Dynapac Vibratory roller CA 602. Operation & Maintenance (2003)

Vibratory Roller

CA 602

Maintenance

M602EN2, August 2003

Diesel engine:

CA 602: Cummins QSB 5.9-C

These instructions apply from:

CA 602 PIN (S/N) *71420603*

The Dynapac CA 602 is available in D (smooth drum) and PD (padfoot) versions, of which the CA

602D is designed for compacting rock fill. The main range of application for the PD versions is on

cohesive material and weathered stone material.

All types of base courses and subbase courses can be compacted deeper and the interchangeable

drums, D to PD, and vice versa, facilitate even greater variety in the range of application.

Certain accessories, such as the compaction meter, tachograph and the CCS/RA field computer,

are described in separate instructions.

Reservation for changes.

Printed in Sweden.

CONTENTS

Page

Lubricants and symbols

Technical specifications

4-6

Maintenance schedule

Maintenance measures

8-9

Every 10 hours of operation (Daily)

10-12

Every 50 hours of operation (Weekly)

13-15

Every 250 hours of operation (Monthly)

16-20

Every 500 hours of operation (Every three months) 21-22

Every 1000 hours of operation (Every six months) . 23-25

Every 2000 hours of operation (Yearly)

26-29

Long-term storage

Special instructions

Electrical system, fuses

32-34

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.

WARNING

If the gas-springs of the hood are out of action

and the hood is put at its upper position - block

the hood so that it cannot fall.

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 inspecting the roller every day before starting

up by checking all round and underneath the machine to

detect any sign of leakage or other faults.

SPARE A THOUGHT FOR THE ENVIRONMENT! Do not

let oil, fuel and other environmentally hazardous substances

CALIFORNIA

contaminate the environment.

Proposition 65 Warning

This manual contains instructions for periodic measures that

should normally be performed by the operator.

Diesel engine exhaust and some of its

CAUTION

constituents are known to the State of

There are additional instructions relating to the diesel

engine, for which the manufacturer’s instructions are

California to cause cancer, birth defects,

detailed in the engine manual. This is found under a

and other reproductive harm.

separate flap in the roller’s product binder.

CA 602 M602EN2

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 TX68 or equivalent

-10°C - +40°C (14°F - 104°F)

ambient air temperature

Shell Tellus 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.

TRANSMISSIONSOLJA

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 CARTRIDGE OIL

Mobil SHC 629

GREASE

SKF LGHB2 (NLGI Class 2) or equivalent for the

articulated joint

Shell Retinax LX2 or equivalent for other grease points

FUEL

See the engine manual

COOLANT

GlycoShell or equivalent

mixed 50/50 with water

Anti-freeze protection down to about -41°C (-106°F).

CAUTION

Other fuel and lubricants are required for operation in

extremely high or extremely low ambient temperature. See

the “Special instructions” chapter, or consult Dynapac.

Engine, oil level

Air 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

CA 602 M602EN2

TECHNICAL SPECIFICATIONS

Weights & dimensions

CA602D

CA602PD

Operating mass with ROPS, EN500, kg (lbs)

18600 (41006)

Operating mass without ROPS, kg (lbs)

18100 (39904)

Operating mass with cab, kg (lbs)

18600 (41006)

Length, standard-equipped roller, mm (in)

6000 (236)

Width, standard-equipped roller, mm (in)

2380 (94)

Height, with ROPS, mm (in)

2929 (115)

2987 (117)

Height, without ROPS, mm (in)

2134 (84)

2208 (87)

Height, with cab, mm (in)

2952 (116)

2987 (118)

Fluid volumes, litres (gal or qts)

CA 602

Rear axle:

• Differential

12 (12.7 qts)

• Planetary gears

1,8 (1.9 qts)/each side

Drum gearbox

3,5 (3.7 qts)

Drum cartridge

2,2 (2.3 qts)/each side

Hydraulic reservoir

52 (13.7 gal)

Oil in hydraulic system

43 (11.4 gal)

Lubrication oil, diesel engine

14 (14.8 qts)

Coolant, diesel engine

26 (6.9 gal)

Fuel tank

320 (84.5 gal)

Electrical system

Battery

12 V, 170 Ah

Alternator

14 V, 105 A / 95 A

Fuses

See under heading “Electrical System”

Tires (all-weather)

Tire dimensions

23.1 x 26.0 8 Ply, 600/60-30,5

Tire pressure

110 kPa (1,1 kp/cm²) (16 psi)

WARNING

The tires can be optionally filled with fluid, (extra weight up to 700 kg/tire)

(1,544 lbs/tire). When servicing, bear this extra weight in mind.

Vibrationdata

CA602D

CA602PD

Static linear load, kg/cm (pli)

59,6 (334)

Amplitude (High), mm (in)

1,8 (0.07)

Amplitude (Low), mm (in)

1,1 (0.04)

Frequency (High/Low ampl.), Hz (vpm)

27/31 (1620/1860)

Centrifugal force

(High amplitude), kN (lb)

276 (62,100)

Centrifugal force

(Low amplitude), kN (lb)

229 (51,525)

CA 602 M602EN2

TECHNICAL SPECIFICATIONS

Tightening torque

Tightening torque in Nm (lbf.ft) for oiled, bright

galvanized bolts tightened with a torque wrench.

STRENGTH CLASS

thread

8.8

10.9

12.9

8,4 (6.2)

12 (8.9)

14,6 (10.8)

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 size:

M24 (P/N 90 39 64)

Strength class:

10.9

Tightening torque:

800 Nm (590 lbf.ft)

(for Dacromet treated)

Hydraulic system

Opening pressure, MPa (psi)

Drive system

38,0 (5,500)

Charge system

2,0 (290)

Vibration system

37,5 (5,400)

Steering system

18,0 (2,600)

Brake release

1,4 (200)

CA 602 M602EN2

TECHNICAL SPECIFICATIONS

Vibrations - Drivers seat

The vibration values are measured in conformance

(ISO 2631)

with the driving mode described in EU directive

2004/14/EC on EU equipped machines, on soft

polymer material with vibration switched ON and

the operator’s seat in transport mode.

Whole-body vibration is measured at less than the

action value of 0.5 m/s² specified in EU directive

2002/44/EC. (The limit value is 1.15 m/s².)

Hand/arm vibration is measured at less than the

action value of 2.5 m/s² specified in the same

directive. (The limit value is 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

2004/14/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

pressure level,

power level

operator’s ear

dB(A)

(platform)

(cab) dB(A)

dB(A)

CA 602

111

CAUTION

Noise level can vary when driving on different

courses and with different seat positions.

CA 602 M602EN2

MAINTENANCE SCHEDULE

24 23 22

19 36

35 34

Fig. 1

Service and maintenance points

1 Radiator grille

14 Scrapers

27 Diesel engine mountings, 4 pcs.

2 Oil level, diesel engine

15 Drum cartridge oil, level plugs, 2 pcs.

28 Feed pump, fuel

3 Fuel filter, initial fuel filter

16 Rubber elements and attachment screws

29 Diesel fuel, filler

4 Air filter

17 Steering joint

30 Battery

5 Engine cover, hinges

18 Steering cylinders, 2 pcs.

31 Radiator

6 Hydraulic fluid reservoir, sightglass

19 Flywheel casing, hydraulic pumps

32 Hydraulic fluid cooler

7 Bleeding filter

20 Wheel nuts

33 Drive belts, cooling, alternator

8 Hydraulic fluid filters (2 filters)

21 Tires, pressure

34 Steering chain

9 Drainage, hydraulic fluidreservoir

22 Rear axle, differential

35 Seat bearing

10 Hydraulic fluid, filler

23 Rear axle, planetary gears, 2 pcs.

36 Steering chain

11 Fuse-box

24 Rear axle suspension, 2 sides

37 Forward/Reverse lever

12 Drum cartridge, filling, 2 fillers

25 Oil filter, diesel engine

13 Drum gearbox

26 Drainage, fuel tank

CA 602 M602EN2

MAINTENANCE MEASURES

The periodic measures should be performed primarily

after the specified hours of operation. Use the daily,

weekly, etc. time periods only where this is not possible.

CAUTION

Remove all dirt before filling, when checking

oils and fuel, and when lubricating with oil or

grease.

CAUTION

The engine manual specifies additional service/

maintenance instructions which relate to the

diesel engine.

Every 10 hours of operation (Daily)

Item. in

Measure

See page

Comments

fig. 1

Before starting each day

Check scraper setting

Check for free circulation of cooling air

Check coolant level

See engine manual

Check diesel engine oil level

See engine manual

Top up fuel tank

Check fluid level in hydraulic reservoir

Check brakes

Every 50 hours of operation (Weekly)

Item. in

Measure

See page

Comments

fig. 1

Check that hoses and couplings are not leaking

Inspect/clean the filter element in the air cleaner 13

Replace as required

Lubricate steering joint

Lubricate steering cylinders’ attachments

Check the wheel-nuts are tightened

Check tire pressure

Inspect the air conditioning

Optional

CAUTION

After the first 50 hours of operation,

change only the drum oil and all the oil filters.

CA 602 M602EN2

MAINTENANCE MEASURES

Every 250 hours of operation (Monthly)

Item. in

Measure

See page

Comments

fig. 1

Check oil level in rear axle/planetary gearing

Check oil level in drum gearbox

Check oil level in the drum cartridge

Clean the radiators

20, 24

Re-tighten bolted joints

Applies only to new or

reconditioned component

Check rubber elements and screw fasteners

Change engine oil and oil filter

See engine manual

Check battery

Inspect the air conditioning

Optional

Every 500 hours of operation (Every three months)

Item. in

Measure

See page

Comments

fig. 1

Replace fuel filter

See engine manual

Lubricate controls and joints

Replace fuel pre-filter

Lubricate the steering chain

Optional

Lubricate the seat bearing

Optional

Every 1000 hours of operation (Every six months)

Item. in

Measure

See page

Comments

fig. 1

Change hydraulic fluid filter

Drain condensate from hydraulic reservoir

Drain condensate from fuel tank

Replace air cleaner main filter

Change oil in rear axle differential

Change oil in the rear axle planetary gearing

Replace the fresh air filter in the cab

Optional

Check diesel engine valve clearance

See engine manual

Check belt tension for drive belt system

See engine manual

Every 2000 hours of operation (Yearly)

Item. in

Measure

See page

Comments

fig. 1

9, 10

Change fluid in hydraulic reservoir

12, 15

Change oil in the drum cartridge

Change oil in drum gearbox

Lubricate Forward/Reverse control

Overhaul air conditioning

Optional

CA 602 M602EN2

EVERY 10 HOURS OF OPERATION (Daily)

Scrapers

- Checking / Adjustment

Loosen the screws (2) and adjust to 20 mm (0.8 in).

Tighten the screws.

Repeat the procedure on the other scraper.

Fig. 2

Scrapers

1. Scraper blade

2. Screws

Soft scrapers (Optional)

Loosen the screws (2) and adjust to light contact

against the drum. Tighten the screws.

Fig. 3

Scrapers

1. Scraper blade

2. Screws

Circulation of air - Inspection

Ensure that the engine has free circulation of cooling air

through the vents in the hood.

To open the engine hood, turn the locking arms upward

(1) and raise the hood to its fully open position, check-

ing that the red safety catch on the left gas spring is

latched.

WARNING

If the gas-springs of the hood are out of

action and the hood is put at its upper

position - block the hood so that it cannot

fall.

Fig. 4

Cooling vents

1. Hood lock

CA 602 M602EN2

EVERY 10 HOURS OF OPERATION (Daily)

Coolant level

- Check

Check that level of the coolant is between the max. and

min. marks.

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 page 3 in these instructions and in the engine

manual.

CAUTION

Fig. 5

Radiator

Flush the system every other year and

1. Max level

change the coolant. Ensure also that air can

2. Min level

flow unrestricted through the radiator.

3. Filler cap

Diesel engine

- Check oil level

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

Danger of burns. Take care not to touch

any hot parts of the engine or the radiator

when removing the dipstick.

The dipstick is located on the engine’s right side.

Pull up the dipstick (1) and check that the oil level is

between the upper and lower marks. For further details,

Fig. 6

Engine compartment

refer to the engine manual.

1. Oil dipstick

CA 602 M602EN2

EVERY 10 HOURS OF OPERATION (Daily)

Fuel tank - Filling

Refuel daily with diesel fuel up to the lower edge of the

filler pipe (1). Follow the engine manufacturer’s

specification with regard to the quality of diesel fuel.

WARNING

Switch off the diesel engine. Short-circuit

(press) the filler gun against a non-insula-

ted part of the roller before refuelling, and

against the filler pipe (1) while refuelling.

WARNING

Never refuel while the engine is running,

do not smoke, and avoid spilling fuel.

Fig. 7

Fuel tank

The fuel tank holds 320 liters (84.5 gal.).

1. Filler pipe

Hydraulic reservoir

- Check fluid level

Position the roller on a level surface and check that the

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.

Fig. 8

Hydraulic fluid reservoir

1. Sight glass

2. Filler pipe

Brake function - Check

WARNING

Check operation of the brakes as follows:

Drive the roller slowly forward.

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

lamp 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.

Fig. 9

Control panel

1. Reserve/parking brake knob

2. Forward/reverse lever

The roller is now ready for operation.

CA 602 M602EN2

EVERY 50 HOURS OF OPERATION (WEEKLY)

Air cleaner

- Check/clean

CAUTION

Replace or clean the air cleaner’s main filter if

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 backup filter (4).

Fig. 10

Air cleaner

1. Locking braces

2. Cover

3. Main filter

4. Backup 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 psi) pressure should be used. Blow up

and down along the paper creases on the inside 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.

Wipe the inside of the cover (2) and filter housing (5).

Fig. 11

Main filter

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

Backup filter

Once the main filter has been cleaned a

- Replacement

maximum of 5 times, it must be replaced.

Replace the backup filter with a new one at every 5th

replacement or cleaning of the main filter. The backup

filter cannot be cleaned.

When replacing the backup filter (4), pull out the old fil-

ter 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. 12 Air filter

4. Backup filter

CA 602 M602EN2

EVERY 50 HOURS OF OPERATION (Weekly)

Steering joint/Steering cylinders

- 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 befo-

re lubricating.

Turn the steering wheel fully to the left to gain access

Fig. 13 Steering joint, right side

to all lubricating nipples of the steering system on the

right-hand side of the machine (x7).

Steering joint - Lubrication

CAUTION

Use grease as per the lubricant specification.

Wipe off any dirt and grease from the nipples.

Lubricate each nipple (1, 2, and 3) with five strokes of a

manual grease gun. Check that grease penetrates

through 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. 14 Steering joint, right side

1. Lubricating nipples, steering joint (x3)

2. Lubricating nipple, steering joint

3. Lubricating nipples, cylinder mount (x1)

Steering cylinder

- Lubrication

Wipe all the nipples clean from dirt and grease.

Grease the nipples (4 and 5) with five strokes of the

hand grease gun.

Turn the steering wheel fully to the right to gain access

to the front lubricating nipple on the left steering

cylinder and the lubricating nipple on the bearing bush-

ing. Allow a little grease to remain on the nipples after

lubrication, it will prevent dirt from entering.

Fig. 15 Steering cylinder, right side

4. Lubricating nipple, rear right steering

cylinder mount (x1)

5. Lubricating nipple, rear left steering

cylinder mount (x1)

CA 602 M602EN2

EVERY 50 HOURS OF OPERATION (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.

CAUTION

When changing the tires it is important that

both of them have the same rolling radius. This

is necessary to ensure proper functioning of

the anti-slip in the rear axle.

Check the tightening torque of the wheel nuts (2) at 470

Fig. 16

Wheels

Nm (350 lbf.ft). Check both wheels and all the nuts.

1. Air valve

(Applies only to new machine or recently fitted wheels.)

2. Wheel nut

WARNING

Check the safety manual that accompanies

the roller before filling the tires with air.

WARNING

Air conditioning (Optional)

Note: The tires are filled with liquid.

- Inspection

This makes the wheels heavier than normal.

WARNING

Never work under the roller with the engi-

ne running. Park on a level surface, chock

the wheels and press the parking brake

control.

Open the engine hood while the unit is running and look

at the sight glass (1) to make sure that no bubbles are

visible on the dryer filter. The filter is located on the left

side in the front of the engine compartment. If bubbles

are visible through the sight glass, it is a sign that the

level of refrigerant is too low. If so, stop the unit. There

is a risk of damage to the unit if it is run with insufficient

Fig. 17

Drying filter

1. Sight glass

refrigerant.

Clean the condenser element (1) free from dust as

necessary.

Fig. 18

Cab

1. Condenser element

CA 602 M602EN2

EVERY 250 HOURS OF OPERATION (Monthly)

Rear axle differential

- Check oil level

WARNING

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

specification.

Fig. 19

Oil level check - differential 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.

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. 20

Oil level check - planetary gear

1. Oil level/Filler plug

Drum gearbox

- Check oil level

Position the roller with the level plug (1) at 3 o’clock.

Wipe clean the area around the plug (1) and then undo

the plug.

Ensure that the oil level reaches up to 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.

Clean and screw in the plugs tightly.

Fig. 21

Oil level check - Drum gearbox

1. Oil level plug

2. Filler plug

3. Drainplug

CA 602 M602EN2

EVERY 250 HOURS OF OPERATION (Monthly)

Drum cartridge

- Checking the oil level

Position the machine level so that the indicator pin (1)

on the inside of the drum is aligned with the top of the

drum frame.

Fig. 22

Left side of drum

1. Indicator pin

Drum cartridge

- Checking the oil level

Wipe the filling plug and level plug clean from dirt.

Unscrew the filling plug (1)

Fig. 23

Roller, right-hand side

1. Filler plug

2. Drain plug

3. Level plug

Drum cartridge

Then unscrew the level plug (3) at the bottom of the

cartridge (wrench width 24 mm (0.9 in)) until the hole in

the middle of the plug becomes visible.

Top off with oil through the filling plug (1), until oil begins

to run out from the level-plug hole. The level is correct

when it stops running.

CAUTION

Ensure that only MOBIL SHC 629 is used in

the cartridges.

Clean and refit the plugs. Repeat the procedure on the

Fig. 24

Drum cartridge

opposite side.

2. Drain plug

CAUTION

3. Level plug

Do not overfill with oil - risk for overheating.

CA 602 M602EN2

EVERY 250 OPERATING HOURS (Monthly)

Drum cartridge

- Cleaning the ventilation screw

Clean the drum ventilation hole. The hole is required to

eliminate excess pressure inside the drum.

Fig. 25

Drum

1. Ventilated screw

Radiator

- Check/clean

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.

Check that air can flow freely through the radiators (1)

and (2).

A dirty radiator should be blown clean with compressed

air, or alternatively cleaned with a high-pressure washer.

Blow or wash the cooler in the opposite direction to that

Fig. 26

Engine room

of the cooling air.

1. Water cooler

CAUTION

2. Hydraulic fluid cooler

Be careful when using a high-pressure washer

3. Intercooler

- do not place the nozzle too close to the

radiator.

WARNING

Use protective goggles when working with

compressed air or a high-pressure washer.

CA 602 M602EN2

EVERY 250 HOURS OF OPERATION (Monthly)

Bolted joints

- Checking tightening torque

Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.

Steering pump against engine (1) 38 Nm (28 lbf.ft).

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 only.)

Fig. 27

Right side of machine

1. Steering pump

2. Rear axle

3. Engine suspension

4. Wheel nuts

Rubber elements and screw

fasteners - Check

Check all the rubber elements (1), and replace them all if

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. 28

Roller, vibration side

1. Rubber element

2. Screw fasteners

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) is most easily accessible from

underneath the engine. It is fitted on a tube to the rear

axle. Drain the oil when the engine is warm. Place a

receptacle for at least 15 litres (16 qts) underneath the

drain plug.

WARNING

Danger of being scalded when draining off

hot oil. Protect your hands.

Change the engine oil filter (2) at the same time.

See also the engine manual.

Fig. 29

Left side of engine

1. Drain plug

Dispose of the drained oil and filter in an

2. Oil filter

approved manner.

CA 602 M602EN2

EVERY 250 HOURS OF OPERATION (Monthly)

Battery

- Check electrolyte level

WARNING

Make sure there are no open flame in the

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. 30

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

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 in all the cells. If the level is lower, top up to the

correct level with distilled water. If the ambient air tem-

perature is below freezing point, the engine should be

run for a while after the distilled water is added, other-

10 mm

wise there is a risk that the water might freeze.

(0.4 in)

Check that the ventilation holes in the cell covers are

not blocked, then refit the covers.

The cable terminals must be properly tightened and

clean. Corroded cable connections should be cleaned

Fig. 31

Electrolyte level in battery

and greased with alkaline Vaseline.

1. Cell cover

2. Electrolyte level

CAUTION

3. Plate

When disconnecting the battery, always

disconnect the negative cable first. When

connecting the battery, always connect the

positive cable first.

Discard used batteries properly. Batteries

Air conditioning (Optional)

contain lead, which is detrimental to the

environment.

- Inspection

WARNING

Before doing any electric welding on the

machine, disconnect the battery ground

cable and then all electrical connections

to the alternator.

Inspect refrigerant hoses and connections and make

sure that there are no signs of oil film that could indicate

leakage of refrigerant.

Fig. 32

Air conditioning

1. Refrigerant hoses

2. Condenser element

CA 602 M602EN2

EVERY 500 HOURS OF OPERATION (Every three months)

Controls and moving

joints - Lubrication

Lubricate engine hood hinges (1) and the slide rails of

the operator’s seat with grease, other joints and

controls with oil. Lubricate the cab hinges with grease.

See lubricant specification.

Fig. 33

Engine hood

1. Hinge

Prefilter - Cleaning

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.

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

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.

Fig. 34

Engine

WARNING

1. Screw

Make sure there is adequate ventilation

2. Glass bowl

(extraction) if the diesel engine is run in-

3. Strainer

doors. Risk of carbon monoxide poisoning.

CA 602 M602EN2

EVERY 500 HOURS OF OPERATION (Every three months)

Steering chain and

Seat bearing - Lubrication

Optional on rollers without cab

CAUTION

Remember that the chain is a vital part of the

steering mechanism.

Clean and lubricate the chain (1) between the seat

bearing and steering valve with grease. The chain is

accessible underneath the platform.

It is not necessary to remove the chain.

Adjust the chain as follows if it has slackened so that

size “a” is less than 30 mm (1.2 in): Loosen the nuts (4)

and adjust the mount (5) backwards with the adjusting

nut (3) until size “a” is 50 mm (2 in).

Fig. 35

Underneath operator’s position

1. Steering chain

2. Chain-tightening device

3. Adjusting nut

4. Nuts

5. Control valve mount

Seat bearing - Lubrication

CAUTION

Remember that the chain is a vital part of the

steering mechanism.

Remove the cover (5) to gain access to the lubrication

nipple (1).

Lubricate the slew bearing of the operator’s seat with

three strokes of a hand-operated grease gun.

Lubricate the seat locking latch (7), accessible from

below.

Also grease the slide rails of the seat (6).

CAUTION

If the seat begins to bind when resetting, it

needs to be lubricated more often.

Clean and grease the chain (3) between the seat and

the steering column.

If the chain becomes slack on the cogwheel (2), loosen

the screws (4) and move the steering column forward,

tighten the screws and check the tension of the chain.

Fig. 36

Seat bearing

1. Lubrication nipple

2. Cogwheel

3. Steering chain

4. Adjusting screw

5. Cover

6. Slide rails

7. Slew interlock

CA 602 M602EN2

EVERY 1000 HOURS OF OPERATION (Every six months)

Hydraulic fluid filter

WARNING

Place the roller on a level surface. Switch

- Change

the engine off and push in the reserve/

parking brake knob for all checking and

adjustments on the roller, unless otherwise

specified.

Undo the cover/bleeder filter (2) on top of the reservoir

so that over-pressure inside the reservoir can be elimi-

nated.

Check that the bleeder filter (2) is not blocked - air

should flow freely through the cover in both directions.

If there is a blockage in either direction, clean the filter

with a little diesel oil and blow through with compressed

air until the blockage disappears, or replace the cover

with a new one.

WARNING

Always use protective goggles when work-

Fig. 37

Hydraulic fluid reservoir

ing with compressed air.

2. Filler cover/bleeder filter

3. Sight glass

Clean thoroughly around the oil filters.

Remove the oil filters (1) and dispose of them

in an approved manner. They are single-use

filters and cannot be cleaned.

CAUTION

Check that the old sealing rings do not remain

stuck on the filter holders, otherwise this might

give rise to oil leakage between the old and

new seals.

Clean the filter holder sealing surfaces thoroughly.

Apply a thin film of hydraulic fluid on the seals of the

new filter. Screw on the filter by hand.

CAUTION

Fig. 38

Engine compartment

First tighten the filter until its seal is in contact

1. Hydraulic fluid filters (x2)

with the filter attachment. Then turn an addi-

tional half revolution. Do not over-tighten the

filter as this might damage the seal.

Start the engine and ensure that there is no leakage of

hydraulic fluid from the filters. Check level of fluid in the

sight glass (3) and top up as required.

WARNING

Hydraulic reservoir

Make sure there is adequate ventilation

- Drainage

(extraction) if the diesel engine is run in-

doors. Risk of carbon monoxide poisoning

Condensate in the hydraulic reservoir is removed via

the drainage tap (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.

Open the tap (1) and let any trapped condensate run out.

Fig. 39 Hydraulic reservoir, underside

Shut the drainage tap.

1. Drainage tap

2. Plug

Refit the plug.

CA 602 M602EN2

EVERY 1000 HOURS OF OPERATION (EVERY SIX MONTHS)

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

this side somewhat lower, so that water and sediment

will gather near the drainage plug (1). Drain as follows:

Fig. 40 Fuel tank

1. Drainage plug

Place a container under the plug (1).

Air filter - Replacement

Undo the plug and drain off the water and sediment until

only clean diesel fuel appears through the plug opening.

Refit the plug.

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

has not yet been cleaned five times, see under 50

hours for filter replacement.

CAUTION

If a clogged filter is not replaced the exhaust

fumes will be black and the engine will loose

power. There will also be danger of severe

damage to the engine.

Fig. 41 Air cleaner

1. Locking braces

2. Cover

3. Main filter

4. Backup filter

5. Filter housing

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

receptacle. The volume is almost 12 litres (12.7 qts).

Save the oil and deposit it in an approved

manner.

Refit the drainage plugs and top up with fresh oil until

the correct level is reached.

Note: It takes a while for the oil to flow into the axle. Do

not fill the entire volume all at once.

Fig. 42 Rear axle

Refit the oil-level/filler plug. Use transmission oil, see

1. Oil level/Filler plug

the lubrication specification.

2. Drainage plugs

CA 602 M602EN2

EVERY 1000 HOURS OF OPERATION (Every six months)

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 2 litres (2.1 qts).

Save the oil and deposit it in an approved

manner.

Fig. 43 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.

Refit the plug and repeat the process on the other side.

Use transmission oil. See the lubrication specification.

Fig. 44 Planetary gear/filling position

1. Plug

Fresh air filter - Replacement

Loosen the two screws (2) at the rear of the cab roof.

Take down the whole holder and remove the filter

insert.

Replace with a new filter.

It may be necessary to replace the filter more often if

the machine is used in a dusty environment.

Fig. 45

Cab

1. Fresh air filter

2. Screw (x2)

CA 602 M602EN2

EVERY 2000 HOURS OF OPERATION (Yearly)

Hydraulic reservoir

WARNING

Place the roller on a level surface. Switch the

engine off and push in the reserve/parking

- Fluid change

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).

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

ilar item which is placed beside the roller. The fluid then

runs in a hose from the drainage plug (1) to the oil

drum, after the plug (2) has been removed and the tap

opened.

Fig. 46

Hydraulic reservoir, underside

1 Drainage tap

2. Plug

Save the oil and deposit it in an approved

manner.

Fill up with fresh hydraulic fluid as per the instructions

under the heading “Hydraulic reservoir - Check fluid

level”.

Drum cartridge

Replace the hydraulic fluid filters at the same time.

- Oil change

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.

Position the machine level so that the indicator pin (1)

on the inside of the drum is aligned with the top of the

Fig. 47

Left side of drum

drum frame.

1. Indicator pin

Place a receptacle for about 5 litres (5.3 qts)

underneath the level/drain plug (2).

Save the oil and deposit it in an approved

manner.

Clean and unscrew the filler plug (1) and the drain plug

(2). Allow all of the oil to drain off. Fit the drain plug, and

fill with fresh synthetic oil according to the instructions

under the "Drum cartridge-checking the oil level"

heading, page 17.

Repeat the procedure on the opposite side.

Fig. 48

Right side of the drum

CAUTION

1. Filler plug

Ensure that only MOBIL SHC 629 is used in

2. Drain plug

the cartridges.

3. Level plug

CA 602 M602EN2

EVERY 2000 HOURS OF OPERATION (Yearly)

Drum gearbox

- Changing the oil

Place the roller on a level surface with the plugs (1) and

(2) as illustrated.

Wipe clean, unscrew the plugs (1, 2 and 3) and drain

the oil into a suitable receptacle, capacity about 3.5

liters (3.7 qts).

Refit the plug (1) and fill with oil up to the level plug (3),

according to “Drum gearbox - Checking the oil level”

(see page 16).

Use transmission oil, see Lubricant Specification.

Fig. 49

Drum gearbox

Clean and refit the level plug (3) and filler plug (2).

1. Drain plug

2. Filler plug

3. Level plug

Forward/Reverse lever

- Lubrication

Unscrew the screws (1) and remove the plate (2).

Grease the contact surface of the cam disc (3).

Refit the plate (2) with the screws (1).

Fig. 50

Forward/Reverse lever

1. Screw

2. Plate

3. Cam disk

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. 51

Steering joint

CA 602 M602EN2

EVERY 2000 OPERATING HOURS (Yearly)

Air conditioning (Optional)

- Overhaul

Regular inspection and maintenance are necessary to

ensure satisfactory long-term operation.

Clean the condenser element (1) free from dust with

the aid of compressed air. Blow from above.

CAUTION

The air jet could damage the flanges of the

elements if it is too powerful.

WARNING

Wear protective goggles when working

with compressed air.

Inspect the fastening of the condenser element.

Fig. 52

Cab

1. Condenser element

Clean the cooler unit and the cooling elements (1) free

from dust with the aid of compressed air.

Inspect the system hoses for chafing. Make sure that

drainage from the cooling unit is unobstructed so that

condensation does not accumulate inside the unit.

Drain by pressing the valves (2) that are located under

the cab.

Fig. 53

Aircondition

1. Cooling element

2. Drain valve (x2)

CA 602 M602EN2

EVERY 2000 OPERATING HOURS (Yearly)

Inspect the compressor and hydraulic motor

fastenings.

The unit should be run at least five minutes every

week, if possible, to ensure lubrication of rubber

gaskets in the system.

CAUTION

The air unit should not be run when the

outdoor temperature is below 0°C (32°F).

Fig. 54

Compressor

WARNING

Never work under the roller with the engi-

ne running. Park on a level surface, chock

the wheels and press the parking brake

control.

Open the engine hood while the unit is operating and

check in the sight glass (1) that no bubbles are visible

on the dryer filter. If bubbles are visible through the

sight glass, it is a sign that the level of refrigerant is too

low. If so, stop the unit. There is a risk of damage to the

unit if it is run with insufficient refrigerant.

Check the moisture indicator (2). The color should be

Fig. 55

Drying filter in engine compartment

blue; if it is beige the dryer cartridge must be replaced

1. Sight glass

by an authorized service company.

2. Moisture indicator

WARNING

The compressor will be damaged if the unit

is run with too little refrigerant.

WARNING

Do not disconnect the hose coupling.

WARNING

The cooling system is pressurized.

Incorrect handling can result in serious

personal injuries.

WARNING

The system contains pressurized refriger-

ant. Releasing refrigerants into the air is

prohibited. The refrigerant circuit may only

be repaired by an authorized company.

CA 602 M602EN2

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. 56 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.

Lubricate the steering joint bearings and the steering

Steering cylinder, hinges etc.

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 602 M602EN2

SPECIAL INSTRUCTIONS

Standard lubricants and other

Upon delivery from the factory, the various systems

and components are filled with the oils specified see

recommended oils

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

standard oil, but the following oils must be used in the

max. +50°C (122°F)

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

When washing the machine, do not direct the

High-pressure washing

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.

When an auxiliary starter battery is used, always

Starting assistance

connect the positive terminal on the auxiliary battery to

the positive terminal on the roller’s battery, and

negative to negative.

CA 602 M602EN2

ELECTRICAL SYSTEM, FUSES

Fuses and relays

The electrical regulating and control system is

protected against overload by 27 fuses and 12 relays.

The number depends on how much extra equipment is

fitted on the machine.

The four fuse boxes (1,2,3,4) and the relays are

located behind the lower instrument plate, which can be

removed by turning the four quick-screws (5) a ¼-turn.

The machine is equipped with a 12 V electrical system

5 1 2 5

3 4 5

and an alternator.

Fig. 57 Instrument panel

WARNING

Connect the battery to the correct polarity

1,2,3,4. Fuse boxes

5. Quick-screws

(- to ground). The cable between battery

6. Relays

and alternator must not be disconnected

when the engine is running.

Fuses on the machine

The figure shows the rating and function of the different

fuses.

All fuses are flat pin fuses.

The tachograph and memory for the radio are protected

at the battery master disconnect switch by a 0,5A and

3A fuse, respectively.

Fig. 58

Fuse box, left side (1)

Fuse box, right side (3)

7,5A

1. Brake valve, starter relay, hourmeter

20A

1. Working lights, left

7,5A

2. VBS relay

20A

2. Working lights, right, instrument illumination

7,5A

3. Indicating panel

7,5A

3. Headlight, left

7,5A

4. Horn

7,5A

4. Headlight, right, instrument illumination*

7,5A

5. Low/High speed/Strike-off blade

6. Reversing alarm

Fuse box, left side (2)

Fuse box, right side (4)

7.5A

1. Instrumentation

10A

1. Hazard beacon

2. Compaction meter

10A

2. Direction indicators, main fuse

7.5A

3. Hazard beacon

7.5A

3. Position light, left, front and rear

7.5A

4. Anti-spin

4. Position light, right, front and rear

20A

5. Air cond.

5. Direction indicator, left, front, rear and side

20A

6. Air cond.

6. Direction indicator, right, front, rear and side

= Optional

* When driving lights are fitted

CA 602 M602EN2

ELECTRICAL SYSTEM, FUSES

Fuses in the cab

The electric system in the cab is equipped with its own

fuse box, located overhead at the front right part of the

cab.

The figure shows the ampere rating and function of the

different fuses. All fuses are of the flat pin type.

Fig. 59

Fuse box overhead in cab

20A

1. Rear cab spotlight

10A

2. Front cab spotlight. radio

3. Cab interior lighting

25A

4. Heater/fresh air fan

10A

5. Rear screen wiper/screen-wash

10A

6. Front screen wiper/screen-wash

Main fuses

There are four main fuses (1). These are located behind

the battery master disconnect switch. The three screws

need to be unscrewed to remove the plastic cover.

The fuses (1) are of the flat pin type.

Supply, machine

30 A (Green)

Supply, cab

50 A (Red)

Supply, lighting

40 A (Orange)

Supply, Aircondition

30 A (Green)

The start relay (2) and the preheating relays (3) for the

Engine compartmentMotorrum

engine are also fitted here.

1. Main fuses

2. Fuel solenoid relay

3. Starter relay

Relays

VBS relay

Main relay

Horn relay

Hourmeter relay

Fuel level relay

Reverse alarm relay

Lights relay

Direction indicator relay

K10

Brakes relay

K11

Air cond. relay

= Optional

Fig. 61

Instrument panel

CA 602 M602EN2