5. INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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6. INTRODUCTION
Safety rules
Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to
safeguard your safety and personal integrity.
Your safety and that of the people around you depends on you.
It is essential that you understand this manual for a correct inspection, lubrication and repair of this machine.
Read this manual carefully and check that:
• You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.
• You understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any
doubt, consult your Dealer.
The safety messages in this section concern situations which may arise during normal machine operation, servicing
and repair. These safety messages also indicate the different ways of coping with these situations. Other safety
messages are used throughout the manual to indicate specific dangers.
The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you
from observing traffic regulations or the requirements of insurance companies.
The presence of grease, oil, mud or (in winter) ice on the
steps and access handles can cause accidents. Make
sure they are always clean.
When mounting or dismounting from the machine always
face the machine and use the steps and access handles
on the left-hand side of the machine.
LELI12TLB0048AB 1
Wear close fitting clothing and safety equipment
appropriate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If the environment conditions make it necessary, the
following personal safety equipment should be at hand:
• Respirators (or dustproof masks)
• Ear plugs or acoustic ears protections
• Goggles with lateral shield or masks for eyes protection
Do not wear rings, wristwatches, jewels, unbuttoned or
flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught into
moving parts.
Any functional disorders, especially those affecting the
safety of the machine, should therefore be rectified im-
mediately.
LELI12TLB0049AB 2
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7. INTRODUCTION
Make sure that you fully understand the symbols of the
safety decals applied on the machine. Make sure that
they are always clean and perfectly legible.
Be prepared for emergencies.
Always keep a first aid kit and a fire extinguisher close at
hand on the machine.
Make sure that the fire extinguisher is serviced in accor-
dance with the manufacturer’s instructions.
LELI12TLB0050AB 3
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8. INTRODUCTION
Product identification
PTIL17COM0094GB 1
1. Hydraulic oil filters 14. Steering cylinder
2. Vibration pump 15. Hydraulic oil cooler
3. Travel pump 16. Steering unit
4. Engine 17. Radiator
5. Articulation Joint 18. Vibration motor
6. Front roller drum 19. Operators seat
7. Front travel motor 20. Steering pump
8. Scraper 21. Rear tank
9. Sprinkler tube 22. Battery
10. Front exciter shaft 23. Rear exciter shaft
11. Front roller frame 24. Rear travel motor
12. Elastic suspension 25. Rear chassis
13. Front tank 26. Rear roller drum
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11. Engine - Engine and crankcase
Engine and crankcase - Service instruction
The S8000 series of engine is a vertical, water cooled,
direct Injection, with rotary pump compression ignition,
4 cylinder engine. The standard direction of rotation
is anti-clockwise when looking from the flywheel end.
Cylinders are numbered ascending from the radiator
end, with first cylinder being nearest to the cooling fan.
The engine has an integral block and crank case for
rigidity and a single piece cylinder head unit covering
all cylinders, with replaceable valve seat inserts. Each
cylinder has two valves, one inlet and one exhaust. The
valve nearest to the cooling fan is the exhaust valve fol-
lowed inlet valve. This sequence of valves continues
uniformly for all cylinders
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12. Engine - Engine and crankcase
Engine and crankcase - Remove
1. Remove the hood, see the Engine shields, hood
latches, and trims - Remove - Hood Removal
(90.102).
2. Remove the cooling pack. See the Engine cooling
system - Remove - Cooling pack (10.400).
3. Loosen and remove the thermostat mounting hose con-
nections and cap the openings.
4. Swing the hoses clear of the engine (1).
5. Disconnect the alternator connections. See the Alter-
nator - Remove (55.301).
6. Disconnect the engine oil pressure sensor connection.
7. Loosen the clamp and remove the silencer assembly.
See the Exhaust pipes - Remove (10.254)
8. All the hydraulic and oil connector openings to be cov-
ered properly to avoid entry of dust.
9. Disconnect the clog indicator connection and remove
the air filter assembly with housing and pipes to intake
manifold. See the Air pre-cleaner - Exploded view
(10.202)
10. Disconnect all the starter connections. See the En-
gine starter - Remove (55.201) .
11. Remove the travel and vibration pumps. See the
Pump - Remove - Travel pump (29.218).
12. Lift the pump and set it aside.
13. Remove the hydraulic filter assembly.
14. Loosen the bolts (2) and remove the adapter (1) from
the engine bell housing.
PTIL16TLB0324AB 1
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13. Engine - Engine and crankcase
15. Loosen the bolts (2) and remove the coupling (1) from
the flywheel.
PTIL16TLB0325AB 2
16. Disconnect the hydraulic lines (1) at the steering pump
end and cap the openings. Set the hose aside.
PTIL14COM1364AB 3
17. Disconnect the fuel hoses from the fuel tank to mud
filter and cap them.
18. Disconnect the fuel hose from filter to engine and to
mud filter and cap them.
19. Disconnect the emergency stop switch.
20. Disconnect the throttle cable at the pump end and
clear the cable from the engine.
21. Connect a suitable lifting device to the engine.
22. Loosen and remove the bolts (1) with washer (2).
23. Loosen and remove the bolts (3) with washer (4).
NOTE: The bolt (5) is different from other bolts on the
mounting bracket and has an additional alternator bracket
spacer (6). Put an identification tag on the bolt and make
sure to install the bolt in same location while mounting the
engine.
PTIL18COM0019AA 4
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14. Engine - Engine and crankcase
24. Lift the engine slowly.
25. Clear any cables or wires that may be in the way.
26. Lift the engine clear of the machine and mount on a
trolley or stand.
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15. Engine - Engine and crankcase
Engine and crankcase - Install
PTIL18COM0016GB 1
1. Place the engine on the machine by using suitable lift-
ing device.
2. Tighten the mounting bolts (1) with washer (2) to a
torque of 115 – 125 N·m.
3. Tighten the mounting bolts (3) with washers (4) and (5)
to a torque of 110 – 120 N·m.
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16. Engine - Engine and crankcase
4. Torque the mounting bolt (6) to 115 – 125 N·m.
NOTE: The mounting bolt (6) is different from other mount-
ing bolts on the same bracket and has additional alternator
bracket spacer (7).
PTIL18COM0019AA 2
NOTE: Apply anabond 121 E on bolts (2) and (4) threads from approximately middle of thread length up to end of
thread length. Allow minimum 6 h of curing time before applying the dynamic load on bolts. Before applying anabond,
clean the bolt and corresponding thread hole so that it should be free from oil and dirt.
5. Install the throttle cable at the pump end and install the
cable to the engine.
6. Install the emergency stop switch.
7. Install the fuel hose from filter to engine and to mud
filter.
8. Install the fuel hoses from the fuel tank to mud filter.
9. Clean the hose and connect the hydraulic lines (1) at
the steering pump and cap opening.
PTIL14COM1364AB 3
10. Install the coupling (1) on to the flywheel. Install the
washer and tighten the bolts (2) to a torque of 5 kgm.
PTIL16TLB0325AB 4
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18. Engine - Engine and crankcase
11. Install the adapter (1) on to the engine bell housing
and tighten the bolts (2) to a torque of 6.3 kgm.
PTIL16TLB0324AB 5
12. Install the hydraulic filter assembly.
13. Install the travel and vibration pumps.
14. Install all the starter connections. Refer Engine
starter - Install (55.201)
15. Install the air filter assembly with housing and pipes
to intake manifold and connect the clog indicator con-
nection.
16. Remove the cover from hydraulic and oil connector
openings assembly.
17. Install the silencer assembly and tighten the clamp.
18. Install the engine oil pressure sensor connection.
19. Install the alternator connections. Refer Alternator -
Install (55.301)
20. Install the thermostat mounting hose connections and
cap openings.
21. Install the cooling pack and hood.
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19. Engine - Engine and crankcase
Engine and crankcase - Disassemble - Top Engine
1. Disconnect the battery and store it in a dry place.
2. Remove the radiator fan.
3. Disconnect wiring from the alternator.
4. Remove fan belt. Discard if it is damaged.
5. Remove the alternator (1) from the engine.
PTIL16TLB0326AB 1
6. Drain out water from the radiator.
NOTE: If coolant is used, collect it in a container and use
again.
7. Drain the lubricating oil from the sump and discard the
O-ring from the drain plug.
8. Disconnect the radiator from the engine and discard the
old hoses.
9. Disconnect the air cleaner and hose assembly from the
bracket and inlet manifold. Discard the hose if it is
cracked or damaged.
10. Disconnect the exhaust pipe from the exhaust flange.
11. Follow the procedure on turbocharger,
1. Disconnect the rubber hose (1) connecting the air
cleaner to the turbocharger.
2. Disconnect the air delivery pipe with the heat shield
from the turbocharger air outlet and air inlet mani-
fold.
3. Disconnect the exhaust pipe (1) from the tur-
bocharger expansion bellow flange and discard the
joint.
4. Disconnect and remove the exhaust diffuser from
the bracket.
PTIL16TLB0333AB 2
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20. Engine - Engine and crankcase
5. Disconnect the lubrication oil inlet (1) and drain pipe
from the turbocharger.
PTIL14COM1301AB 3
PTIL14COM1357AA 4
6. Disconnect the turbocharger from the exhaust man-
ifold and discard the joint.
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![Contents
INTRODUCTION
Machine completion and equipment .............................................. 05
[05.102] Machine completion................................................................ 05.1
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.202] Air cleaners and lines .............................................................. 10.2
[10.254] Intake and exhaust manifolds and muffler ......................................... 10.3
[10.400] Engine cooling system ............................................................. 10.4
[10.310] Aftercooler.......................................................................... 10.5
[10.216] Fuel tanks .......................................................................... 10.6
Hydrostatic drive......................................................................... 29
[29.218] Pump and motor components...................................................... 29.1
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.300] Reservoir, cooler, and filters........................................................ 35.2
Frames and ballasting ................................................................. 39
[39.100] Frame .............................................................................. 39.1
[39.500] Vibratory roller...................................................................... 39.2
Steering..................................................................................... 41
[41.101] Steering control .................................................................... 41.1
[41.200] Hydraulic control components...................................................... 41.2
[41.206] Pump ............................................................................... 41.3
[41.216] Cylinders ........................................................................... 41.4
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
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