle.
Fig. 17 Wheels
1. Air valve
2. Wheel nut
Check the tightening torque of the wheel nuts (2) at 470
Nm (350 lbf.ft). Check both wheels and all the nuts.
(Applies only to new machine or recently fitted wheels.)
WARNING
Check the safety manual that accompanies
the roller before filling the tires with air.

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 EVERY 250 OPERATING HOURS (Monthly)

Rear axle differential

– Check oil level WARNING
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
WARNING
1 Never work under the roller with the engi-
ne running. Park on a level surface. Block
the wheels securely.

Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
Fig. 18 Oil level check – differential specification.
housing
1. Oil level/Filler plug

Rear axle planetary gears

– Check oil level
Position the roller with the level plug (1) in the planetary
gears at 9 o’clock.
1
Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
specification.

Check the oil level in the same way in the rear axle’s
other planetary gear.
Fig. 19 Oil level check – planetary gear
1. Oil level/Filler plug

Drum
– Checking the oil level
Position the roller on a flat surface so that the filler plug
2 (1) and number plate (2) on the right side of the drum
are straight up.
1
Oil level should reach up to the sight glass (3).

Top off as required through the filler plug (1) halfway on

the sight glass.

Clean the magnetic filler plug (1) from any metal parti-
cles before refitting it.
3
See lubricant specification for the right grade of oil.
Fig. 20 Right side of drum
1. Filling plug CAUTION
2. Number plate
3. Sight glass Do not overfill with oil, risk of overheating.

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 EVERY 250 OPERATING HOURS (Monthly)
Coolers – Checking/cleaning
Open the engine cover to gain access to the water and
hydraulic coolers.

Ensure that the flow of air through the coolers (1) and
(2) is unobstructed.

Clean a dirty radiator using compressed air or a high-

pressure water jet. Blow or wash the radiator in the
opposite direction to that of the cooling air.
CAUTION
2 1 Take care when using a high-pressure water
jet; do not hold the nozzle too near the cooler.
Fig. 21 Hydraulic cooler The cooler may otherwise be damaged.
1. Water cooler
2. Hydraulic fluid cooler WARNING
Wear protective goggles when working
with compressed air or high-pressure
water jet.
Bolted joints
– Checking tightening torque
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, 470
Nm (347 lbf.ft), oiled.

(The above applies to new or replaced components

3 only.)
2
1

Fig. 22 Right side of machine

1. Rear axle
2. Engine suspension
3. Wheel nuts

Rubber elements and screw

fasteners – Check
Check all the rubber elements (1), and replace them all if
1 more than 25% of the elements on the same side of the
roller have cracks deeper than 10–15 mm (0.4-0.6 in).

Use a knife blade or other pointed tool when carrying

out this check.

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

Fig. 23 Roller, vibration side

1. Rubber element
2. Screw fasteners

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 EVERY 250 OPERATING HOURS (Monthly)

Diesel engine
– Changing the filter and oil
WARNING
Position the roller on a level surface. Stop
the engine and apply the parking brake/
reserve brake.

The oil drain plug (1) located in a mount on the rear axle
is 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.
WARNING
Danger of being scalded when draining off
hot oil. Protect your hands.

2 1 Change the engine oil filter (2) at the same opportunity.

See also the engine manual.
Fig. 24 Left side of engine
1. Drain plug
2. Oil filter Dispose of the drained oil and filter in an
approved manner.

Battery
– Check electrolyte level
WARNING
Make sure there are no naked flames in the
1 2 3 1 vicinity when checking the electrolyte level.
An explosive gas is formed in the battery
during the charging process.

Lift up the engine compartment cover and undo the

quick-release screws (1).

Raise the battery cover (2).

Dry the upper face of the battery.

WARNING
Fig. 25 Battery box Use protective goggles. The battery con-
1. Quick-release screws tains corrosive acid. In the event of con-
2. Battery cover tact, rinse with water.
3. Battery

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 EVERY 250 OPERATING HOURS (Monthly)

Battery cell
Remove the cell covers and check that the fluid level is
about 10 mm (0.4 in) above the plates. Check the level
1 in all the cells. If the level is lower, top up to the correct
2 level with distilled water. If the ambient air temperature
is below freezing point, the engine should be run for a
while after the distilled water is added, otherwise there
is a risk that the water might freeze.
10 mm
Check that the ventilation holes in the cell covers are
3 not blocked, then refit the covers.

The cable terminals must be properly tightened and

Fig. 26 Electrolyte level in battery clean. Corroded cable connections should be cleaned
1. Cell cover and greased with alkaline Vaseline.
2. Electrolyte level CAUTION
3. Plate When removing the battery, always undo the
negative cable first.
When fitting the battery, always connect the
positive cable first.

Dispose of the old battery in the approved

environmentally suitable manner – batteries
contain toxic lead.
WARNING
When carrying out electrical welding on
the machine, disconnect the battery’s
negative cable and then all the electrical
connections leading to the alternator.

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 EVERY 500 OPERATING HOURS (Every three months)

Fuel pre-filter – Cleaning WARNING

Place the roller on a level base. The engine
3 must be switched off and the parking brake
applied for all checking and adjustments
2 on the roller unless stated otherwise.

Loosen the screw (1) and remove the bowl (2).

1
Take out the strainer (3) and clean using a non-
flammable fluid. Reinstall the strainer and the bowl.

Start the engine and check that the pre-filter does not
leak.
WARNING
Fig. 27 Engine Make sure there is adequate ventilation
1. Screw
(extraction) if the diesel engine is run in-
2. Glass bowl
3. Filter doors. Risk of carbon monoxide poisoning.

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 EVERY 1000 OPERATING HOURS (Every six months)

Hydraulic filter
– Replacement WARNING
Place the roller on a level base. The engine
2 must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Loosen the cap/breather filter (2) on top of the reservoir
to relieve any excess pressure inside.
Ensure that the breather filter (2) is not clogged, air
must have unobstructed passage through the cap in
both directions.

3 If clogged in either direction, clean with a little diesel oil

and blow with compressed air until free passage is
Fig. 28 Hydraulic reservoir assured, or replace the cap with a new one.
2. Filler cap/Breather filter WARNING
3. Sight glass Wear protective goggles when working
with compressed air.

Clean thoroughly round the hydraulic filter. Remove the

hydraulic filter (1) and scrap it. They are of the
expendable type and cannot be cleaned.
CAUTION
Ensure that the old sealing ring is not left on
1 the filter holder. Leakage may otherwise occur
between the new and the old seals.
Thoroughly clean the sealing surface of the filter holder.
Apply a thin coat of fresh hydraulic fluid on the new
filter seal.
Fig. 29 Engine compartment CAUTION

1. Hydraulic filter (x1) First, screw on until the filter seal lies against
the filter holder. Then screw a further half turn.
Do not tighten the filter too hard, which could
damage the gasket.

Start the engine and ensure that there is no leakage of

hydraulic fluid from the filter. Check the fluid level in the
sight glass (3) and top off as required.
WARNING
Ensure that ventilation (extraction) is
adequate if the engine is run indoors.
Risk of carbon monoxide poisoning.

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 EVERY 1000 OPERATING HOURS (Every six months)

Hydraulic tank – Drainage Condensate in the hydraulic reservoir is removed via

the drainage tap (1).
1 Drainage should be performed when the roller has been
standing for a long period of time, for example over-
night. Drain as follows:
Remove the plug (2).
Place a container under the tap.
2
Open the tap (1) and let any trapped condensate run out.
Shut the drainage tap.
Refit the plug.
Fig. 30 Hydraulic tank, underside
1. Drainage tap
2. Plug

Fuel tank – Drainage

Water and sediment in the fuel tank are removed via
the drainage plug in the bottom of the fuel tank.
CAUTION
Be very careful during draining. Do not drop
the plug or else all the fuel will flow out.

Drainage should be performed when the roller has been

standing 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 with

1
this side somewhat lower, so that water and sediment
will gather near the drainage plug (1). Drain as follows:
Fig. 31 Fuel tank
1. Drainage plug Place a container under the plug (1).

Undo the plug and drain off the water and sediment until
only clean diesel fuel appears through the plug opening.
Air filter – Replacement Refit the plug.

Replace the main filter (3) of the air cleaner even if it

2 3
has not yet been cleaned five times, see under 50
hours for filter replacement.

1 4 5

Fig. 32 Air cleaner

1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing

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 EVERY 1000 OPERATING HOURS (Every six months)

Rear axle differential

– Oil change WARNING
Never work under the roller with the engi-
ne running. Park on a level surface and
block the wheels securely.

Wipe clean and remove the level/filler plug (1) and all
three drain plugs (2), and drain the oil into a suitable
1 receptacle. The volume is about 7 quarts.

Save the oil and deposit it in an approved

manner.

2 Refit the drainage plugs and top up with fresh oil until
the correct level is reached.
Fig. 33 Rear axle
1. Oil level/Filler plug Note: It takes a while for the oil to flow into the axle. Do
2. Drainage plugs not fill the entire volume all at once.
Refit the oil-level/filler plug. Use transmission oil, see
the lubrication specification.

Rear axle planetary gears

– Oil change
Position the roller with the plug (1) at its lowest position.

Wipe clean, unscrew the plug (1) and drain the oil into a
suitable receptacle. The volume is about 1 litre (1.1 qts).

Save the oil and deposit it in an approved

manner.

Fig. 34 Planetary gear/drainage position

1. Plug

Position the roller with the plug at 9 o’clock.

Fill with oil to lower edge of level hole. Use transmis-

sion oil. See lubricant specification.

Clean and screw in the plug. Use transmission oil. See

1 lubricant specification.

Change oil in the same way in the other planetary

gears of the rear axle.

Fig. 35 Planetary gear/filling position

1. Plug

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 EVERY 2000 OPERATING HOURS (Every year)

Hydraulic tank
– Fluid change
WARNING
Place the roller on a level surface. Switch the
1
engine off and push in the reserve/parking
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
WARNING
Danger of being burned when draining hot
oil. 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).

2 A suitable container may be an empty oil drum or sim-

ilar item which is placed beside the roller. The fluid then
Fig. 36 Hydraulic tank, underside runs in a hose from the drainage plug (1) to the oil
1. Drainage tap
drum, after the plug (2) has been removed and the tap
2. Plug
opened.

Save the oil and deposit it in an approved

manner.

Fill with fresh hydraulic fluid according to instructions

under the heading ”Hydraulic reservoir—checking the
level”. Change the hydraulic filter at the same time

Start the diesel engine and operate the various hydrau-

lic functions.
WARNING
Make sure there is adequate ventilation
(extraction) if the diesel engine is run
indoors.
(Risk of carbon monoxide poisoning)

Check the fluid level and top up if necessary.

Drum – Changing the Oil
3 Place the roller on a level surface so that the drain plug
(1) is straight down and place a receptacle that will hold
at least 15 liters under the plug.

Save the oil and deposit it in an approved

manner.

Clean and unscrew the plug (1). Allow all of the oil to
drain off. Fill with oil according to “Drum—checking the
oil level”.
2 1
WARNING
There is danger of being scalded when
Fig. 37 Drum, right side draining hot oil. Protect your hands.
1. Drain/Filler plug
2. Number plate
3. Sight glass

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 EVERY 2000 OPERATING HOURS (Every year)

Steering joint – Check

Inspect the steering joint to detect any damage or
cracks.

Check and correct any loose bolts.

Check also for any stiffness and play.

Fig. 38 Steering joint

Controls and pivoted joints

– Lubrication
Lubricate the forward/reverse control mechanism.
Unscrew the two screws (2) and take off the protective
cover (1). Oil the mechanism.

Refit the protective cover.

2
1

Fig. 39 Operator’s station

1. Protective cover
2. Screws (x2)

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 LONG-TERM STORAGE

CAUTION
For long-term storage (longer than one month),
the following instructions should be followed.

These instructions apply for storage lasting up

to 6 months.

Before re-commissioning the roller, the points

marked with an asterisk * must be restored.

Fig. 40 Protecting the roller from the

elements

Diesel engine * See the manufacturer’s instructions in the engine

instruction manual, which is supplied together with
the roller.

Battery * Remove the battery from the roller, clean it’s

exterior, check its electrolyte level and recharge it
once a month.

Air cleaner, exhaust pipe * Cover the air cleaner or its opening with plastic or
tape, and cover also the exhaust pipe’s opening.
This is done so as to prevent moisture from
penetrating into the engine.

Fuel tank Fill the fuel tank completely to prevent condensation.

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

Steering cylinder, hinges etc. Lubricate the steering joint bearings and the steering
cylinder’s two bearings with grease.
Grease the steering cylinder’s piston with
conservation grease.
Grease also the engine compartment cover’s hin-
ges, the seat slide rails, the engine-speed control
and the forward/reverse control mechanism.

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

Covers, tarpaulin * Place the instrument cover on the steering column.

Cover the entire machine with a tarpaulin, which
should hand some way off the ground. If possible,
store the roller indoors, preferably in a building with a
uniform temperature.

CA 150 M150EN2 27

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 SPECIAL INSTRUCTIONS

Standard lubricants and other Upon delivery from the factory, the various systems
recommended oils and components are filled with the oils specified see
lubricant specification and they can be used at ambient
temperatures from -10°C to +40°C (14°F - 104°F).
CAUTION
A maximum temperature of +35°C (95°F)
applies for biological hydraulic fluid.

When operating in hotter ambient temperatures, but up

to max. +50°C (122°F), the following instructions apply:

Higher ambient temperature The diesel engine can handle this temperature with the
max. +50°C (122°F) standard oil, but the following oils must be used in the
other components:
Hydraulic system with mineral fluid: Shell Tellus TX100
or corresponding.
Other components using transmission oil:
Shell Spirax HD 85W/140 or corresponding.

Temperatures The temperature limits apply for a roller with standard

features.

Rollers with extra equipment such as noise suppress-

ers etc. may require additional attention at the upper
temperatures.
CAUTION

High-pressure washing When washing the machine, do not direct the

jet of water directly at the fuel or hydraulic fluid
tank covers. This is particularly important
when using a high-pressure washing unit.

Do not spray water directly on electric components or

the instrument panel. Put a plastic bag over the filler
cap of the fuel tank and secure with a rubber band.
This will prevent water from entering the venting hole in
the filler cap. This could otherwise cause operational
disturbance, for example, a clogged filter.

Extinguishing fires If there is a fire in or on the machine, it is best to use an

ABE-class fire extinguisher. However, a BE-class CO2
extinguisher is also suitable.

If the roller is equipped with a protective structure

ROPS, protective cab (ROPS, Roll Over Protective Structure), or protective
cab, never subject the structure or cab to welding or
drilling. Never attempt to repair a damaged structure or
cab; they must be replaced with new ones.

Starting assistance When an auxiliary starter battery is used, always

connect the positive terminal on the auxiliary battery to
the positive terminal on the roller’s battery, and
negative to negative.

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 ELECTRICAL SYSTEM, FUSES

Fuses and relays

The electrical regulating and control system is
1
protected by fuses and relays. The number depends on
how much additional equipment the machine is
prepared for.

The two fuse boxes (3, 4) and the relays (5, 6, 7, 8) are
located behind the lower instrument plate, which is
2 2 removed by unscrewing the screws (1 and 2).

The machine is equipped with a 12 V electrical system

and an alternator.
WARNING
Connect the battery to the correct polarity
(– to ground). The cable between battery
and alternator must not be disconnected
when the engine is running.
Fig. 41 Instrument panel
1. Screws (x2)
2. Screws (x8)

3 4

5 6 7 8

Fig. 42 Instrument panel

3,4. Fuse box
5. VBS relay
6. Main relay
7. Hourmeter relay
8. Lights relay

= Optional

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 ELECTRICAL SYSTEM, FUSES

Fuses
Fig. 43 shows the rating and function of the different
fuses. All fuses are flat pin fuses.
1

Fig. 43 Fuse box, left side

7.5A 1. Hourmeter
7.5A 2. VBS relay
7.5A 3. Warning lamp
7.5A 4. Horn
7.5A 5. Fuel gauge
10A 6. Front wiper, cab

Fuse box, right side

7.5A 1. High/Low gear
3A 2. Compaction meter
7.5A 3. Hazard beacon
3A 4. Reversing alarm
20A 5. Working lights
20A 6. Working lights

= Optional

Main fuses
3 2 1 The main fuse (1) is located behind the battery
disconnecter. The fuse a flat pin fuse. The fuel solenoid
relay (2) and the start relay (3) are also fitted here.

Main fuse 30 A (Green)

Fig. 44 Engine compartment

1. Main fuse
2. Fuel solenoid relay
3. Start relay

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