DYNAPAC Vibratory roller CC 422/422C/CC 422HF/CC 422CHF/CC 432, CC 522/522C/CC 522HF/522CHF. Operation & Maintenance (2003)

LUBRICANTS AND SYMBOLS

Always use high-quality lubricants in the recommended amounts. Too much grease or oil can

cause overheating and subsequent increased wear.

ENGINE OIL

ambient temperature

Shell Rimula SAE 15W/40 or equivalent.

-10°C-+40°C (14°F-104°F) API CF-4/SG (CD/CE)

HYDRAULIC FLUID

ambient temperature

-10°C to +40°C (14°F-104°F) Shell Tellus TX68 or equivalent

above +40°C (above 104°F) Shell Tellus TX100 or equivalent

BIOLOGICAL

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.

DRUM OIL

ambient temperature

-15°C to +40°C (5°F-104°F) Mobil SHC 629 or equivalent

TRANSMISSION OIL

ambient air temperature

Shell Spirax SAE 80W/90, HD API, GL-5

-15°C - +40°C (5°F - 104°F)

GREASE

SKF LGHB2 (NLGI Class 2) or equivalent for the

articulated joint.

Shell Retinax LX2 or equivalent for other grease points.

FUEL

See engine manual.

COOLANT

GlycoShell or corresponding.

mixed 50/50 with water

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

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 filter

Engine, oil filter

Battery

Hydraulic reservoir, level

Sprinkler

Hydraulic fluid filter

Sprinkler water

Drum, oil level

Recycling

Lubricating oil

Fuel filter

Air pressure

Sprinkler, tyres

Coolant, level

Transmission, oil level

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

3

MAINTENANCE SCHEDULE

23

5

1

2

3

4

5

6

6

7

7

8

20

19

8

19

18

7 17 16 15 14 13 12 11 10

9

7

21, 22

23

24

25

Fig. 1 Service and maintenance points

1. Air cleaner

10. Articulated steering

19. Rubber element

2. Engine oil

11. Steering cylinder

20. Pivot bearing

3. Fuel cap

12. Hydraulic fluid filter

21. Battery

4. Seat bearing

13. Hydraulic fluid level

22. Hydraulic fluid cooler/Radiator

5. Water tanks

14. Hydraulic reservoir cap

23. Tire (Combi)

6. Watering system

15. Hydraulic reservoir

24. Pump gearing

7. Scrapers

16. Diesel engine

25. Rail catch

8. Drums

17. Hinge

9. Fuel tank

18. Pivot cylinder

8

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 10 HOURS OF OPERATION (Daily)

Diesel engine,

oil level - Check

Place the roller on a level surface. Switch

1

2

the engine off and push in the reserve/

parking brake knob for all checking and

adjustments on the roller, unless otherwise

specified.

The oil dipstick is accessible through the right door of

the engine compartment.

Beware of hot parts of the engine and ex-

haust pipe when taking out the oil dipstick.

Observe caution. Wear gloves and safety

goggles.

Fig. 2

Engine compartment

The dipstick is located on the short side of the engine

1. Oil dipstick

above the hydraulic pumps.

2. Filler cap

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

between the upper and lower mark. For further details,

see the engine manual.

Coolant level - Check

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

1

2

3

min. marks.

Observe caution if the filler cap must be

4

opened while the engine is hot. Wear glo-

ves and safety goggles.

5

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

See page 3 in these instructions and in the engine

manual.

6

Flush the system every other year and

change the coolant. Ensure also that air can

flow unrestricted through the radiator.

Fig. 3

Radiator

1. Filler cap

2. Level/max. mark

3. Level/min. mark

4. Intercooler

5. Radiator

6. Hydraulic fluid cooler

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

11

EVERY 10 HOURS OF OPERATION (Daily)

Hydraulic reservoir,

level check - Filling

Place the roller on a level surface. Switch

3

the engine off and push in the reserve/

parking brake knob for all checking and

2

adjustments on the roller, unless otherwise

specified.

Open the right door of the engine compartment.

Make sure that the oil level is between the max/min

marks. Top off with hydraulic fluid according to the

lubricant specification if the level is too low.

1

Fig. 4

Hydraulic reservoir

1. Oil sight glass

2. Filler hose

3. Filler cap

Fuel tank - Refueling

Refuel every day before starting to work. Screw off the

lockable tank cap (1) and fill diesel fuel to the lower

1

edge of the filler pipe (2).

Never refuel while the engine is running,

2

do not smoke, and avoid spilling fuel.

See the engine handbook for the grade of diesel fuel.

The tank holds 200 litres (52.8 gal) of fuel.

Fig. 5

Fuel tank

1. Tank cap

2. Filler pipe

Water tanks - Filling

Screw off the tank cap (1) and fill with pure

1

water. Do not remove the strainer (2).

2

Fill both water tanks; they hold 485 liters (128 gal)

each.

A step is located on the hydraulic reservoir behind the

right door of the engine compartment to facilitate ac-

cess to the tank cap, and also a retractable step on the

right front drum fork.

Sole additive: A small amount of environment

Fig. 6

Rear water tank

friendly antifreeze, and for combi-models

1. Tank cap

possibly cutting fluid.

2. Strainer

12

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 10 HOURS OF OPERATION (Daily)

Sprinkler system/Drum

- Checking/Cleaning

Start the sprinkler system and make sure that no

nozzle (1) is clogged. If necessary, clean clogged

nozzles and the coarse filter located adjacent to the

water pump (2); see figures below.

3

A pump system is located underneath each water tank

3

behind the cover (2), which is opened by turning the

quick-screws (3) a 1/4 turn counter-clockwise. To lock

the cover, place the screws with the slot vertical and

push straight in.

2

1

Fig. 7

Rear drum

1. Nozzle

2. Pump system/cover

3. Quick-screws

Dismantle the clogged nozzle by hand. Blow the nozzle

2

(2) and fine filter (4) clean with compressed air, or

3

4

install replacement parts and clean the clogged parts at

a later opportunity.

Use protective goggles when working with

compressed air.

Fig. 8

Nozzle

1. Sleeve

2. Nozzle

3. Seal

4. Fine filter

When cleaning the coarse filter (1), close the stopcock

5

4

2

1

(2) and loosen the filter housing (3).

Clean the filter and filter housing, ensure that the rubber

gasket in the filter housing is intact.

After inspection and any cleaning, start the system and

check that it works.

A drain cock (5) is located in the left part of the pump

3

system area. This facilitates draining of both tank and

pump system.

Fig. 9

Pump system

1. Coarse filter

2. Stop cock

3. Filter housing

4. Water pump

5. Drain cock

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

13

EVERY 10 HOURS OF OPERATION (Daily)

Emergency watering

If one of the water pumps stops, the remaining pump

1

will be able to keep the sprinkler system operating -

however, at reduced capacity.

To operate with only one pump, open the stopcock (1)

in the water hose in the engine compartment, and also

the stopcock on the coarse filter by the pump that has

stopped, see pump system.

Fig. 10

Engine compartment, right side

1. Stopcock

Scrapers, fixed

- Checking/Setting

Make sure that the scrapers are undamaged. Adjust the

3

3

scrapers so that they lie 1-2 mm (0.04-0.08 in) from the

drum. For special asphalt compounds, it may be better if

2

the scraper blades (1) lie lightly against the drums.

2

1

Asphalt remnants can accumulate on the scraper and

1

affect the contact force.

Loosen the screws (2) to adjust the scraper blade up or

down.

1-2 mm

1-2 mm

Loosen the screws (3) to adjust the contact pressure of

the scraper blade against the drum.

Fig. 11

Rear drum scrapers

1. Scraper blade

Remember to tighten all the screws after any

2. Adjusting screws

adjustment.

3. Adjusting screws

Scrapers, spring loaded

(Optional) - Checking

Make sure that the scrapers are undamaged. The

spring loaded scrapers require no adjustment because

the spring force provides the correct contact force.

Asphalt remnants can accumulate on the scraper and

affect the contact force.

1

Clean as needed.

2

The scrapers must be retracted from the drum

during transport driving.

Fig. 12

Spring loaded scrapers

1. Spring mechanism

2. Scraper blade

14

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 10 HOURS OF OPERATION (Daily)

Sprinkler system/Wheels

- Checking/Cleaning

Fill the rear tank with emulsion fluid; for example, water

1

mixed with 2% cutting fluid. Make sure that the sprink-

ler nozzles (2) are not clogged. Clean them and the

filter if necessary. See under Sprinkler system/Drum -

Check/Cleaning, for detailed instructions.

Fluids that are flammable or detrimental to

2

the environment may not be used in the

emulsion tank.

Inspect the tire tread now and then to detect

asphalt compound that has fastened. This is

Fig. 13

Wheel rack

likely until the tires are sufficiently warm.

1. Rear water tank

2. Sprinkler nozzle

Scrapers

- Checking/Setting

Make sure that the scrapers are undamaged. Adjust

2

3

the scrapers so that they lie 1-2 mm (0.04-0.08 in) from

the tires. For special asphalt compounds, it may be

better if the scraper blades (1) lie lightly against the

tires. Contact is adjusted with the screw at the back of

the scraper mount.

1

1-2 mm

Fig. 14

Tire scrapers

1. Scraper blade

2. Locking bracket

3. Adjusting screw

The scrapers shall hang freely away from the tyres

2

during transport driving. Lift up the scraper blades (1)

and latch them in the raised position with locking

bracket (2).

1

Fig. 15

Tire scrapers

1. Scraper blade

2. Locking bracket

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

15

EVERY 10 HOURS OF OPERATION (Daily)

Brake function

- Check

Check operation of the brakes as follows:

38

40

Drive the roller slowly forward.

Push the reserve/parking brake knob (38); the warning

lamp on the instrument panel should light and the roller

should stop.

After testing the brakes, set the forward/reverse lever

(40) in neutral.

Pull up the reserve/parking brake knob.

Fig. 16

Control panel

38. Reserve/parking brake knob

The roller is now ready for operation.

40. Forward/reverse lever

16

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 50 HOURS OF OPERATION (Weekly)

Steering joint

- Lubrication

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.

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 before

lubricating.

Turn the steering wheel fully to the left to gain access

to all four grease nipples (1) from the right side of the

machine.

Wipe the grease nipples (1). Grease each nipple with

1

five strokes of the hand-operated grease gun. Make

Fig. 17

Right side of articulation

sure that grease penetrates the bearings. If grease

1. Grease nipples

does not penetrate the bearings, it may be necessary

to relieve the articulation joint with a jack while repea-

Steering cylinder

ting the greasing process.

- Lubrication

Turn the machine back for driving straight ahead. This

makes the two grease nipples of the steering cylinder

accessible from the left side of the machine.

Wipe the nipples (1) and grease each one with three

strokes of the hand-operated grease gun.

1

Fig. 18

Left side of articulation

1. Grease nipples

Pivot cylinder

- Lubrication (Optional)

Allow no one near the rear drum while the

engine is running. Danger of being crus-

hed when the drum is operated.

Turn the rear drum for turning left to make the two

grease nipples (1) accessible from the right side of the

machine.

1

Wipe the nipples and lubricate in the same way as for

1

the steering cylinder above.

Fig. 19

Pivot cylinder

1. Grease nipples

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

17

EVERY 50 HOURS OF OPERATION (Weekly)

Air cleaner

- Check/Cleaning

Replace or clean the main filter of the air

2

3

cleaner when the warning lamp on the instru-

ment panel lights at full engine revs.

Release the three locking braces (1) and pull off the

cover (2), pull out the main filter (3).

Do not remove the backup filter (4).

1

4

5

Fig. 20

Air cleaner

1. Locking braces

2. Cover

3. Main filter

4. Backup filter

5. Filter housing

Main filter - Cleaning with

compressed air

Use compressed air at a maximum pressure of 5 bar

(72 psi) to clean the main filter by blowing up and down

along the inside of the pleated paper filter.

Hold the air nozzle at least 2 to 3 cm (0.8-1.2 in) from

the paper pleats so as not to tear the paper.

Use protective goggles when working with

compressed air.

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

Fig. 21

Main filter

Ensure that the hose clips between the filter

housing and the intake hose are tightened and

that the hoses are intact. Inspect the entire

hose system all the way to the engine.

Change the main filter after cleaning it five

Backup filter

times.

– Replacement

Replace the backup filter with a new one after cleaning

4

or changing the main filter five times. The backup filter

cannot be cleaned and reused.

To change the backup filter (4), pull the old filter out

from its holder, insert a new one and reassemble the air

cleaner in the reverse order.

Fig. 22

Air filter

4. Backup filter

18

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 50 HOURS OF OPERATION (Weekly)

Tires

- Tire pressure

Check the tire pressure with a pressure gauge.

Make sure that the tires have equal pressure.

Recommended pressure: See Technical

Specifications.

The figure shows the position of the air valve on the

outer tires.

1

Fig. 23

Outer wheel

1. Air valve

The figure shows the position of the air valve on the

inner tires.

Check the safety manual that accompanies

the roller before filling the tires with air.

1

Fig. 24

Inner wheel

1. Air valve

Pump drive, oil level

- Checking/Topping up

Position the roller on a flat surface.

1

When checking the oil level, the engine must

be switched OFF and the parking brake

applied.

Open the right door of the engine compartment and

screw off the dipstick (1).

The oil level must be between the two marks at the

bottom of the dipstick.

Fill with transmission oil if required; see lubricant

specification.

Fig. 25

Pump gearing

Ensure that the rubber packing between the dipstick

1. Dipstick

and gear housing is in place, and firmly screw in the

dipstick.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

19

EVERY 50 HOURS OF OPERATION (Weekly)

Air conditioning

- Inspection (Optional)

Never work under the roller with the engi-

ne running. Park on a level surface, chock

the wheels and press the parking brake

control.

When the unit is in operation, check in the sight glass

(1) that no bubbles are visible in the dryer filter.

Steer the roller fully to the right for easier access to the

dryer filter.

1

Always push the parking brake knob.

The filter is located on the left side underneath the cab.

If bubbles are visible in the sight glass it is a sign that

the level of refrigerant is too low. The sight glass is

visible where the hoses go in under the cab floor, see

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

the unit if it is run with insufficient level of refrigerant. Fill

2

with refrigerant.

Fig. 26

Drying filter

1. Sight glass

2. Filter housing

In the event of noticeable deterioration of cooling capa-

1

city, clean the condenser element (1), which is located

at the rear of the cab roof. Also clean the cooling unit

inside the cab.

Fig. 27

Cab

1. Condenser element

Edge cutter - Lubrication

See the Operation manual for how to ope-

rate the edge cutter.

2

Grease the four points indicated in the figure.

1

Additional lubrication should also be with grease, see

Lubricant specifications.

Grease all bearing points with five strokes of a

3

handoperated grease gun.

4

Fig. 28

Four lubrication points

20

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 250 HOURS OF OPERATION (Monthly)

Hydraulic fluid cooler

- Check/Cleaning

Place the roller on a level surface. Switch

the engine off and push in the reserve/parking-

1

brake knob for all checking and adjustments

on the roller, unless otherwise specified.

Open the left-hand door to the engine compartment to

2

gain access to the radiator and the hydraulic fluid

cooler.

Ensure that air can flow unrestricted through the cooler

and radiator, (1), (2) and (3).

3

Blow a dirty cooler and radiator clean with compressed

air, or wash using a high-pressure washing jet.

Take care when using a high-pressure

washing jet, do not hold the nozzle too close to

the cooler.

Fig. 29

Radiator

1. Intercooler

Use protective goggles when working with

2. Radiator

compressed air.

3. Hydraulic fluid cooler

Air conditioning

- Inspection (Optional)

Inspect refrigerant hoses and connections and make

1

2

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

leakage of refrigerant.

Fig. 30

Air conditioning

1. Refrigerant hoses

2. Condenser element

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

21

EVERY 250 HOURS OF OPERATION (Monthly)

Battery - Checking the

electrolyte level

Open the left door of the engine compartment.

Pull out the battery that is located on the floor behind

2

the coolers.

3

Use safety goggles. The battery contains

4

acid. Rinse with water if electrolyte comes

into contact with the body.

Never use an open flame when checking

the electrolyte level. Explosive gas is genera-

ted when the alternator is charging.

1

Take off the cell caps and make sure that electrolyte is

Fig. 31

Battery space

about 10 mm (0.4 in) above the plates. Check the level

1. Battery

of all cells. Top off with distilled water to the right level if

2. Cell cap

the level is low. The engine should be run for a while

3. Cable shoes

before topping off with distilled water if the ambient

4. Pull-out handle

temperature is below freezing. Otherwise, the electrolyte

might freeze.

Battery cell

Make sure that ventilation holes in the cell cover are

not clogged. Then put the cover back on.

1

The cable shoes should be clean and well tightened.

2

Clean corroded cable shoes and grease them with

acid-free Vaseline.

When disconnecting the battery, always

10 mm

disconnect the negative cable first. When

connecting the battery, always connect the

positive cable first.

3

Discard used batteries properly. Batteries

Fig. 32

Electrolyte level in battery

contain lead, which is detrimental to the

1. Cell cap

environment.

2. Electrolyte level

3. Plate

Before doing any electric welding on the

machine, disconnect the battery ground

cable and then all electrical connections to

the alternator.

22

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 500 HOURS OF OPERATION (Every three months)

Engine

- Changing the oil

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.

The engine oil drain plug is located adjacent to the

battery behind the left door of the engine compartment.

Run the engine warm before draining the oil.

Ensure that ventilation (evacuation) is

adequate if the engine is run indoors.

(Risk of carbon monoxide poisoning).

2

1

Place a suitable receptacle, for at least 15 litres (4 gal),

Fig. 33

Engine compartment, left side

under the drain plug.

1. Oil drain

2. Radiator

Observe caution when draining the engine

oil. Wear gloves and safety goggles.

Unscrew the oil drain plug (1). Allow all of the oil to

drain off, and refit the plug.

Fill with fresh engine oil; see lubricant specification or

the engine manual for the correct grade of oil.

Check the dipstick to ensure that the engine oil level is

Engine

correct, for details see the engine manual.

– Changing the oil filter

The oil filter (1) can be reached most easily through the

right-hand door of the engine compartment.

See the engine manual for details concerning changing

of the filter.

1

Fig. 34

Engine compartment, right side

1. Oil filter

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

23

EVERY 500 HOURS OF OPERATION (Every three months)

Drum, oil level

- Inspection/Filling

Position the roller with the filler plug (1) - the large plug -

straight up.

1

Wipe clean around the level plug (2) - the small plug -

and unscrew it.

Make sure that the oil level reaches up to the lower

2

edge of the hole, top off with fresh oil as required. See

Lubricant specification.

When removing the filler plug, wipe it clean from any

metal on its magnet.

Make sure that plug seals are intact and replace with

new seals as required.

Fig. 35

Drum, vibration side

Refit the plugs.

1. Filler plug

2. Level plug

Check both drums.

Drive a distance and make sure that the plugs are tight.

CC 432

1

Position the roller with the filler plug (1) straight up.

Wipe clean round the sight glass (2).

2

Ensure that the oil level reaches half way in the sight

glass, top up with fresh oil if the level is not correct.

See Lubricant specification.

When removing the filler plug, wipe it clean from any

metal on its magnet.

Refit the plug.

Fig. 36

Drum, vibration side (CC432)

1. Filler plug

Inspect all four drum halves.

2. Sight glass

Drive a distance and ensure that the plugs are tight.

24

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 500 HOURS OF OPERATION (Every three months)

Pivot bearing (Optional)

- Lubrication

Grease each nipple (1) with five strokes of a

1

handoperated grease gun.

Use grease according to the lubricant specification.

Fig. 37

Rear drum, right side

1. Grease nipples, 4 off

Rubber elements and

fastening screws - Check

Check all rubber elements (1), replace all of the

1

elements if more than 25% of them on one side of the

drum are cracked deeper than 10-15 mm (0.4-0.6 in).

Use the blade of a knife or pointed object to assist

when checking.

Make sure that the fastening screws (2) are tightened.

2

Fig. 38

Drum, vibration side

1. Rubber element

2. Fastening screws

Hydraulic reservoir cap

- Check

Open the right door of the engine compartment.

1

Unscrew and make sure that the reservoir cap is not

clogged, air must have unobstructed passage through

the cap in both directions.

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

and blow with compressed air until free passage is

assured or replace the cap with a new one.

Use protective goggles when working with

Fig. 39

Engine compartment, right side

compressed air.

1. Tank cap

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

25

EVERY 500 HOURS OF OPERATION (Every three months)

Hinges, controls

- Lubrication

Lubricate both hinges (1) on the engine compartment

doors until grease penetrates through.

Grease the hinges of the cab door in the same way.

Lubricate the hinges of the front and rear spotlight

covers with a few drops of oil.

1

Lubricate the forward/reverse control wires by the

control arm of the hydraulic pump. Apply a few drops of

2

oil to the mouth of the control sleeve.

Fig. 40

Engine hood

1. Hinge

2. Control wires

Seat bearing - Lubrication

Remove both steps from under the operator’s platform,

or one step and cover plate on the other side of the roller

if fitted with a cab.

1

3

Lubricate the seat sliding rails for transverse travel with

five strokes of a hand-operated grease gun. Grease all

four nipples, two of which (1) are accessible from each

2

2

side.

Also grease the slew bearing of the seat with a few

1

strokes of the gun. The lubrication nipple (3) is

accessible after the cover on the seat frame underneath

the front of the seat is removed.

Fig. 41

Seat bearing, underneath

1. Grease nipples

Also lubricate the seat locking mechanism, both for

2. Slide rails

transverse travel and slewing. Use engine oil or drum oil.

3. Lubrication nipple

If the seat begins to bind when resetting, then it

should be lubricated more often than specified

here.

26

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 500 HOURS OF OPERATION (Every three months)

Seat bearing

- Lubrication

Remember that the chain is a vital part of the

5

steering mechanism.

6

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).

If the seat begins to bind when resetting, it

7

needs to be lubricated more often.

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

the steering column.

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

4

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

tighten the screws and check the tension of the chain.

3

2

1

Fig. 42

Seat bearing

1. Lubrication nipple

2. Cogwheel

3. Steering chain

4. Adjusting screw

5. Cover

6. Slide rails

7. Slew interlock

Diesel engine fuel filter

- Change/cleaning

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.

1

Prefilter, loosen the screw (1) and remove the glass

bowl (2).

3

5

2

Take out the strainer (3) and clean using a non-

flammable fluid. Reinstall the strainer and the bowl.

4

Replace fuel filter. See engine manual.

Fig. 43

Diesel engine

1. Prefilter

Start the engine and check that the pre-filter does not leak.

2. Glass bowl

Make sure there is adequate ventilation

3. Strainer

4. Nut

(extraction) if the diesel engine is run in-

5. Fuel filter

doors. Risk of carbon monoxide poisoning.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

27

EVERY 1000 HOURS OF OPERATION (Every six months)

Hydraulic fluid filter

- Changing

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.

1

Open the right door of the engine compartment.

Remove the oil filter (1) and discard it in a safe

manner, it is of the expendable type and

cannot be cleaned.

Thoroughly clean the sealing surface of the filter holder.

2

3

Apply a thin coat of fresh hydraulic fluid on the rubber

Fig. 44

Hydraulic reservoir

gasket of the new filter.

1. Hydraulic filter

2. Reservoir

Screw on the filter by hand, first until the filter gasket

3. Sight glass

makes contact with the filter base and then a further ½

turn.

Start the engine and check that the filter does not leak.

Check level of the hydraulic fluid in the sight glass (3)

and top up as required, see under the heading “Every

10 hours of operation”.

Air filter - Replacement

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

has not yet been cleaned five times; see under the

heading “Every 50 hours of operation” for changing the

filter.

If a clogged filter is not replaced the exhaust

fumes will be black and the engine will loose

3

power. There will also be danger of severe

damage to the engine.

Fig. 45

Air cleaner

3. Main filter

28

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 1000 HOURS OF OPERATION (Every six months)

Pump drive

- Oil change

Observe caution when draining hot oil.

Wear gloves and safety goggles.

Use a receptacle that will hold at least 1.5 litre (1.6 qts)

for draining the oil.

Unscrew the drain plug (1) and also unscrew the

dipstick to allow the oil to flow freely, see under the

”Every 50 hours of operation” heading.

Wipe away any metal particles from the magnetic drain

plug, and refit the plug and its packing.

The gearbox holds 0.8 liter (0.85 qts). For topping off,

1

see under the ”Every 50 hours of operation” heading.

Fig. 46

Pump gearing

1. Drain plug

Fresh air filter - Replacement

Use a stepladder to reach the filter (1).

2

1

2

There are two fresh-air filters (1), one on each side of

the cab. Unscrew the screws (2), take down the entire

housing and remove the filter insert.

Replace with new filters.

It may be necessary to change the filters more often if

the machine is run in a dusty environment.

Fig. 47

Cab

1. Fresh air filter (x2)

2. Screw (x2)

Drum

- Oil change (HF version)

Make sure there is adequate ventilation

(extraction) if the diesel engine is run in-

doors. Risk of carbon monoxide poisoning.

Drive the roller until the drain plug (1) - the large plug -

is straight down.

Switch off the engine and push the reserve/

parking brake knob.

Place a receptacle that will hold at least 20

liters (21 qts) under the plug. Save the oil and

dispose of it in an approved manner.

1

Remove the plug (1) and allow all the oil to run out. See

Fig.48

Drum, vibration side

under the heading ”Every 500 hours of operation” for

1. Drain plug

filling oil.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

29

EVERY 2000 HOURS OF OPERATION (Yearly)

Hydraulic reservoir

- Changing the fluid

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.

Observe caution when draining hot oil.

Wear gloves and safety goggles.

Place a receptacle that will hold at least 50

liters (53 qts) under the plug. Save the oil and

dispose of it in an approved manner.

Remove the drain plug (1) and allow all the oil to run

2

1

out, wipe and refit the drain plug.

Fill with fresh hydraulic fluid of the grade

Fig. 49

Engine compartment, right side

indicated in the Lubricant specification.

1. Drain plug

2. Hydraulic reservoir

Replace the hydraulic filter as described under the

heading ”Every 1000 hours of operation.”

Start the engine and operate the various hydraulic

functions. Check the level in the reservoir and top off

as required.

Drum - Oil change

Make sure that ventilation (extraction) is

adequate if the engine is run indoors. Risk

of carbon monoxide poisoning.

Drive the roller until the drain plug (1) - the large plug -

is straight down.

Switch off the engine and push the reserve/

parking brake knob.

Place a receptacle that will hold at least 20

liters (7 qts) under the plug. Save the oil and

1

dispose of it in an approved manner.

Fig. 50

Drum, vibration side

Remove the plug (1) and allow all the oil to run out. See

1. Drain plug

under the heading ”Every 500 hours of operation” for

filling oil.

CC 432 (four drum halves)

Position the roller with the drain plug (1) straight down.

Place a receptacle that will hold at least 7

liters (21 qts) under the plug. Save the oil and

dispose of it in an approved manner.

Remove the plug (1) and allow all the oil to run out. See

under the heading ”Every 500 hours of operation” for

filling oil.

1

Change the oil in all four drum halves.

Fig. 51

Drum, vibration side (CC432)

1. Drain plug

30

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 2000 HOURS OF OPERATION (Yearly)

Fuel tank

- Cleaning

It is easiest to clean the tank when it is almost empty.

1

Pump out any bottom sediment with a suitable

pump; for example, an oil emptying pump.

Save the oil in a can and dispose of it in an

approved manner.

Remember the danger of fire when hand-

ling fuel.

The fuel tank is made of recyclable plastic

(polyethylene).

Fig. 52

Fuel tank

1. Oil emptying pump

Watering system

- Draining

Remember the risk of freezing during the

winter period and drain the tank, pump and

leads; or mix the water with a small amount of

environmentally friendly antifreeze.

The easiest way to empty the tank is to screw off the

filter housing (1) and disconnect the hoses by releasing

the quick-couplings.

2

3

1

There is also a drain cock (red square) under each

Fig. 53

Pump system

water tank.

1. Filter housing

2. Drain cock

Open the drain cock (2) to empty the water pump.

3. Quick-couplings

Water tank - Cleaning

Clean the tanks with water and a suitable detergent for

plastic surfaces.

Refit the filter housing (1) or the drain plug (2), fill with

water and check for tightness.

The water tanks are made of recyclable

plastic (polyethylene).

1

2

Fig. 54

Water tank

1. Pump system

2. Drain plug

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

31

EVERY 2000 HOURS OF OPERATION (Yearly)

Forward/Reverse lever

- Lubrication

Remove the screws (1) and take off the plate (2).

Lubricate the sliding surface of the cam disc (3) with

grease.

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

1

2

3

Fig. 55

Forward/Reverse lever

1. Screw

2. Plate

3. Cam disc

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. 56

Steering joint

32

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

EVERY 2000 HOURS OF OPERATION (Yearly)

Air conditioning

- Overhaul (Optional)

Regular inspection and maintenance are necessary to

1

ensure satisfactory long-term operation.

Clean the condenser element (1) free from dust with

the aid of compressed air. Blow from above.

The air jet could damage the flanges of the

elements if it is too powerful.

Wear protective goggles when working

with compressed air.

Inspect the fastening of the condenser element.

Fig. 57

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.

Check the drain by squeezing the valves (2) underne-

ath the cab.

1

2

Fig. 58

Aircondition

1. Cooling element

2. Drain valve (x2)

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

33

EVERY 2000 HOURS OF OPERATION (Yearly)

Compressor - Inspection

Inspect fastening of the compressor and hydraulic

motor. These components are located behind the steps

to the cab. Dismantle the steps.

The unit should be run at least five minutes every

week, if possible, to ensure that the rubber gaskets in

the system remain lubricated.

1

2

Fig. 59

Compressor

1. Hydraulic motor

2. Compressor

Drying filter - Inspection

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

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

1

by an authorized service company.

The compressor will be damaged if the unit

is run with too little refrigerant.

2

Do not disconnect the hose coupling.

3

The cooling system is pressurized.

Incorrect handling can result in serious

Fig. 60

Dryer filter, underneath cab

personal injuries.

1. Sight glass

2. Moisture indicator

The system contains pressurized refriger-

3. Dessicator cartridge

ant. Releasing refrigerants into the air is

prohibited. The refrigerant circuit may only

be repaired by an authorized company.

34

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

LONG-TERM STORAGE

The following instructions should be followed

for storage longer than one month:

The measures apply for a period of up to 6

months.

The items marked * must be restored before

using the roller.

Fig. 61

Roller protected against the weather

Diesel engine

See manufacturer’s instructions in the engine

manual that accompanies the roller.

Battery

Remove the battery from the roller, clean it, check

that the electrolyte level is correct (see under the

heading ”Every 50 hours of operation”) and

tricklecharge the battery once a month.

Air cleaner, exhaust pipe

Cover the air cleaner (see under the heading ”Every

50 hours of operation” and also under the heading

”Every 1000 hours of operation”) or its opening with

plastic or tape, and also cover the exhaust opening.

This is necessary to prevent moisture from entering

the engine.

Fuel tank

Fill the fuel tank completely to prevent condensation.

Hydraulic reservoir

Fill the hydraulic reservoir to the uppermost level

mark, see under the heading ”Every 10 hours of

operation.”

Sprinkler system

Empty the water tank completely (see under the

heading ”Every 10 hours of operation”), also hoses,

filter housing and water pump. Remove all the

sprinkler nozzles (see under the heading ”Every 10

hours of operation”).

Steering cylinder, hinges, etc.

Lubricate bearings of the steering joint and both

bearings of the steering cylinder with grease (see

under the heading ”Every 50 hours of operation”).

Grease the piston rod of the steering cylinder with

inhibitor grease. Grease the hinges on doors to the

engine compartment and the cab, and also grease

both ends of the forward/reverse control (bright

parts) (see under the heading ”Every 500 hours of

operation”).

Tires (Combi)

Make sure that tire pressure is at least 200 kPa,

(2,0 kp/cm²) (29 psi).

Hoods, tarpaulin

Lower the instrument shield plate on the steering

*

column. Cover the entire roller with a tarpaulin. The

tarpaulin must be free from the ground. Store the

roller indoors if possible, preferably on premises with

an even temperature.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

35

ELECTRICAL SYSTEM, FUSES

Fuses

The electrical regulating system and control system are

protected by 24 fuses, located in the instrument panel

and in the engine compartment.

The four fuse boxes (1) are located behind the lower

instrument plate, which is opened by turning the four

quick-screws (2) a 1/4 turn counter-clockwise.

2 1 2

2

1

2

Fig. 62

Instrument panel

1. Fuse boxes

2. Quick-screws

Fuses in the engine compartment are located together

with the battery disconnecter, behind the left cover of

the engine compartment.

The machine is equipped with a 12 V electrical system

and an alternator.

Connect the battery to the correct polarity

(- to ground). The cable between battery-

2

1

and alternator must not be disconnec-

tedwhen the engine is running.

Fig. 63

Battery space

1. Battery disconnector

2. Main fuse panel

The main fuse panel is located behind the left cover of

1

2

the engine compartment.

The main fuses and start relay are easily accessible on

lowering the cover forward.

4

3

Fig. 64

Main fuse panel

1. Battery disconnecter

100A

2. Main fuse,,

Cab/standard electricity

125A

3. Preheating, engine

4. Start relay

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

37

ELECTRICAL SYSTEM, FUSES

The control unit and relays for preheating the diesel

1

engine are located behind the left door of the engine

2

compartment on the wall adjacent to the rear drum.

Fig. 65

Engine compartment, left side

1. Control unit for preheating

2. Heating relay

Relays

K1

Lights relay

K2

Direction indicator relay

K3

Brakes relay

K4

Reverse alarm relay

K5

Fuel level relay

K7

Horn relay

K8

Sprinkler

K9

Main relay

K10

AVC

K11

Neutral switch

K12

VBS relay

Fig. 66

Instrument panel

38

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

ELECTRICAL SYSTEM, FUSES

Fuses on the machine

The figure shows the rating and function of the different

fuses. All fuses are flat pin fuses..

1

7

2

8

3

9

4

10

5

11

6

12

Fig. 67

Fuse boxes, left side

Fuse boxes, right side

1. Vacant

7,5A

1. Brake valve, start relay, control relay cab

10A

2.

Direction indicators, main fuse

10A

2. Vibration relay, VBS

7,5A

3.

Left position lights, front and rear,

3A

3. Indicator panel

brake lights

7,5A

4. Horn

5A

4.

Right position lights, front and rear

7,5A

5. Vibration Front/Both/Rear, AVC-relay

5A

5.

Left direction indicator,

10A

6. Hazard beacon

front and rear, side blinkers

5A

6.

Right direction indicator,

front and rear, side blinkers

*/20A

7. Right working lights

7,5A

7. Sprinkler pump front

*/20A

8. Left working lights

7,5A

8. Sprinkler pump rear

7,5A

9. Left front headlight,

15,0A

9. Sprinkler system main fuse

instrument lighting

15,0A 10. Steering, offset up/down

7,5A 10. Right front headlight

7,5A 11. Reversing alarm

7,5A 11. Edge cutter, sprinkler Up/Down

7,5A 12. Instruments, voltmeter, temperature level,

12. Vacant

speedometer, tachometer, frequency meter

*/ If driving lights 10A

Fuses in the cab

The electrical system in the cab has an individual fuse

box located in the right front side of the cab roof. The

figure shows the rating and function of the different

1

´

3

4

5

6

fuses. All fuses are flat pin fuses.

Fig. 68

Fuse box in cab

15A

1. Rear cab working light

15A

2. Front cab working light,

drum headlight

5A

3. Cab interior lighting

20A

4. Heating/fresh-air fan

15A

5. Windshield wiper/washer

15A

6. Front windshield wiper/washer

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5

39

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