chapter 18 cleaning instructions – rollers general · 2020. 5. 20. · uncontrolled if printed...

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18-1

ADF Force Extraction Cleaning Manual

CHAPTER 18

CLEANING INSTRUCTIONS – ROLLERS GENERAL

18.1 This chapter provides basic cleaning requirements for selected vehicles. Where there is a specific requirement or need to highlight particular problem areas detailed cleaning guides are provided as tables and figures or as Annexes in this chapter.

18.2 Rollers/compactors are very complex pieces of machinery and while all contamination and BRM must be removed, the main areas of concern are:

a. external areas;

b. cabin;

c. engine bay;

d. wheels, rims, suspension and rollers;

e. other high risk areas;

f. tyres (new, old and spares).

18.3 All points are not specific to all rollers.

External Areas

18.4 The cleaning instructions for a roller’s external areas include the points detailed in Table 18-1.

Table 18–1: Cleaning Instructions for a Roller’s External Areas

Serial Comments or Tasks Technical Time (hours)

1 All CES is to be removed and independently cleaned. Where possible/practical do not refit until after the vehicle has been inspected by DA.

2 Lights are to be loosened and cleaned and any damaged lights are to be removed to allow cleaning of the fitting to ensure there is no soil, plant or insect matter.

3 Access panels and rock guards are to be removed and the track area cleaned of all soil, plant and insect matter with high-pressure water.

4 Remove floor panels and machine body access plates (if applicable) from underside of machine.

0.5

5 Clean areas on top of transmission and underneath the engine to remove dirt and dust that has accumulated in the body of the machine.

6 Pressure-wash the exterior of the vehicle to remove all dust and dirt.

7 The chassis is to be cleaned using flexible nozzle high-pressure water cleaning equipment. Particular attention is to be paid to small apertures which may act as reservoirs for soil, insect, snails and plant material. Additionally, check that no animals are hiding or nesting within the


18-2



chassis.

8 Mounting points are to be disconnected, if necessary, to facilitate cleaning.

1.0

9 Hydraulic lines are to be wiped clean of all soil and fluid. Cable conduit is to be cleaned with high-pressure water or removed.

0.1

10 Hydraulic hose guards and hydraulic cylinder mounting points are to be cleaned with high-pressure water.

11 Toolboxes/stowage compartments are to be emptied and cleaned. The rubber seals around the doors are to be inspected to ensure all soil, plant and insect matter is removed.

0.5

12 Refer bellow for detailed cleaning guidelines for tyres and wheels.

Cabin

18.5 The cleaning instructions for a roller’s cabin include the points detailed in Table 18-2.

Table 18–2: Cleaning Instructions for the Roller’s Cabin


1 Remove any rubber floor mats and clean floor surface.

2 Remove and clean all door rubbers, internal door panelling and clean all windowsills (if applicable).

3 Clean behind the dash lining/panelling. Access will be required for inspection.

4 Remove and clean under the seat, including the rubber seat shroud.

5 Remove rubber pedal covers and clean.

6 Remove any non-affixed floor panel if applicable and clean underneath.


8 Clean behind all cabin walls lining/panelling. Access will be required for inspection (if applicable).

9 All air-conditioning vents must be internally cleaned. Access will be required for inspection (if applicable).

10 Clean inside all joystick controls. Access will be required for inspection.

11 Check cleanliness of cabin roof, both inside and out.

12 Clean ladder to cabin (may have hollow frame) and under each footstep.

13 Internally clean all light covers. Access will be required for inspection.

14 Empty windscreen reservoir (if applicable).

15 Check for false floor under cabin and remove for cleaning, if applicable.

16 Check if the vertical cabin housing can be flushed via drainage holes. (If applicable).

17 Clean around roll over protection support structure.


18-3


Engine Bay

18.6 The cleaning instructions for a roller’s engine bay include the points detailed in Table 18-3.

Table 18–3: Cleaning Instructions for the Roller’s Engine Bay


1 Remove air-filter pre-cleaner cover and clean.

2 Remove air-filter and clean with air.

3 Clean inside fan-belt flywheels (harmonic balancer).

4 Check all surfaces of engine block including between tappet covers.

5 Remove belly plates if applicable and clean.

6 Remove all non-affixed engine covers to allow access for cleaning and inspection.

7 Remove all engine cover rubbers for cleaning and inspection.

8 Check engine housing for open-ended or spot-welded hollow support framework - flush to verify cleanliness.

9 Chassis rails either side of engine are hollow and maybe flushed via drainage holes on underside of the rail (Access maybe available once belly plate bolts have been removed).

10 Flush radiator and oil cooler from both sides to verify fin/core cleanliness.

11 Loosen radiator shroud to let any loose debris fall through after flushing.

12 Check battery boxes for cleanliness. Loosen batteries and clean under.

13 Check either side of radiator for vertical hollow support structures. Flush to verify internal cleanliness if present.

14 Check all wiring harnesses for internal cleanliness.

15 Check under all hydraulic looming for cleanliness.

16 Ensure all engine mounts are clean.

17 Ensure that all surfaces of sump and engine block is clean.

18 All water reservoirs must be emptied (excluding radiator).

19 Remove all contaminated grease from universal joints.


21 Removing zip-ties and electrical tape that hold electric and process hydraulic hoses together can facilitate the cleaning and inspection

22 Check above the sway bar – for cleanliness.

23 Flush under all checker-plate (non-slip footings) to ensure clean

Wheels, Rims, Suspension and Rollers

18.7 The cleaning instructions for a roller’s wheels, rims, suspension and rollers include the points detailed in Table 18-4.


18-4


Table 18–4: Cleaning Instructions for the Roller’s Wheels, Rims, Suspension and Rollers


1 Check the internals of each cleat/boot on each wheel drum – generally these boots are only spot-welded or hollow with access points.

2 Inside wheel rims may require plates to be removed to access brake drums - remove and clean thoroughly.

3 Not completely sealed (only spot welded) boots create small recesses, allowing contaminants inside the hollow cavity. These will require further investigation to verify cleanliness. Flushing via the small recess with a pin jet will not suffice in removing contamination or verifying internal cleanliness.

4 There may be evidence on some drums of repair (old welding tracks present). In this instance, the internal cleanliness of these drums will also be required.

5 The outside of the roller rim. Check that all countersunk holes and around each nut is free of contamination.

6 Check all surfaces of the rim for any cracks, splits or evidence of repair. Repair seams will require flushing to verify cleanliness.

7 Ensure that top of the axels around each nut and the undulating surfaces inside the rim are free of contamination.

8 Mud and other debris collect in the inside area on the inner side of the wheel. Ensure that this area is cleaned well.

9 Ensure suspension rocker beam mounts on chassis are clean and free of soil, plant and insect material.

10 Mud and other debris collect in the spring seat, where the spring is mounted to the axle assembly, and are difficult to remove from the base of the springs. Ensure that this area is cleaned well.

11 Ensure axles and mounts on chassis are clean and free of soil, plant and insect material.

Other High Risk Areas

18.8 Cleaning instructions for a roller’s other high risk areas include the points detailed in Table 18-5.

Table 18–5: Cleaning Instructions for the Roller’s Other High Risk Areas


1 Check all surfaces of oil tank (generally located near the ladder to cabin) to ensure clean.

2 Check all surfaces of fuel cell to ensure clean.

3 Clean under all non-slip checker-plate surfaces.

4 Flush under all checker-plate (non-slip footings) to ensure clean

5 Check the internal of all light covers & cavities behind.

6 Check all wheel arches for hollow support framework – may also have to loosen from chassis to clean where arch joins frame.


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7 Rear drawbar generally hollow – remove towing pin and flush hollow drawbar if applicable.

8 Remove all contaminated grease on the machine, including around pivot points.

Tyres (New, Old and Spares)

18.9 The cleaning instructions for Tyres (New, Old and Spares) include the points detailed in Table 18-6.

Table 18–6: Cleaning Instructions for Tyres (New, Old and Spares)


1 All tyres are to be washed and scrubbed to remove all BRM.

2 Damaged tyres are to be inspected and their suitability for return to Australia determined. If necessary, damaged tyres (for example, perished, cracked or split) are to be removed and disposed of in accordance with the tyre disposal policy.

3 Cracked tyres have the risk of containing BRM therefore perished tyres are to be subject to disposal.

4 All tyres are to be treated with an approved residual insecticide after cleaning.

5 Fitted tyres that are damaged should be replaced with new tyres.

6 Used and fitted tyres on rims are to be individually verified that the tyres are on rims, inflated with beading sealed and that the tyres are clean, free of water and other BRM.

7 Tyres that are not fitted to rims are to be stored in such a manner that water cannot collect inside the tyre. The preferred DA solution is that tyres are stored within containers. Tyres not fitted on rims will require fumigation on return to Australia.

8 DA considers a Non-Commercial consignment of tyres to contain a maximum of 8 tyres (inclusive of the wheels on the vehicle) and be imported with an accompanying vehicle. If tyres are to be transported back to Australia in containers or crates, please refer to the DA BICON (Biosecurity Import Conditions system) internet site (http://www.agriculture.gov.au/import/online-services/bicon) for the commodity “tyres”.

Annexes:

A. Cleaning Instructions - Caterpillar CS-563D Roller B. Cleaning Instructions - Ingoersol Rand Self Propelled SP56 Roller C. Cleaning Instructions - BOMAG Roller D. Cleaning Checklist - Rollers


18A - 1


ANNEX A TO CHAPTER 18

CLEANING INSTRUCTIONS – CATERPILLAR CS-563D ROLLER

1. This annex provides basic and specific cleaning requirements for selected vehicles. Where there is a specific requirement or need to highlight particular problem areas detailed cleaning guides are provided as tables and figures in this annex.

2. The cleaning requirements that follow are in addition to those points for rollers included in Chapter 18 of this publication.

3. The operator is required to be with the vehicle while cleaning to pivot the vehicle to facilitate cleaning.

External Areas

4. The cleaning instructions for the Caterpillar CS-563D Roller’s external areas as illustrated in Figures 18A-1 and 18A-2, include the points detailed in Table 18A-1

Figure 18A-1; Caterpillar CS-563D Roller with Dimple Roller


18A - 2


Figure 18A-2; Caterpillar CS-563D Roller with Flat Roller

Table 18A-1: Cleaning Instructions for the Caterpillar CS-563D Roller’s External Areas


1 Remove the panels and clean the engine bay area, including items around the bay area such as the horns.

2 Clean the roller attachments including the internal areas. If necessary, remove them so that the attachment points can be cleaned using high-pressure water. The cleaning bar is to be removed for cleaning.

3 Wipe down all electrical and hydraulic lines paying attention to the conduit areas that may require removal to facilitate cleaning.

4 Clean the articulated area of the vehicle using degreaser and high-pressure water.

5 Tyres are to be inspected for damage and damaged tyres are to be removed for disposal.

6 Refer to Chapter 18 for detailed cleaning guidelines.

Cabin

5. The cleaning instructions for the Caterpillar CS-563D Roller’s cabin as illustrated in Figures 18A-3 to 18A-5, include the points detailed in Table 18A-2


18A - 3


Figure 18A-3; Caterpillar CS-563D Roller’s Seat and Steering Consul

Figure 18A-4; Caterpillar CS-563D Roller’s Seat

Figure 18A-5; Caterpillar CS-563D Roller’s Consul


18A - 4


Table 18A-2: Cleaning Instructions for the Caterpillar CS-563D Roller’s Cabin


1 Remove and clean under the seat, including the rubber seat shroud.



18B - 1


ANNEX B TO CHAPTER 18

CLEANING INSTRUCTIONS – INGOERSOL RAND SELF

PROPELLED SP56 ROLLER



External Areas

3. The cleaning instructions for the Ingoersol Rand Self Propelled SP56 Roller external areas, as illustrated in Figures 18B-1 and 18B-2, include the points detailed in Table 18B-1.

Figure 18–1: Ingoersol Rand Self Propelled SP56 Roller’s Dimple Roller


18B - 2


Figure 18–2: Ingoersol Rand Self Propelled SP56 Roller’s Flat Roller

Table 18–1: Cleaning Instructions for the SP56 Roller’s External Areas


1

Clean the roller attachments including the internal areas. If necessary, remove them so that the attachment points can be cleaned using high-pressure water.

0.5

2 Clean ladder to cabin (may have hollow frame) and under each footstep.


Cabin

4. The cleaning instructions for the SP56 roller’s cabin, as illustrated in Figures 18B-3 to 18B-5, include the points detailed in Table 18B-2.


18B - 3


Figure 18B–3: SP56 Roller’s Front and Cabin Area

Figure 18B-4: SP56 Roller’s Toolboxes


18B - 4


Figure 18B-5: SP56 Roller’s Toolboxes

Table 18B–2: Cleaning Instructions for the SP56 Roller’s Cabin


1 Remove and clean under the seat, including the rubber seat shroud (refer Fig 18B-4).


3 Clean inside all joystick controls. Access will be required for inspection.



6 Empty and clean tool boxes and tool box contents (refer Fig 18B-5).

7 Clean around roll over protection support structure.


Engine Bay

5. The cleaning instructions for SP56 Roller’s Engine Bay, as illustrated in Figures 18B-6 to 18B-9, include the points detailed in Table 18B-3.

Figure 18B–6: SP56 Roller’s Engine Bay


18B - 5


Figure 18B–7: SP56 Roller’s Engine and Radiator Fan

Figure 18B–8: SP56 Roller’s Battery Bay

Figure 18B–9: SP56 Roller’s Hydraulics and Hydraulic Looming


18B - 6


Table 18B–3: Cleaning Instructions for the SP56 Roller’s Engine Bay


1 Clean all areas of the engine bay and radiator (refer Figures 18B-6 and Fig 18B-7)

2 Check battery boxes for cleanliness. Loosen batteries and clean … under (refer Fig 18B-8).

3 Check and clean all hydraulics and hydraulic looming (refer Fig 18B-9).



6. The cleaning instructions for the SP56 roller’s wheels, rims, suspension and rollers, as illustrated in Figure 18B-10, include the points detailed in Table 18B-4.

Figure 18B–2: SP56 Roller’s Suspension

Table 18B–4: Cleaning Instructions for the SP56 Roller’s Wheels, Rims, Suspension and Rollers




18C - 1


ANNEX C TO CHAPTER 18

CLEANING INSTRUCTIONS – BOMAG ROLLER



External Areas

3. The cleaning instructions for the Bomag Roller’s external areas, as illustrated in Figures 18C-1 to 18C-3, include the points detailed in Table 18C-1.

Figure 18C–1: BOMAG Roller’s with Dimple Roller’s External Areas

Figure 18C–2: BOMAG Roller’s with Smooth Roller’s External Areas


18C - 2


Figure 18C–3: BOMAG Roller’s with Dimple and Smooth Roller

Table 18C–1: Cleaning Instructions for the Bomag Roller’s External Areas



Cabin

4. The cleaning instructions for the BOMAG roller’s cabin, as illustrated in Figures 18C-4 to 18C-6, include the points detailed in Table 18C-2.

Figure 18C–4: BOMAG Roller’s Cabin Seat


18C - 3


Figure 18C-5: BOMAG Roller’s Instrument Panel

Figure 18C-6: BOMAG Roller’s Instrument Panel Underneath Area

Table 18C–2: Cleaning Instructions for the BOMAG Roller’s Cabin


1 Remove and clean under the seat, including the rubber seat shroud (refer Figure 18C-4).


3 Clean all instrument panel and joystick controls. Access will be required for inspection (refer Figure 18C-4).



Engine Bay

5. The cleaning instructions for Bomag Roller’s Engine Bay, as illustrated in Figures 18C-7 to 18C-12, include the points detailed in Table 18C-3.


18C - 4


Figure 18C–7: BOMAG Roller’s Engine Bay

Figure 18C–8: BOMAG Roller’s Engine

Figure 18C–9: BOMAG Roller’s Battery Compartment


18C - 5


Figure 18C–10: BOMAG Roller’s Battery Bay

Figure 18C–11: BOMAG Roller’s Battery Compartment Extractor Fan

Figure 18C–12: BOMAG Roller’s Hydraulics


18C - 6


Table 18C–3: Cleaning Instructions for the BOMAG Roller’s Engine Bay


1 Clean all areas of the engine bay and radiator (refer Figures 18C-7 and 18C-7)

2 Check battery boxes for cleanliness. Loosen battery and clean battery and cradle (refer Figures 18C-9 and 18C-10).

3 Clean the extractor fan located within the battery compartment above the battery (refer Figures 18C-9 to 18C-11)

4 Check and clean all hydraulics and hydraulic looming (refer Figure 18C-12).



6. The cleaning instructions for the BOMAG roller’s wheels, rims, suspension and rollers, as illustrated in Figure 18C-13, include the points detailed in Table 18C-4.

Figure 18C–23: BOMAG Roller’s Hydraulics and Suspension

Table 18C–4: Cleaning Instructions for the BOMAG Roller’s Wheels, Rims, Suspension and Rollers




18D - 1


ANNEX D TO CHAPTER 18

CLEANING CHECKLIST – ROLLERS

All serials may not specific to all Rollers

Vehicle Registration No: ……………………………….

Serial

Description

Tick

External Areas

1 All CES is to be removed and independently cleaned.

2 All lights and fittings have been loosened and cleaned.

3 All access panels and rock guards have been removed and cleaned.

4 All floor panels and machine body access plates (if applicable).

5 The top of transmission and underneath the engine has been cleaned.

6 The exterior of the vehicle has been cleaned.

7 The chassis has been cleaned.

8 All mounting points have been cleaned.

9 All hydraulic lines have been wiped clean.

10 All hydraulic hose guards and hydraulic cylinder mounting points have been cleaned.

Cabin

1 Rubber floor mats removed and floor surface cleaned.

2 All door rubbers, internal door panelling and all windowsills cleaned.

3 Seat (including the rubber seat shroud) remove and cleaned.

4 Non-affixed floor panels removed and cleaned.

5 Rubber pedal covers removed and cleaned.

6 Cabin wall lining/panelling removed and cleaned.


18D - 2


Serial

Description

Tick

7 All air-conditioning vents internally cleaned.

8 All joystick controls cleaned.

9 Cabin roof, cleaned both inside and out.

10 Ladder to cabin (may have hollow frame) and under each footstep cleaned.

11 All light covers removed and cleaned internally.

12 Windscreen reservoir emptied.

13 False floor under cabin removed and cleaned.

14 Vertical cabin housing flushed via drainage holes.

15 Roll over protection support structure cleaned.

Engine Bay

1 Air-filter pre-cleaner cover removed and cleaned.

2 Air-filter removed and cleaned with air.

3 Inside of fan-belt flywheels (harmonic balancer) cleaned.

4 Surfaces of engine block including between tappet covers cleaned.

5 All belly plates removed and cleaned.

6 All non-affixed engine covers removed for cleaning and inspection.

7 All engine cover rubbers removed and cleaned.

8 Engine housing checked for open-ended or spot-welded hollow support framework and flushed.

9 Hollow chassis rails either side of engine flushed via drainage holes on underside of the rail.

10 Radiator and oil cooler from flushed both sides to verify fin/core cleanliness.

11 Loosen radiator shroud loosened and loose debris cleaned after flushing.

12 Battery boxes checked for cleanliness with batteries loosened and cleaned under.


18D - 3


Serial

Description

Tick

13 Either side of radiator checked for vertical hollow support structures and flushed to verify internal cleanliness.

14 All wiring harnesses checked for internal cleanliness.

15 All hydraulic looming checked underneath for cleanliness.

16 All engine mounts are cleaned.

17 All surfaces of sump and engine block cleaned.

18 All water reservoirs (excluding radiator) emptied.

19 All contaminated grease from universal joints removed and cleaned.

20 All light covers internally cleaned.

21 All zip-ties and electrical tape that hold electric and process hydraulic hoses together removed and cleaned.


1 The internals of each cleat/boot on each wheel drum have been cleaned.

2 Inside wheel rims have been cleaned.

3 The outside of the Compactor rim has been cleaned.

4 All cracks, splits or evidence of repaired surfaces of the rim have been cleaned.

5 The top of the axels around each nut and the undulating surfaces inside the rim have been cleaned.

6 Axles and mounts on chassis have been cleaned.

7 Suspension rocker beam mounts on chassis have been cleaned.

8 Mud and other debris collect in the spring seat, where the spring is mounted to the axle assembly, have been cleaned.

9 Mud and other debris on the inner side of the wheel have been cleaned.

Other High Risk Areas

1 Check battery box – loosen batteries and clean under.

2 Check all surfaces of oil tank (generally located near the ladder to cabin) to ensure clean.

3 Check all surfaces of fuel cell to ensure clean.


18D - 4


Serial

Description

Tick

4 Clean under all non-slip checker-plate surfaces.

5 Flush under all checker-plate (non-slip footings) to ensure clean.

6 Check the internal of all light covers & cavities behind.

7 Check all wheel arches for hollow support framework – may also have to loosen from chassis to clean where arch joins frame.

8 Rear drawbar generally hollow – remove towing pin and flush hollow drawbar if applicable.

9 Remove all contaminated grease on the machine, including around pivot points.

Tyres (New, Old and Spares)

1 All tyres have been washed and scrubbed to remove all BRM.

2 Cracked/ perished tyres have been assessed for disposal.

3 All tyres have been treated with an approved residual insecticide after cleaning.

4 All fitted tyres that were damaged have been replaced with new tyres.

5 Used and fitted tyres on rims have been individually verified that the tyres are on rims, are inflated with beading sealed and that the tyres are clean, free of water and other BRM.

6 Tyres not fitted to rims have been stored in such a manner that water has not collected inside the tyre.

7 The consignment contains a maximum of 8 tyres and is to be imported with an accompanying vehicle

or

The consignment contains more than a maximum of 8 tyres and will not be imported with an accompanying vehicle.

(Delete whichever is not applicable)

Signed ………………………………………. Date: ………………….

Name: ………………………………………

chapter 18 cleaning instructions – rollers general · 2020. 5. 20. · uncontrolled if printed...

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