DYNAPAC Vibratory roller CC800/900/1000. Operation & Maintenance (2020)
Instruction manual
Operating & Maintenance
Vibratory roller
CC800/900/1000
Engine
Kubota D1105-E4B
Kubota D1105-E4B T4F / Stage V
Serial number
10000357xxA012892 -
10000358xxA012889 - xA023346
10000360xxA012890 - xA023344
10000440xxA023605 -
10000441xxA023347 -
10000443xxA023345 -
Translation of original instruction
Reservation for changes
Printed in Sweden
Table of Contents
Introduction
1
The machine
1
Intended use
1
Signal symbols and meaning
1
Safety information
1
General
2
CE marking and Declaration of conformity
3
Safety - General instructions
5
Safety - when operating
7
Sitting position
7
Work driving
7
Driving near edges
8
Special instructions
9
Standard lubricants and other recommended oils and fluids
9
Higher ambient temperatures, above +40°C (104°F)
9
Lower ambient temperature - Freeze risk
9
Temperatures
9
High pressure cleaning
9
Fire fighting
10
Roll Over Protective Structure (ROPS)
10
Battery handling
10
Jump starting
11
Technical specifications
13
Vibrations - Operator station
13
Noise level
13
Electrical system
13
Slopes
13
Dimensions, side view
14
Dimensions, top view
15
Weights and volumes
16
Working capacity
16
General
17
CO2-emission
17
Tightening torque
18
ROPS - bolts
19
Hydraulic system
19
Machine description
21
Diesel engine
21
Electrical system
21
Propulsion system/Transmission
21
Brake system
21
Steering system
21
ROPS
21
Identification
22
Product identification number on the frame
22
Machine plate
23
Explanation of 17PIN serial number
23
Engine plates
24
Decals
25
Location - decals
25
Location - decals, CALIFORNIA
27
Safety decals
27
Info decals
30
Fuel
31
Instruments/Controls
32
Locations - Instruments and controls
32
Locations - Control panel and controls
33
Function description
34
Electrical system
36
Fuses
36
Fuses in engine compartment
37
Relays
37
Operation
39
Before starting
39
Battery isolation switch - On - Optional
39
PLUS version
39
CC version
39
Driver seat (CC version) - Adjustment
39
Driver seat (Plus version) - Adjustment
40
Instruments and lamps - Checking
40
Interlock
41
Operator position
42
Starting
43
Starting the engine
43
Driving
45
Operating the roller
45
Interlock/Emergency stop/Parking brake - Check
46
Vibration
46
Manual/Automatic vibration
46
Manual vibration - Switching on
47
Braking
47
Normal braking
47
Emergency braking
48
Switching off
48
Parking
49
Chocking the drums
49
Master switch - Optional
49
PLUS version
49
CC version
49
Long-term parking
51
Engine
51
Battery
51
Air cleaner, exhaust pipe
51
Sprinkler system
51
Fuel tank
51
Hydraulic reservoir
52
Steering cylinder, hinges, etc
52
Hoods, tarpaulin
52
Miscellaneous
53
Lifting
53
Locking the articulation
53
Lifting the roller
53
Unlocking the articulation
54
Transport
54
Securing CC800/900/1000 for loading
55
Towing/Recovering
56
Releasing the brake
57
Towing the roller
58
Operating instructions - Summary
59
Preventive maintenance
61
Acceptance and delivery inspection
61
Warranty
61
Maintenance - Lubricants and symbols
63
Maintenance symbols
65
Maintenance - Maintenance schedule
67
Service and maintenance points
67
General
68
Every 10 hours of operation (Daily)
68
After the FIRST 50 hours of operation
69
Every 50 hours of operation (Weekly)
69
Every 250 / 750 / 1250 / 1750 hours of operation
69
Every 500 / 1500 hours of operation
70
Every 1000 hours of operation
71
Every 2000 hours of operation
72
Service - Checklist
73
Maintenance, 10h
75
Diesel engine Check oil level
75
Hydraulic reservoir, Level check - Filling
76
Check - Coolant system
76
Refueling
77
Water tank - Filling
77
Sprinkler system/Drum
Cleaning of sprinkler nozzle
78
Sprinkler system - Check, cleaning
78
Air circulation - Check
79
Scrapers - Check, adjustment
79
Warning lamps - Check
80
Air cleaner indicator
80
Brakes - Check
81
Maintenance - 50h
83
Air cleaner - emptying
83
Rubber elements and fastening screws - Check
84
Belt tension on the hydraulic vibration and steering pump drive belt -
Check
84
Maintenance measures - 250 h
85
Air cleaner - Cleaning - Change
85
Hydraulic fluid cooler - Cleaning
86
Forward/Reverse controls and joints - Check and lubrication
86
Maintenance measures - 500 h
87
Hydraulic fluid cooler - Cleaning
87
Forward/Reverse controls and joints - Check and lubrication
88
Air cleaner - Cleaning - Change
89
Engine oil and oil filter - Change
90
Check - Coolant system
91
Drum - Checking the oil level
91
Hydraulic reservoir - Check/venting
92
Belt tension on the hydraulic vibration and steering pump drive belt -
Check
92
Maintenance - 1000h
93
Hydraulic fluid cooler - Cleaning
93
Forward/Reverse controls and joints - Check and lubrication
94
Air cleaner - Cleaning - Change
95
Engine oil and oil filter - Change
96
Check - Coolant system
97
Drum - Checking the oil level
97
Hydraulic reservoir - Check/venting
98
Hydraulic fluid filter - Change
99
Alternator belt - Checking tension - Change
99
Belt tension on the hydraulic vibration and steering pump drive belt -
Check
100
Maintenance - 2000h
101
Hydraulic fluid cooler - Cleaning
101
Forward/Reverse controls and joints - Check and lubrication
102
Air cleaner - Cleaning - Change
103
Engine oil and oil filter - Change
104
Check - Coolant system
105
Drum - Checking the oil level
105
Hydraulic reservoir - Check/venting
106
Hydraulic fluid filter - Change
107
Hydraulic reservoir - fluid change
108
Alternator belt - Checking tension - Change
109
Water tank - Cleaning
109
Drum - Changing the oil
110
Fuel tank - Cleaning
110
Steering joint - Check
111
Belt tension on the hydraulic vibration and steering pump drive belt -
Check
111
Introduction
Introduction
The machine
Dynapac CC800/900/1000 are self-propelled vibratory
tandem rollers in the 1,6 metric tonnes class featuring
800/900/1000 mm wide drums. The machine is
equipped with drive, brakes, and vibration on both
drums.
Intended use
CC800/900/1000 are primarily used for smaller
compaction works, such as minor roads, sidewalks,
cycle ways and minor parking places.
Signal symbols and meaning
WARNING ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in death or serious injury.
CAUTION ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in minor or moderate injury, damage to
the machine or property.
Safety information
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
1
Introduction
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Prevent persons from entering or remaining in
the risk zone, i.e. a distance of at least 7 m (23
ft) in all directions from operating machines.
The operator may allow a person to remain in
the risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
CALIFORNIA
Proposition 65
Decal and location of decal shown in section
Machine description.
General
This manual contains instructions for machine
operation and maintenance.
The machine must be correctly maintained for
maximal performance.
The machine should be kept clean so that any
leakages, loose bolts and loose connections are
discovered at as early a point in time as possible.
Inspect the machine every day, before starting.
2
Introduction
Inspect the entire machine so that any leakages or
other faults are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
This manual contains instructions for periodic
maintenance, where maintenance after every 10 and
50 hours of operation can be performed by the
machine operator. Other maintenance intervals must
be carried out by accredited (Dynapac) service
personnel.
Additional instructions for the engine can be
found in the manufacturer's engine manual.
Specific maintenance and checks on diesel
engines must be performed by engine supplier
authorized personnel.
CE marking and Declaration of conformity
(Applies to machines marketed in EU/EEC)
This machine is CE marked. This shows that on
delivery it complies with the basic health and safety
directives applicable for the machine in accordance
with machinery directive 2006/42/EC and that it also
complies with other regulations and directives
applicable for this machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable regulations
and directives with supplements, as well as the
harmonized standards and other regulations that are
applied and according to the regulations must be
declared in writing.
3
Introduction
4
Safety - General instructions
Safety - General instructions
(Also read the safety manual)
•
The operator must be familiar with the contents of the OPERATION section
before starting the roller.
•
Ensure that all instructions in the MAINTENANCE section are followed.
•
Only the operator is allowed to be on the roller. Remain seated at all times
when operating the roller.
•
Never use the roller if it is in need of adjustment or repair.
•
Only ascend and descend the roller when it is stationary. Use the intended
footsteps, grips and rails. Always use the three-point grip (both feet and one
hand, or one foot and both hands) when ascending or descending the
machine. Never jump down from the machine.
•
Dynapac always recommends mounted ROPS (Roll Over Protective
Structure), or a ROPS-approved cab and seat belt usage.
•
Drive slowly in sharp bends.
•
Avoid driving across slopes. Drive straight up or straight down the slope.
•
Never operate with the drum outside the edge, the substrate might not have
full bearing strength or the edge is close to a slope. Avoid operating close to
edges and ditches and the like as well as on poor ground conditions that
jeopardizes the bearing strength and capacity to support the roller.
•
Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
•
Drive particularly carefully on uneven ground.
•
Keep the roller clean. Clean any dirt or grease that accumulates on the
footsteps or operator platform to avoid slipping risk. Keep all signs and
decals clean and legible.
•
Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle by keeping it in contact to the tank
opening to avoid sparks.
•
Before repairs or service:
- Chock the drums/wheels.
- Lock the articulation if necessary.
- Place blocks under overhanging equipment, such as strike-off blade, edge
cutter/compactor and chip spreader.
5
Safety - General instructions
•
Hearing protection is recommended if the noise level exceeds 80 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
•
Modifications to the roller, including the use of any attachment/equipment,
not approved by Dynapac that might compromise safety (including visibility)
are not allowed. Any modifications are only to be made after written approval
has been given by Dynapac.
•
Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold.
•
For your own protection always wear:
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
Also wear:
- helmet if no cab or FOPS, or if required by worksite management
- working gloves if no cab and for work outside operator´s platform.
•
If the machine seems to be responding abnormally during travel, stop and
check it.
6
Safety - when operating
Safety - when operating
Prevent persons from entering or remaining in
the risk zone, i.e. a distance of at least 7 m (23
ft) in all directions from operating machines.
The operator may allow a person to remain in
the risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
Avoid driving across a slope. Drive straight up
and down sloping ground.
Sitting position
Remain seated at all times when operating the roller. If
the operator stands up during operation, a buzzer
sounds. After 4 seconds the brakes are activated and
the engine stops. Brace yourself for a sudden stop.
Always use the seat belt where fitted. Where the
seat belt is not used, there is a great risk that the
1
operator will be thrown off and land under the
machine if the machine topples over.
2
Fig. Seat position
1. ROPS
The seat belt is standard equipment on rollers fitted
2. Seat belt
with Roll Over Protective Structure (ROPS) (1).
ROPS should always be in the raised position
when machines with foldable ROPS are operated
Work driving
Dynapac always recommends mounted ROPS
(Roll Over Protective Structure) and seat belt
usage.
On machines with foldable ROPS, make sure that
the ROPS is correctly mounted in the upright
position during all operation.
7
Safety - when operating
Avoid operating close to edges and ditches and the
like as well as on poor ground conditions that
jeopardizes the bearing strength and capacity to
support the roller. Pay attention to potential obstacles
above the machine, such as overhead cables and the
branches of trees etc.
Pay particular attention to the stability of the substrate
when compacting close to edges and holes. Do not
compact with a large overlap from the previous track in
order to maintain roller stability. Consider other
compaction methods such as remote-control or a
walk-behind roller close to steep slopes or where the
bearing strength of the substrate is unknown.
Driving near edges
Never operate with the drum outside the edge, the
substrate might not have full bearing strength or
the edge is close to a slope.
Keep in mind that the machine's center of gravity
moves outwards when steering. For example, the
center of gravity moves to the right when you steer
to the left.
8
Special instructions
Special instructions
Standard lubricants and other recommended
oils and fluids
Before leaving the factory, the systems and
components are filled with the oils and fluids specified
in the lubricant specification. These are suitable for
ambient temperatures in the range -15°C to +40°C
(5°F - 105°F).
The maximum ambient temperature for
biological hydraulic fluid is +35°C (95°F).
Higher ambient temperatures, above +40°C
(104°F)
For operation of the machine at higher ambient
temperatures, however maximum +50°C (122°F), the
following recommendations apply:
The diesel engine can be run at this temperature using
normal oil. However, the following fluids must be used
for other components:
Hydraulic system - mineral oil Shell Tellus S2V100 or
similar.
Lower ambient temperature - Freeze risk
Make sure that the watering system is empty/drained
of water (sprinkler, hoses, tank/s) or that anti-freeze
has been added, to prevent the system freezing.
Temperatures
The temperature limits apply to standard versions of
rollers.
Rollers equipped with additional equipment, such as
noise suppression, may need to be more carefully
monitored in the higher temperature ranges.
High pressure cleaning
Do not spray water directly onto electrical components
or the instrument panels.
Place a plastic bag over the fuel filler cap and secure
with a rubber band. This is to avoid high pressure
water entering the vent hole in the filler cap. This could
cause malfunctions, such as the blocking of filters.
Never aim the water jet directly at the fuel tank
cap, or into exhaust pipe. This is particularly
important when using a high-pressure cleaner.
9
Special instructions
Fire fighting
If the machine catches fire, use an ABC-class powder
fire extinguisher.
A BE-class carbon dioxide fire extinguisher can also
be used.
Roll Over Protective Structure (ROPS)
Never carry out any welding or drilling in the
Roll Over Protective Structure (ROPS).
Never repair a damaged ROPS structure, it must
be replaced with a new one.
Battery handling
When removing batteries, always disconnect the
negative cable first.
When fitting batteries, always connect the
positive cable first.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
10
Special instructions
Jump starting
Do not connect the negative cable to the
negative terminal on the dead battery. A spark
can ignite the oxy-hydrogen gas formed
around the battery.
Check that the battery used for jump starting
has the same voltage as the dead battery.
1
2
Turn the ignition and all power consuming equipment
off. Switch off the engine on the machine which is
providing jump start power.
First connect the jump start battery's positive terminal
(1) to the flat battery's positive terminal (2).Then
3
connect the jump start battery's negative terminal (3)
to, for example, a bolt (4) or the lifting eye on the
machine with the flat battery.
4
Start the engine on the power providing machine. Let it
run for a while. Now try to start the other machine.
Disconnect the cables in the reverse order.
Fig. Jump starting
11
Special instructions
12
Technical specifications
Technical specifications
Vibrations - Operator station
(ISO 2631)
The vibration levels are measured in accordance with the operational cycle described in
EU directive 2003/14/EC on machines equipped for the EU market, with vibration switched
on, on soft polymer material and with the operator’s seat in the transport position.
Measured whole-body vibrations are below the action value of 0.5 m/s² as specified in Directive
2002/44/EC. (Limit is 1.15 m/s²)
Measured hand/arm vibrations also were below the action level of 2.5 m/s² specified in the same
directive. (Limit is 5 m/s²)
Noise level
The noise level is measured in accordance with the operational cycle described in EU
directive 2003/14/EC on machines equipped for the EU market, on soft polymer material
with vibration switched on and the operator's seat in the transport position.
Guaranteed sound power level, LwA
104 dB (A)
Sound pressure level at the operator's ear (platform), LpA
80 ±3 dB (A)
Electrical system
Machines are EMC tested in accordance with EN
13309:2000 'Construction machinery'
Slopes
The recommended max slope angle is for a straight
machine on hard, flat surface.
Unstable ground, vibration on, speed and steering the
Max 20° or 36%
machine can all cause the machine to topple at
smaller angles than specified here.
13
Technical specifications
Dimensions, side view
Dimensions
mm
in
A
Wheel base
1350
53.2
D
Diameter, drum
588
23.2
H
Height, with ROPS
2300
90.6
h
Height, without ROPS
1520
59.8
K1
465
18.3
L1
2095
82.5
L2
2040
80.3
S
Thickness, drum amplitude,
Nominal
CC800
14
0.55
CC900
15
0.59
CC1000
13
0.51
14
Technical specifications
Dimensions, top view
Dimensions
mm
in
B
Machine width
CC800
874
34.4
CC900
974
38.4
CC1000
1074
42.3
R1
Turning radius, outer
CC800
2650
104.3
CC900
2700
106.3
CC1000
2750
108.3
R2
Turning radius, outer, drum edge
CC800
2610
102.8
CC900
2660
104.7
CC1000
2710
106.7
W
Drum width
CC800
800
31.5
CC900
900
35.4
CC1000
1000
39.4
15
Technical specifications
Weights and volumes
Weights
Service weight with ROPS
(EN500)
CC800
1510 kg
3,329 lbs
CC900
1580 kg
3,483 lbs
CC1000
1650 kg
3,638 lbs
Fluid volumes
Fuel tank
23 liters
6,0 gal
Water tank
- Standard (CC version)
110 liters
29 gal
- Large (Plus version)
190 liters
50 gal
Working capacity
Compaction data
Static linear load
Front
Rear
CC800
8,8
10,1
kg/cm
49,3
56,6
pli
CC900
8,6
8,9
kg/cm
48,2
49,9
pli
CC1000
8,1
8,4
kg/cm
45,4
47
pli
Amplitude
CC800
0,4
mm
0.02
in
CC900
0,4
mm
0.02
in
CC1000
0,35
mm
0.01
in
Vibration frequency
68
Hz
4,080
rpm
Centrifugal force
17
kN
3,825
lb
16
Technical specifications
Propulsion
Speed range
0-8
kph
0-5
mph
Climbing capacity (theoretical)
40
%
Note: The frequency is measured at high revs. The
amplitude is measured as the real value and not
the nominal.
General
Engine
Manufacturer/Model
Kubota D1105-E4B
Power
- kW
18.1
- HP
24,6
Engine speed
2800 rpm
CO2-emission
CO2-emissions measured according to applicable test
cycle in Regulation (EU) 2016/1628.
Manufacturer/Model
Test-cycle
CO2-emission
(g/kWh)
Kubota D1105-E4B T4F / Steg V Stage V
NRSC
1018.0
NRTC: Non-road transient test cycles.
Electrical system
Battery
12V 60Ah
Alternator
12V 40A
Fuses
See the Electrical system section - fuses
17
Technical specifications
Tightening torque
Tightening torque in Nm for oiled or dry bolts tightened
with a torque wrench.
Metric coarse screw thread, bright galvanized (fzb):
STRENGTH CLASS:
M -
8.8, Oiled
8.8, Dry
10.9, Oiled
10.9, Dry
12.9, Oiled
12.9, Dry
thread
M6
8,4
9,4
12
13,4
14,6
16,3
M8
21
23
28
32
34
38
M10
40
45
56
62
68
76
M12
70
78
98
110
117
131
M14
110
123
156
174
187
208
M16
169
190
240
270
290
320
M20
330
370
470
520
560
620
M22
446
497
626
699
752
839
M24
570
640
800
900
960
1080
M30
1130
1260
1580
1770
1900
2100
Metric coarse thread, zinc-treated
(Dacromet/GEOMET):
STRENGTH CLASS:
M - thread
10.9, Oiled
10.9, Dry
12.9, Oiled
12.9, Dry
M6
12,0
15,0
14,6
18,3
M8
28
36
34
43
M10
56
70
68
86
M12
98
124
117
147
M14
156
196
187
234
M16
240
304
290
360
M20
470
585
560
698
M22
626
786
752
944
M24
800
1010
960
1215
M30
1580
1990
1900
2360
18
Technical specifications
ROPS - bolts
Bolt dimensions :
M12 (PN 4700508063)
Strength class :
8.8
Tightening torque :
70 Nm
ROPS-bolts which are to be torque tightened
must be dry.
Hydraulic system
Opening pressure
MPa
Psi
Drive system
35,0
5076
Supply system
2,0
290
Vibration system
22,0
3190
Control systems
7,0
1015
Brake disengagement
2,0
290
19
Technical specifications
20
Machine description
Machine description
Diesel engine
The machine is equipped with a water-cooled, straight
three cylinder, four-stroke, turbocharged diesel engine.
Electrical system
The machine has the following control units (ECU,
Electronic Control Unit) and electronic units.
• Main ECU (for the machine)
Propulsion system/Transmission
The propulsion system is a hydrostatic system with a
hydraulic pump supplying two motors connected in
parallel.
The motors drive the front and rear drums.
The speed of the machine is proportional to the
deflection/angle of the control lever from neutral.
Brake system
The brake system consists of a service brake,
secondary brake and parking brake.
The service brake is hydrostatisc and is activated by
moving the control lever to neutral.
Secondary/Parking brake
The secondary and parking brake system consists of
sprung multiple disc brakes in the motors. The brakes
are released with hydraulic pressure and are operated
with a switch on the instrument panel.
Steering system
The steering system is a hydrostatic system.
The control value on the steering column distributes
the flow to the control cylinder, which actuates the
articulation.
The steering angle is proportional to the deflection of
the steering wheel.
ROPS
ROPS is the abbreviation for "Roll Over Protective
Structure".
If any part of the ROPS structure's protective
construction displays plastic deformation or cracks, the
ROPS structure must be replaced immediately.
Never perform unauthorized modifications on the
ROPS structure without first having discussed the
modification with Dynapac's production unit. Dynapac
21
Machine description
determines whether the modification could result in the
approval according to the ROPS standards becoming
invalid.
Identification
Product identification number on the frame
The machine PIN (Product Identification Number) (1)
is punched on the right edge of the front frame.
1
Fig. PIN right side
1
Fig. PIN front right
22
Machine description
Machine plate
The machine plate (1) is attached to the front right side
of the rear frame, beside the steering joint.
The plate specifies the manufacturers name and
address, the type of machine, the PIN, Product
Identification Number (serial number), operating
1
weight, engine power and year of manufacture. CE
markings and the year of manufacture may be omitted
on machines supplied to markets outside the EU.
Fig. Operator's platform, right side
1. Machine plate
Please state the machine’s PIN when ordering
spares.
Explanation of 17PIN serial number
100
00123
V
x
A
123456
A= Manufacturer
A
B
C
F
B= Family/Model
C= Check letter
F= Serial number
23
Machine description
Engine plates
The engine's type plate (1) is located on top of the
cylinder head cover.
The plate specifies the type of engine, its serial
number and the engine specification.
Please specify the engine serial number when
ordering spares. Refer also to the engine manual.
1
Fig. Engine
1. Type plate
24
Machine description
Decals
Location - decals
5, 8
15
2
10
3
1
16
13
9
5
8
14
4
12
17
11
1, 6
8
9
14
18
7
5
Fig. Location, decals and signs
1.
Warning, Crush zone
4700903422
8.
Lifting point
4700357587
2.
Warning, Rotating engine components
4700903423
9.
Hoisting plate
4700904870
3.
Warning, Hot surfaces
4700903424
10.
Handbook compartment
4700903425
4.
Warning, Instruction manual
4700903459
11.
Battery disconnector (Option)
4700904835
5.
Warning, Locking
4700908229
12.
Hydraulic fluid level
4700272373
6.
Acoustic power level
4700791293
13.
Bio hydraulic fluid PANOLIN
4700792772
(Option)
7.
Diesel fuel
4700991658
14. Fixing point
4700382751
15. Warning, Tip-over risk *)
4811000351
*) Applies only CC800/900
16. Warning, Starting gas
4700791642
equipped with ROPS.
17. Starting instruction
4700379012
18. Warning - Locking during transport 4812125363
25
Machine description
Decals
Location - decals
5, 8
15
2
10
3
1
16
13
9
5
8
14
4
12
17
11
1, 6
8
9
14
18
7
5
Fig. Location, decals and signs
1.
Warning, Crush zone
4700903422
2.
Warning, Rotating engine components
4700903423
9.
Hoisting plate
4700904870
3.
Warning, Hot surfaces
4700903424
10.
Handbook compartment
4700903425
4.
Warning, Instruction manual
4700903459
11.
Battery disconnector (Option)
4700904835
5.
Warning, Locking
4700908229
12.
Hydraulic fluid level
4700272373
6.
Acoustic power level
4700791293
13.
Bio hydraulic fluid PANOLIN
4700792772
(Option)
7.
Diesel fuel
4700991658
14. Fixing point
4700382751
8.
Lifting point
4700357587
15. Warning, Tip-over risk *)
4811000351
*) Applies only CC800/900
16. Warning, Starting gas
4700791642
equipped with ROPS.
17. Starting instruction
4700379012
18. Warning - Locking during transport 4812125363
26
Machine description
Location - decals, CALIFORNIA
Proposition 65
1
1.
Warning, CALIFORNIA
4812129673
Proposition 65
Fig. Location
Safety decals
Always make sure that all safety decals are completely
legible, and remove dirt or order new decals if they
have become illegible. Use the part number specified
on each decal.
If a part is replaced and this part have a decal, make
sure to also order the decal.
4700903422
Warning - Crush zone, articulation/drum.
Maintain a safe distance from the crush zone.
(Two crush zones on machines fitted with pivotal steering)
4700903423
Warning - Rotating engine components.
Keep your hands at a safe distance.
4700903424
Warning - Hot surfaces in the engine compartment.
Keep your hands at a safe distance.
27
Machine description
4700903459
Warning - Instruction manual
The operator must read the safety, operation and
maintenance instructions before operating the
machine.
4700908229
Warning - Risk of crushing
The articulation must be locked when lifting.
Read the instruction manual.
4811000351
Warning - Risk of tip over
If ROPS (Roll Over Protective Structure) is fitted to
the roller, always wear the seat belt.
Read the instruction manual.
4700791642
Warning - Starting gas
Starting gas is not to be used.
4812125363
Warning - Locking
The articulation must be locked during transport
and lifting,
but be open during operation.
Read the instruction manual.
28
Machine description
4812129673
Warning
CALIFORNIA - Proposition 65
29
Machine description
Info decals
Noise power level
Diesel fuel
Lifting point
Hoisting plate
Handbook compartment
Battery isolation switch
Hydraulic oil level
Biological hydraulic fluid
Securing point
PANOLIN
Starting instruction
30
Machine description
Fuel
If using diesel fuel not compliant with EN 590 or ASTM
D975, consult the engine manual.
The Diesel Fuel Specification Type and Sulfur content
% (ppm) used, must be compliant with all applicable
emission regulations for the area in which the
machine is operating.
Ultra low sulfur fuel (< 15 ppm) is for example
mandatory when operated in US EPA regulated areas,
in Regulation (EU) 2016/1628 areas, in South Korea
and in Japan.
It is always recommended to use < 15 ppm sulfur fuel
to comply with declared engine emission levels.
Though, this engine can be operated on diesel fuel
with sulfur content up to 1000 ppm without engine
harm, but with higher emission levels.
If fuel with even higher sulfur content than 1000 ppm
is used consult the engine manual regarding
restrictions including engine oil and filter change
intervals.
31
Machine description
Instruments/Controls
Locations - Instruments and controls
16
22
14
13
12
15
17
21
20
18
31
19
Fig. Instruments and control panel
12.
Manual/automatic sprinkler
17.
Hazard beacon
13.
Sprinkler timer
18.
Direction indicators
14.
Road lights
19.
Horn
15.
Working lights
20.
Vibration manual/automatic
16.
Hazard warning lights
21.
Vibration selector Front/rear drum
22.
Control panel
*
= Option
31.
Parking brake On/Off
32
Machine description
Locations - Control panel and controls
26
24
25
27
9
31
23
8
29
Fig. Control panel
3
30
28
7
1
6
Fig. Operator's
station
4
5
2
Fig. Operator position
1
Starter switch
23
Low fuel level
2
Engine speed control
24
Oil pressure, engine
3
Emergency stop
25
Parking brake lamp
4
Vibration On/Off
26
Fuel level
5
Handbook compartment
27
Water temperature, engine
6
Forward/reverse lever
28
Battery/charging
7
Seat switch
29
Glow plug
8
Fuse box
30
Hourmeter
9
Instrument cover
31
Parking brake
33
Machine description
Function description
No
Designation
Symbol
Function
1.
Starter switch
Positions 1-2: Shut off position, key can be removed.
Position 3a: All instruments and electric controls are
supplied with power.
Position 3b: Glowing. Hold the starter switch in this
position until the lamp goes out. The starter motor is
activated in the next position.
Position 3c: Starter motor activation.
2.
Engine speed
Raise the lever and release it into the groove to the
control
left to set engine speed to operating speed. To
select idling speed, move the lever to the right and
downwards.
3.
Emergency stop
When pressed, the emergency stop is activated. The
engine switches off and the brakes are activated.
Brace yourself for a sudden stop.
4.
Vibration On/Off.
Press once and release to switch vibration on. Press
Switch
again to switch the vibration off.
5.
Handbook
Pull up and open the top of the compartment for
compartment
access to handbooks.
6.
Forward/Reverse
The engine can only be started when the lever is in
lever
neutral. The engine will not start if the
forward/reverse lever is not in the neutral position.
Direction of travel and speed of the roller is regulated
with the forward/reverse lever. Move the lever
forward to drive the roller forwards, etc.
The speed of the roller is proportional to the distance
of the lever from the neutral position. The further the
lever is from the neutral position, the higher the
speed.
7.
Seat switch
Remain seated at all times when operating the roller.
If the operator stands up during operation, a buzzer
sounds. After 4 seconds the brakes are activated
and the engine stops.
8.
Fuse box (on
Contains fuses for the electrical system. See under
control column)
the heading ‘Electrical system’ for a description of
fuse functions.
9.
Instrument cover
Lowered over the instrument plate to protect the
instruments from the weather and sabotage. Lockable
12.
Sprinkler, switch
Upper position = switching on of flow of water to
drum.
Intermediate position = Sprinkling switched off
Lower position = switching on of water to drum via
forward/reverse lever.
The flow of water can be controlled by means of the
sprinkler timer (13).
Watering off
Water supply to drum via forward/reverse lever in
AUTO
AUTO mode. The flow of water can be controlled by
means of the sprinkler timer (13).
34
Machine description
No
Designation
Symbol
Function
13.
Sprinkler timer
Stepless regulation of the water flow from 0-100%.
(Optional)
Only functions where AUTO (12.) is depressed.
14.
Road lights,
Where the upper position is depressed, the road
switch (Optional)
lights are on. Where the lower position is, depressed
the parking lights are on.
15.
Working lights,
When depressed, the working lights are on
switch
16.
Hazard warning
Where depressed, the hazard warning lights are on
lights, switch
(Optional)
17.
Hazard beacon,
Where depressed, the hazard beacon is on
switch
18.
Direction
When depressed to the left, the left direction
indicators,
indicators are on etc. In the middle position the
switch (Optional)
function is shut off.
19.
Horn, switch
Press to sound the horn.
20.
Vibration
In the upper position, the vibration is switched on/off
MAN/AUTO switch
with the switch on the forward/reverse lever. The
function is activated with the switch.
In the middle position, the vibration system is
switched off.
In the lower position, vibration is automatically
switched on or off via the forward/reverse lever.
21.
Vibration selector
In the depressed forward position, vibration is
front/rear drum,
activated on the front drum. In the middle position,
switch (Optional)
vibration is activated on both drums. In the
depressed rear position, vibration is activated on the
rear drum.
22.
Control panel
23.
Warning lamp, low
The lamp comes on when the fuel level in the tank is
fuel level
low.
35
Machine description
No
Designation
Symbol
Function
24.
Warning lamp, oil
This lamp lights if the lubricating pressure in the
pressure
engine is too low. Stop the engine immediately and
locate the fault.
25.
Warning lamp,
The lamp lights when the parking brake is activated.
parking brake
26.
Fuel level
Shows the fuel level in the diesel tank.
27.
Warning lamp,
The light comes on if the water temperature is too
water temperature
high.
28.
Warning lamp,
If the lamp lights while the engine is running the
battery charging
alternator is not charging. Stop the engine and
locate the fault.
29.
Warning lamp,
The lamp must go out before the starter switch is
glow plug
moved to position 3c for activation of the starter
motor.
30.
Hourmeter
Shows the number of hours the engine has run.
31.
Parking brake
To activate the brakes, press the top of the switch to
On/Off, switch
change the position of the lever.
To disengage the brakes, press down the red part at
the same time as the switch, and change the position
of the lever.
NOTE: When starting the machine, the parking brake
must be activated.
Always use the parking brake when the machine
is stationary on a sloping surface.
Electrical system
Fuses
The figure shows the position of the fuses.
The table below gives fuse amperage and function. All
fuses are flat pin fuses.
Fig. Fuse box
Fuses in the fusebox
1.
ECU Instrument panel, Sprinkler
20A
5.
Hazard beacon
10A
2.
Horn, Alternator, Fuel pump
10A
6.
Direction indicators, Power socket 12V
10A
3.
Right direction indicators, Side
5A
7.
Driving lights, Working lights main headlight
15A
repeaters
front
4.
Left direction indicators, Side repeaters
5A
8.
Driving lights, Position lights, Brake lights,
15A
Working lights rear, Number sign lighting
36
Machine description
Fuses in engine compartment
1
The figure shows the position of the fuses.
2
The amperage and function of the fuses are shown
below. All fuses are flat pin fuses.
Fuses in engine compartment
F10
Main fuse (Type E - High)
30A
Fig. Fuses, engine compartment
F20
Heater plugs
50A
1. Heater plugs
2. Main fuse
Relays
4
1.
K1
Starting
2.
K5
Glow plug
3.
K9
Direction indicators
4.
K10
Brake lights
3
2
1
Fig. Relays
37
Machine description
38
Operation
Operation
Before starting
Battery isolation switch - On - Optional
Remember to carry out daily maintenance. Refer to
the maintenance instructions.
PLUS version
The battery disconnector is located on the left side of
the engine compartment.
Turn the key (1) to the On position.
CC version
3
2
1
Fix the red cable lug (3) on the plus terminal on the
battery.
Fig. Left side of engine
The roller is now supplied with power.
1. Battery disconnector
(only PLUS version)
2. Power socket, 12V
The engine cover must be unlocked when
3. Cable lug
operating, so that the battery can be quickly
disconnected if necessary.
Driver seat (CC version) - Adjustment
Adjust the operator’s seat so that the position is
comfortable and so that the controls are within easy
reach.
The seat can be adjusted lengthways (1).
1
Fig. Operator's seat
1. Length adjustment
39
Operation
Driver seat (Plus version) - Adjustment
Adjust the operator’s seat so that the position is
comfortable and so that the controls are within easy
reach.
2
1
The seat can be adjusted as follows.
4
- Length adjustment (1)
3
- Weight adjustment (2)
Fig. Driver seat
- Back support angle (3)
1. Lock lever - Length adjustment
2. Weight adjustment
3. Back support angle
4. Seat belt
Always make sure that the seat is secure before
beginning operation.
Do not forget to use the seat belt (4).
Instruments and lamps - Checking
Make sure that the emegency stop is pulled out
22
and the parking brake is activated. When the
forward/reverse lever is in neutral, the automatic
12
brake function is engaged.
3
1
1
Figure. Instrument panel
Turn the switch (1) to position 3a.
1. Starter switch
3. Emergency stop
Check that the warning lamps in the warning panel
12. Switch, watering
(22) come on.
22. Warning panel
Set the sprinkler switch (12) to the operating position
and check that the system is functioning.
40
Operation
Interlock
The roller is equipped with Interlock.
Roller equipped with Sauer-Danfoss ECU:
The diesel engine with switch off after 4 seconds if the
operator gets off the seat when going
forwards/backwards.
If the control is in neutral when the operator stands up
a buzzer will go on until the parking brake button is
activated.
The engine does not stop if the parking brake is
activated.
The diesel engine will switch off immediately if for any
reason the forward/reverse lever is moved out of
neutral when the operator is not sitting down and the
parking brake button has not been activated.
Roller equipped with HY-TTC 71 ECU:
If the operator is leaving the seat with the diesel
engine running, travel lever in neutral position and
parking brake disengaged, the buzzer will set and the
diesel engine will shut down after four seconds.
During these four seconds the diesel engine shut
down can be rescinded either by engaging the parking
brake or to be seated.
If the operator is not seated and move the travel lever
out of neutral position, the buzzer will set and the
diesel engine will shut down instantly.
Sit down for all operations!
41
Operation
Operator position
Replace the seat belt (1) if it shows signs of
wear or has been subjected to high levels of
force.
Never use the forward/reverse levers as a handle
when mounting or disembarking from the roller.
2
Check that the rubber elements (4) on the
platform are intact. Worn elements will reduce
1
comfort.
Ensure that the anti-slip (5) on the platform is in
4, 5
good condition. Replace where anti-slip friction is
poor.
Fig. Operator's seat
1. Seatbelt
2. ROPS
4. Rubber element
5. Anti-slip
Machines with folding ROPS must always be
operated with the ROPS raised and locked in
position.
The interlock must always be checked before
operating. To do this the operator stands up from
the seat as shown in the instructions in the
section Operation.
If ROPS (Roll Over Protective Structure) is fitted to the
roller, always wear the seat belt (1) provided and wear
a protective helmet.
42
Operation
Starting
Starting the engine
The operator must remain seated when starting.
29
31
Make sure that the emegency stop (3) is pulled out
20
and the parking brake (31) is activated.
Set the forward/reverse lever (6) in neutral. The
3
engine can only be started when the lever is in neutral.
1
Set the vibration switch (20) for manual/automatic
6
vibration in (position O).
2
Do not run the starter motor for too long. If
the engine does not start, wait a minute or so
before trying again.
Figure. Control panel
1. Starter switch
2. Engine speed control
3. Emergency stop
6. Forward/Reverse lever
At high ambient temperatures, set the speed control
20. Vibration switch man/auto
29. Glow lamp
(2) to the position just over idling.
31. Parking brake
Set the speed control to full speed when starting a
cold engine. Preheating: Turn key to position II. When
the glow lamp (29) goes off: Turn the starter switch (1)
to the right. As soon as the engine starts, release the
starter switch and reduce the engine speed to just
over idling (because high revs can damage a cold
engine). As soon as the engine is running smoothly,
reduce the revs down to idling.
Warm up the engine at idling speed for a few minutes,
although longer if ambient temperature is below +10°C
(50°F).
43
Operation
Check while warming the engine that the warning
lamps for the oil pressure (24) and charging (28) go
out.
The warning lamp (25) should remain on.
When starting and driving a machine that is cold,
20
remember that the hydraulic fluid is also cold and
that braking distances can be longer than normal
Fig. Instrument panel
until the machine reaches the working temperature.
20. Vibration switch
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
25
24
28
29
Fig. Control panel
24. Oil pressure lamp
25. Brake lamp
28. Charging lamp
29. Glow lamp
44
Operation
Driving
Operating the roller
Under no circumstances is the machine to be
operated from the ground. The operator must be
seated inside the machine during all operation.
3
Make sure that the area in front of and behind the
roller is clear.
1
6
2
Release the parking brake (31) and check that the
parking brake lamp (25) goes off.
Figure. Instrument panel
1. Starter switch
Turn the engine speed control upwards (2) and lock it
2. Engine speed control
in the working position.
3. Emergency stop
6. Forward/reverse lever
Check that the steering is working correctly by turning
the steering wheel once to the right and once to the
left while the roller is stationary.
When compacting asphalt, remember to turn on the
sprinkler system (12).
25
Carefully move the forward/reverse lever (6) forwards
or backwards, depending on which direction of travel
is required.
Speed increases as the lever is moved away from the
neutral position.
The speed should always be controlled using the
12
forward/reverse lever and never by changing the
31
engine speed.
Figure. Instrument panel
12. Switch for sprinkler
25. Parking brake lamp
31. Parking brake
Check when operating that the warning lamps do not
come on.
45
Operation
Interlock/Emergency stop/Parking brake -
Check
The interlock, emergency stop and parking brake must
be checked daily before operating. A function check of
the interlock and emergency stop requires a restart.
The interlock function is checked by the operator
standing up from the seat when the roller is moving
very slowly forwards/backwards. (Check in both
directions). Hold the steering wheel firmly and brace
yourself for a sudden stop. A buzzer goes on and after
4 seconds the engine switches off and the brakes are
activated.
Check the function of the emergency stop by pressing
the emergency stop when the roller is moving slowly
forwards/backwards. (Check in both directions). Hold
the steering wheel firmly and brace yourself for a
sudden stop. The engine switches off and the brakes
are activated.
Check the function of the parking brake by activating
the parking brake when the roller is moving very
slowly forwards/backwards. (Check in both
directions). Hold the steering wheel and brace yourself
for a sudden stop when the brakes are activated. The
engine does not switch off.
Vibration
Manual/Automatic vibration
Manual or automatic vibration activation/deactivation is
selected using switch (20).
In the manual position, the operator must activate the
vibration using the switch(4) on underside of the
forward/reverse lever grip.
In the automatic position, vibration is activated when
the pre-set speed is reached. Vibration is
automatically deactivated when the lowest pre-set
20
speed is reached.
Fig. Instrument panel
20. Switch Man/Aut.
46
Operation
Manual vibration - Switching on
Vibration should not be active when the roller is
stationary. This can damage both the surface and
the machine.
Engage and disengage vibration using the switch (4)
on the underside of the forward/reverse lever.
Always switch off vibration before the roller comes to a
standstill.
4
Fig. Forward/Reverse lever
4. Switch, vibration On/Off
Braking
Normal braking
Braking is normally activated using the
forward/reverse lever. The hydrostatic transmission
brakes the roller when the lever is moved towards the
neutral position.
Press the switch (4) to switch off the vibration.
Move the forward/reverse lever (6) to the neutral
position to stop the roller.
31
When starting and driving a machine that is cold,
remember that the hydraulic fluid is also cold and
that braking distances can be longer than normal
3
until the machine reaches the working temperature.
6
Never leave the operator platform without
activating the parking brake (31).
4
2
Figure. Control panel
2. Engine speed control
3. Emergency stop
4. Vibration On/off
6. Forward/reverse lever
31. Parking brake
47
Operation
Emergency braking
There is a brake in each drum motor that acts as an
emergency brake during operation.
To brake in an emergency situation, push in the
emergency stop (3), hold the steering wheel firmly
and be prepared for a sudden stop. The diesel
engine stops.
3
Fig. Control panel
After braking, return the forward/reverse lever to the
3. Emergency stop
neutral position and pull out the emergency stop.
Restart the engine.
Switching off
22
Turn the engine speed control (2) back to idling. Allow
31
the engine to idle for a few minutes to cool.
9
Activate the parking brake (31).
1
Check instruments and warning lamps to see if any
2
faults are indicated. Switch off all lights and other
electrical functions.
Figure. Instrument panel
Turn the starter switch (1) to the left to the switched off
1. Starter switch
position. At the end of the shift, fold over the
2. Engine speed control
instrument cover (9) and lock.
9. Instrument cover
22. Panel for warning lamps
31. Parking brake
48
Operation
Parking
Chocking the drums
Never leave the operator platform without
activating the parking brake (31).
1
Make sure that the roller is parked in a safe place
with respect to other road users. Chock the drums
if the roller is parked on sloping ground.
Fig. Set-up
1. Chocks
Keep in mind that there is a risk of freezing during
the winter. Drain the water tanks and water lines.
Master switch - Optional
The power to the roller should be disconnected at the
end of the working shift.
PLUS version
Put the battery disconnector (1) in the Off position and
remove the key.
CC version
Remove the red cable lug (3) from the plus terminal on
the battery.
3
2
1
This will prevent battery discharging and will also
make it difficult for unauthorized persons to start and
operate the machine. Lock also the engine cover.
Fig. Battery compartment
1. Battery disconnector
(only PLUS version)
2. Power socket, 12V
3. Cable lug
49
Operation
50
Long-term parking
Long-term parking
The following instructions should be followed
when long term parking (more than one month).
These measures apply when parking for a period of up
to 6 months.
Before re-commissioning the roller, the points marked
with an asterisk * must be returned to the pre-storage
state.
Wash the machine and touch up the paint finish to
Fig. Roller weather protection
avoid rusting.
Treat exposed parts with anti-rust agent, lubricate the
machine thoroughly and apply grease to unpainted
surfaces.
Engine
* Refer to the manufacturer’s instructions in the engine
manual that is supplied with the roller.
Battery
* Remove the battery from the machine, clean, grease
the cable connectors (terminals) and trickle charge the
battery once a month. The battery is otherwise
maintenance free.
Air cleaner, exhaust pipe
* Cover the air cleaner (see under the heading ‘Every
50 hours of operation’ or ‘Every 500 hours of
operation’) or its inlet with plastic or tape. Also cover
the exhaust pipe opening. This is to avoid moisture
entering the engine.
Sprinkler system
* Drain the water tank completely (see under the
heading ‘Every 2000 hours of operation’). Drain all
hoses, filter housings and the water pump. Remove all
sprinkler nozzles (see under the heading ‘Every 10
hours of operation’).
Fuel tank
Fill the fuel tank completely full to prevent
condensation.
51
Long-term parking
Hydraulic reservoir
Fill the hydraulic reservoir to the uppermost level mark
(see under the heading ‘Every 10 hours of operation.’)
Steering cylinder, hinges, etc.
Grease the steering cylinder piston with conservation
grease.
Grease the hinges on the doors to the engine
compartment. Grease both ends of the
forward/reverse control (bright parts) (see under the
heading ‘Every 500 hours of operation’).
Hoods, tarpaulin
* Lower the instrument cover over the instrument
panel.
* Cover the entire roller with a tarpaulin. A gap must
be left between the tarpaulin and the ground.
* If possible, store the roller indoors and ideally in a
building where the temperature is constant.
52
Miscellaneous
Miscellaneous
Lifting
Locking the articulation
3
Before lifting the roller the steering joint must be
locked to prevent it turning.
2
1
Turn the steering wheel to the straight ahead position.
Switch off the machine. Apply the parking brake.
Pull out the locking pin (1), turn the locking arm (2) to
the front frame, secure the locking arm to the front
frame half by inserting the locking bolt (3) through the
Fig. Steering joint
bracket in the front frame and the locking arm.
1. Cotter pin
2. Locking arm
Secure the position of the locking arm by refitting the
3. Locking bolt
locking pin (1).
Lifting the roller
Weight: refer to the hoisting plate on
The machine’s gross weight is specified on the
the roller
hoisting plate (1). Refer also to the Technical
specifications.
Lifting gear such as chains, steel wires, straps,
and lifting hooks must be dimensioned and used
1
in accordance with the applicable safety
regulations for lifting devices.
Stand well clear of the hoisted machine! Make sure
that the lifting hooks are properly secured.
Fig. Roller prepared for lifting
1. Hoisting plate
53
Miscellaneous
Unlocking the articulation
Remember to unlock the articulation before
operating.
3
2
Pull out the locking pin (1), turn the locking arm (2) for
the rear frame, secure the locking arm by inserting the
locking bolt (3) through the mounting in the rear frame
and locking arm. Insert the locking pin.
1
Fig. Articulation
1. Locking pin
2. Locking arm
3. Locking bolt
Transport
Tie-down and secure the machine according to the
Cargo Securing Certificate for the specific machine if
this is avaliable and applicable.
If not, tie down and secure the machine according to
the cargo securing rules that are valid for the country
where the transport takes place.
Never lash over the machine’s articulated joint, nor
over the machine’s operator platform.
Before securing the machine ensure that :
• the parking brake is applied and in good working condition
• the articulated joint is in closed position
• the machine is centered laterally on the platform
• the lashings are in good condition and fulfills the
corresponding rules for transport securing.
54
Miscellaneous
Securing CC800/900/1000 for loading
Securing the CC800/900/1000 vibratory roller from
Dynapac for transport.
Roller loaded in forward
direction
Direct of travel
1 - 2
= double lashings, i.e. one lashing with two parts secured to two different lashing mounts,
3 - 4
symmetrically located on the right and left sides.
5
= rubber
The lashings' permitted distance interval in meters
(1 - 4: Double lashings, LC at least 1.7 tonnes (1700 daN), STF 300 kg (300daN))
Double L1 - L2
Double L3 - L4
0,6 - 3,0
0,1 - 3,0
The distance L1 above is between points D and E. D is the projected point directly at right angles laterally in relation to
the edge of the platform from the lashing mount C on the roller. E is the lashing mount at the edge of the platform. L2 -
L3 have a corresponding relationship.
55
Miscellaneous
Load carrier
-
When loaded, the vibratory roller is centered laterally on the platform (± 5 cm).
-
The parking brake is applied and in good working condition, and the articulated joint lock is
closed.
-
The drum is placed on a rubber liner, so that the static friction between the surfaces is at least
0.6.
-
The contact surfaces must be clean, wet or dry, and free from frost, ice and snow.
-
The lashing mounts on the load carrier have LC/MSL at least 2 tonnes.
Lashings
-
The lashings comprise a lashing strap or chain with a permitted load (LC/MSL) of at least 1.7
tonnes (1,700 daN) and a pre-tension STF of at least 300 kg (300 daN). The lashings are
re-tightened as required.
-
Each of lashings 1-3 is either a double or two single lashings. A double lashing runs in a sling
through a lashing point or around a machine part and down into two different mounts on the
platform.
-
Lashings in the same direction are placed in different lashing mounts on the trailer. Lashings
that are pulled in opposite directions may be placed in the same lashing mount, however.
-
The lashings are as short as possible.
-
The lashing hooks must not lose grip if the lashings become slack.
-
The lashings are protected against sharp edges and corners.
-
The lashings are located symmetrically in pairs on the right and left sides.
Towing/Recovering
The roller can be moved up to 300 meters (330 yards)
using the instructions below.
Switch off the diesel engine and push in the
emergency stop knob. Chock the drum to prevent
the roller from moving when the brakes are
disengaged.
The brakes in each propulsion motor must be
mechanically released, as described below,
1
before the roller is towed.
Fig. Drum
1. Propulsion motor, located left
front and right rear.
56
Miscellaneous
Releasing the brake
1. Remove the 2 plugs (191).
Figure. Releasing the brake
2. Press the screws (192) inwards to compress the
springs (193) so that the screw reaches the brake
(107) inner thread.
3. Tighten the two screws (192) alternately a little at a
time so that the brake piston (107) loose (screw
approximately 2 turns).
Tightening the screws (192) too hard can damage
the inner mechanism
The machine should be started with reactivated
brake.
57
Miscellaneous
Restored brake
Undo the two screws (192) alternately, and then insert
the plugs (191).
Tightening torque
Screws (192)
Plugs (191)
Towing the roller
A towing bar must be used when towing, as the
roller has no brakes and can only be slowed and
stopped by the vehicle towing the roller.
The roller must be towed slowly, max. 3 km/h (2
mph) and for short distances only, max. 300 m
(1000 ft).
Fig. Towing the roller
When towing/recovering a machine, the towing device
must be connected to both lifting holes. Pulling forces
shall act longitudinally on the machine as illustrated.
Max total towing force 50.8 kN (11,430 lbf), 25.4 kN
(5,715 lbf) per fork.
Reset the steps taken for towing as described in
the towing instructions on the previous page.
58
Operating instructions - Summary
Operating instructions - Summary
1.
Follow the SAFETY INSTRUCTIONS specified in the Safety Manual.
2.
Make sure that all instructions in the MAINTENANCE section are followed.
3.
Turn the master switch to the ON position.
4.
Move the forward/reverse lever to the NEUTRAL position.
5.
Set the switch for Manual/Automatic vibration to the 0 position.
6.
Set the engine speed control to full speed.
7.
Set the emergency stop in the pulled out position.
8.
Start the engine and allow it to warm up.
9.
Set the engine speed control to the operating position.
10. Drive the roller. Operate the forward/reverse lever with care.
11. Check the brakes, drive slowly. Remember that the braking distance will be
longer if the roller is cold.
12. Use vibration only when the roller is in motion.
13. Check that the drums are thoroughly watered when watering is required.
14. IN AN EMERGENCY:
- Press the EMERGENCY STOP
- Hold the steering wheel firmly.
- Brace yourself for a sudden stop. The engine stops.
15. Parking: - Stop the engine and chock the drums.
16. When lifting: - Refer to the relevant section in the Instruction Manual.
17. When towing: - Refer to the relevant section in the Instruction Manual.
18. When transporting: - Refer to the relevant section in the Instruction Manual.
19. When recovering - Refer to the relevant section in the Instruction Manual.
59
Operating instructions - Summary
60
Preventive maintenance
Preventive maintenance
Complete maintenance is necessary for the machine
to function satisfactorily and at the lowest possible
cost.
The Maintenance section includes the periodic
maintenance that must be carried out on the machine.
The recommended maintenance intervals assume that
the machine is used in a normal environment and
working conditions.
Acceptance and delivery inspection
The machine is tested and adjusted before it leaves
the factory.
On arrival, before delivery to the customer, delivery
inspection must be conducted as per the check list in
the warranty document.
Any transport damage must be reported immediately
to the transport company, as this is not covered by the
product warranty.
Warranty
The warranty is only valid if the stipulated delivery
inspection and the separate service inspection have
been completed as per the warranty document, and
when the machine has been registered for starting
under the warranty.
The warranty is not valid if damage has been caused
by inadequate service, incorrect use of the machine,
the use of lubricants and hydraulic fluids other than
those specified in the manual, or if any other
adjustments have been made without the requisite
authorization.
61
Preventive maintenance
CALIFORNIA
Proposition 65
Decal and location of decal shown in section
Machine description.
62
Maintenance - Lubricants and symbols
Maintenance - Lubricants and symbols
Fluid volumes
Hydraulic reservoir
12 liters
3,2 gal
Engine
5,1 liters
5.4 qts
Coolant
5,2 liters
5.5 qts
Drum
- CC800
2,5 liters
2.6 qts
- CC900
3,5 liters
3.7 qts
- CC1000
4,5 liters
4.8 qts
Always use high-quality lubricants and the
amounts recommended. Too much grease or
oil can cause overheating, resulting in rapid
wear.
Other fuel and lubricants are required when
operating in areas with extremely high or
extremely low ambient temperatures. See the
‘Special instructions’ chapter, or consult
Dynapac.
63
Maintenance - Lubricants and symbols
ENGINE OIL
Air temperature -15°C - +50°C
Dynapac Engine Oil
P/N 4812161855 (5 liter)
(5°F-122°F)
200
P/N 4812161856 (20 litres)
P/N 4812161857 (209 liter)
HYDRAULIC FLUID
Air temperature -15°C - +40°C
Dynapac Hydraulic 300
P/N 4812161868 (20 liter)
(5°F-104°F)
P/N 4812161869 (209 liter)
Air temperature over +40°C
Shell Tellus S2 V100
(104°F)
BIOLOGICAL
When it leaves the factory, the
PANOLIN HLP Synth 46
HYDRAULIC FLUID,
machine may be filled with
PANOLIN
biologically degradable fluid.
The same type of fluid must be
used when changing or topping
up.
BIOLOGICAL
When it leaves the factory, the
BP Biohyd SE-S46
HYDRAULIC FLUID
machine may be filled with
biologically degradable fluid.
The same type of fluid must be
used when changing or topping
up.
DRUM OIL
Air temp. -15°C - +40°C
Dynapac Gear Oil 300
P/N 4812161883 (5 liter)
(5°F-104°F)
P/N 4812161884 (20 liter)
P/N 4812161885 (209 liter)
Air temp. 0°C (32°F) - above
Shell Spirax AX
+40°C (104°F)
85W/140, API GL-5
GREASE
Dynapac Roller Grease
P/N 4812030096 (0.4 kg)
FUEL
See engine manual.
-
-
To comply with emission
requirements for Kubota D1105
you must use fuel with a low or
extremely low sulphur content.
COOLANT
Anti-freeze protection down to
Dynapac Coolant 100
P/N 4812161854 (20 liter)
about -37°C (-34.6°F)
(mixed 50/50 with water)
64
Maintenance - Lubricants and symbols
Maintenance symbols
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
Coolant level
65
Maintenance - Lubricants and symbols
66
Maintenance - Maintenance schedule
Maintenance - Maintenance schedule
Service and maintenance points
3
2
1
6
4
5
7
8
14
9
17
10
16
11
15
13
Fig. Service and maintenance points
12
11
1.
Water tank, filling
7.
Air cleaner
13. Hydraulic fluid, filling
2.
Forward/Reverse lever
8.
Battery (maintenance free)
14. Fuel tank, refilling
3.
Emergency brake
9.
Sprinkler
(left side)
4.
Hydraulic fluid cooler/ radiator
10. Scrapers
15. Steering joint
5.
Alternator belt
11. Rubber element
16. Drums, filling with oil
6.
Engine
12. Hydraulic fluid filter
17. ROPS
67
Maintenance - Maintenance schedule
General
Periodic maintenance should be carried out after the
number of hours specified. Use the daily, weekly etc.
periods where number of hours cannot be used.
Remove all dirt before filling, when checking
oils and fuel and when lubricating using oil or
grease.
The manufacturer’s instructions found in the
engine manual also apply.
Specific maintenance and checks on diesel
engines must be carried out by the engine
supplier’s certified personnel.
Where both operational hours and time intervals
are specified, maintenance should be carried out
at the point in time that occurs first.
Every 10 hours of operation (Daily)
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
Before starting up for the first time on that day
6
Check the engine oil level
Refer to the engine manual
13
Check the hydraulic reservoir level
4
Check the coolant level
14
Refuel
1
Fill the water tanks
9
Check the sprinkler system
4
Check for free circulation of cooling air
10
Check the scraper setting
Check the warning lamps
7
Check the air cleaner indicator
3
Test the brakes
68
Maintenance - Maintenance schedule
After the FIRST 50 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Action
Comment
6
Change the engine oil and oil filter
Refer to the engine manual
12
Change the hydraulic fluid filter
Check the belt tension on the hydraulic vibration and
steering pump drive belt
Every 50 hours of operation (Weekly)
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
7
Empty the air cleaner dust trap
11
Check rubber elements and bolted joints
Every 250 / 750 / 1250 / 1750 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
7
Clean the air cleaner filter element, check that hoses
and connectors are tight
4
Clean the outside of the radiator core.
In dusty environments, as
necessary.
2
Check lubrication of controls and pivots
Lubricate as necessary
5
Check fan belt tension and condition
Replace where necessary
6
Change the engine oil and oil filter
Refer to the engine manual
69
Maintenance - Maintenance schedule
Every 500 / 1500 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
4
Clean the outside/inside of the radiator core
In dusty environments, as
necessary
2
Check lubrication on controls and joints
Lubricate if necessary
5
Check the tension and condition of the fan belt
Replace if necessary
7
Replace the air cleaner filter element, check that
hoses and connectors are tight
6
Change the fuel filter
Refer to the engine manual
6
Change the engine oil and oil filter
Refer to the engine manual
4
Check coolant freezing point
Change the coolant every
other year
16
Check the oil level in the drums
5
Replace fan belt
Refer to the engine manual
13
Check the hydraulic reservoir cover/breather
Check the belt tension on the hydraulic vibration and
steering pump drive belt
70
Maintenance - Maintenance schedule
Every 1000 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
4
Clean the outside/inside of the radiator core
In dusty environments, as
necessary
2
Check lubrication on controls and joints
Lubricate if necessary
5
Check the tension and condition of the fan belt
Replace if necessary
7
Replace the air cleaner filter element, check that
hoses and connectors are tight
6
Change the fuel filter
Refer to the engine manual
6
Change the engine oil and oil filter
Refer to the engine manual
4
Check coolant freezing point
Change the coolant every
other year
16
Check the oil level in the drums
13
Check the hydraulic reservoir cover/breather
12
Change hydraulic fluid filter
6
Check the engine valve clearances
Refer to the engine manual
5
Replace fan belt
Refer to the engine manual
Check the belt tension on the hydraulic vibration and
steering pump drive belt
71
Maintenance - Maintenance schedule
Every 2000 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
4
Clean the outside/inside of the radiator core
In dusty environments, as
necessary
2
Check lubrication on controls and joints
Lubricate if necessary
5
Check the tension and condition of the fan belt
Replace if necessary
7
Replace the air cleaner filter element, check that
hoses and connectors are tight
6
Change the fuel filter
Refer to the engine manual
6
Change the engine oil and oil filter
Refer to the engine manual
4
Check coolant freezing point
Change the coolant every
other year
16
Check the oil level in the drums
13
Check the hydraulic reservoir cover/breather
12
Change hydraulic fluid filter
6
Check the engine valve clearances
Refer to the engine manual
5
Replace fan belt
Refer to the engine manual
13
Change the hydraulic fluid
6
Replace the breather valve on the engine
Refer to the engine manual
16
Change the oil in the drums
1
Drain and clean the water tank
14
Drain and clean the fuel tank
15
Check the condition of the articulation
Check the belt tension on the hydraulic vibration and
steering pump drive belt
Replace the hydraulic pump drive belt
72
Maintenance - Maintenance schedule
Service - Checklist
73
Maintenance - Maintenance schedule
74
Maintenance, 10h
Maintenance, 10h
Every 10 hours of operation (Daily)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Ensure that the engine cover is fully open when
work is carried out under the cover.
Diesel engine Check oil level
Open the engine cover lock and lower the engine
cover forwards.
1
2
Check the oil level using the dipstick (1). The level
should be between the marks. If the level is near the
lower mark, top off with fresh engine oil via the filler
cap (2). See under the heading lubricants for the
correct oil grade.
Never overfill with oil, as this can damage the
engine.
Fig. Engine
1. Dipstick
2. Filler cap
75
Maintenance, 10h
Hydraulic reservoir, Level check - Filling
Wipe the sight glass (1) clean. Check that the fluid
level is between the min. and max. markings. Where
required, top off with fresh hydraulic fluid through the
2
filler hose (2).
See under the heading ‘Lubricants’ for the correct fluid
grade.
1
Fig. Hydraulic reservoir
1. Sight glass
2. Filler hose
Check - Coolant system
Check that all hoses/hose connectors are intact and
1
tight. Fill with coolant as specified in the lubricants
specification.
Take great care when opening the radiator cap
while the engine is hot. Wear protective gloves and
goggles.
2
Also check the freezing point. Change the coolant
every other year.
Figure. Cooling water container
1. Filler cap
2. Level marking
76
Maintenance, 10h
Refueling
Refuel the tank every day before starting work. Open
the tank cap and fill through the filler pipe (1).
Never refuel while the engine is running. Do not
smoke and avoid spilling fuel.
Stop the engine. Short circuit the fueling nozzle
during refueling by pressing it against the filler
pipe (1)
1
Fig. Left side
The tank holds 23 liters (6.1 gal) of fuel.
1. Filler pipe/cap
Water tank - Filling
Unscrew the tank cap (1), and fill with clean water.
Fill the water tank.
The CC version tank holds 110 liters.
The Plus version tank holds 190 liters.
1
Only additive: A small amount of environmentally
friendly antifreeze.
Fig. Water tank
1. Tank cap
77
Maintenance, 10h
Sprinkler system/Drum
Cleaning of sprinkler nozzle
Dismantle the blocked nozzle by hand.
Blow the nozzle (1) and fine filter (3) clean using
compressed air. Alternatively, fit replacement parts
and clean the blocked parts later on.
1
Nozzle
Colour
l/min (at 2.0
gal/min (at
2
bar)
40 psi)
Standard
yellow
0.63
0.20
3
Option
blue
0.98
0.30
Option
red
1.31
0.40
Figure. Nozzle
Option
brown
1.63
0.50
1. Nozzle
2. Gasket
3. Filter
After inspecting and carrying out any necessary
cleaning, start the system and check that it works.
Wear protective goggles when working with
compressed air.
Sprinkler system - Check, cleaning
Check that the holes in the sprinkler nozzles (1) are
not blocked. Clean where necessary.
1
Fig. Sprinkler system
1. Sprinkler nozzles
78
Maintenance, 10h
Sprinkler system - Check, cleaning
Check that the water filter (1) is not blocked. Clean
where necessary. Clean the water filter by unscrewing
1
the filter’s lower section, and clean the strainer and
filter housing. Reassemble in the reverse order.
Fig. Bay under the floor
1. Water filter
1
Air circulation - Check
Check that the circulation of air to the engine through
the grille in the engine cover is unobstructed.
Fig. Engine cover
1. Cooling air grille/engine
Scrapers - Check, adjustment
Make sure that the scrapers are undamaged. Adjust
the scrapers if necessary in the following way:
2
For firmer application of the scraper, undo the locking
nut (2) and adjust it until the desired application is
achieved.
3
Lock the setting by tightening the lock nut against the
mounting bracket (3).
Fig. Front scrapers in transport
position
Adjust the pressure on both scraper brackets.
2. Locking nut
3. Mounting plate
To set a lower scraper pressure, adjust in the reverse
order to the above.
79
Maintenance, 10h
Warning lamps - Check
Check that the warning lamps on the control panel
function.
Fig. Control panel.
Air cleaner indicator
If the indicator (1) on the air cleaner turns red, empty
the dust pouch (2) on the air cleaner. The dust pouch
is emptied by pressing the rubber bellows with your
fingers. Check also that the air hoses are in good
condition.
Clean the air cleaner when operated in extremely
dusty environments.
1
Fig. Air cleaner
1. Indicator
2
Fig. Air cleaner, right side
2. Dust pouch
80
Maintenance, 10h
Brakes - Check
Check operation of the brakes as follows:
25
Run the roller very slowly forward. Hold the steering
wheel firmly and brace yourself for a sudden stop.
3
Press in the emergency stop button (3). The roller will
Figure. Instrument panel
stop abruptly and the engine will switch off.
3. Emergency stop
25. Parking brake lamp
After testing the brakes, set the forward/reverse lever
in neutral.
Pull out the emergency stop button (3). Start the
engine.
The roller is now ready for operation.
Refer also to the section in the manual on operation.
81
Maintenance, 10h
82
Maintenance - 50h
Maintenance - 50h
Every 50 hours of operation (Weekly)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Ensure that the engine cover is fully open when
work is being carried out under it
After the first 50 hours of operation, the oil filters
should be changed.
Air cleaner - emptying
Empty the air cleaner dust trap (1) through pressing
the rubber bellows using the fingers. Check also that
the air hoses are intact.
Clean the air cleaner when operated in extremely
dusty environments .
1
Refer also to the section in the manual on operation.
Fig. Air cleaner
1. Dust trap
83
Maintenance - 50h
Rubber elements and fastening screws - Check
Check all the rubber elements (1), and replace all the
elements if more than 20% of them on one side of the
drum are cracked deeper than 10-15 mm.
Use a the blade of a knife or pointed object to check.
1
Check also that the screw fasteners (2) are tightened.
The screws on the rubber elements are sealed
with Loctite. Check the rubber elements on both
2
sides of the roller.
Figure. Drum suspension
1. Rubber element
2. Fastening screws
Belt tension on the hydraulic vibration and
steering pump drive belt - Check
If the hydraulic pump drive belt can be pressed in 5-6
mm between the pulleys with a force of 50 Nm, then
the belt is correctly tensioned.
Do as follows to tension the belt:
- Undo the screws (1) and (2).
- Press over the hydraulic pump so that the belt
tensions to the specified extent.
1
- Tighten screw (1) and then screw (2).
2
- Check that the belt still has the correct tension after
tightening.
Fig. Engine compartment
1. Screw
Replace the belt when necessary, or after 2000 h.
2. Screw
84
Maintenance measures - 250 h
Maintenance measures - 250 h
Every 250/750/1250/1750
hours of operation (every
3 months)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Ensure that the engine cover is fully open when
work is being carried out under it
Air cleaner - Cleaning - Change
2
Clean the air cleaner. Remove the main filter (3) by
undoing the catches (1), and then the cover (2).
Check that the filter element is undamaged. Clean the
element by banging it against your hand or other soft
5
object.
1
3
4
Then blow clean with compressed air (max 5 bars)
from the inside of the filter. Also clean the filter
Fig. Air cleaner
1. Catches
housing (5) and the cover (2).
2. Cover
Replace the filter cartridge after 5 cleanings or
3. Main filter
more frequently.
4. Backup filter
5. Filter housing
85
Maintenance measures - 250 h
Hydraulic fluid cooler - Cleaning
Clean the hydraulic fluid cooler’s cooling flanges,
ideally with compressed air. Blow the cooler clean by
blowing air from the inside outwards.
1
Wear gloves and eye protectors when working
with compressed air.
Fig. Engine compartment
1. Hydraulic fluid cooler
Forward/Reverse controls and joints - Check
and lubrication
Remove the plate (1). Check the friction of the
forward/reverse controls. The friction screws should be
set so that the forward/reverse lever remains in the
position in which it is set whilst the machine is
operated. The control’s ‘0 position’ is determined by a
screw which engages with the groove on the shaft
between the controls.
If the control begins to be stiff after a longer period of
use, lubricate the controls by the bearings and the
1
control cable with a few drops of oil.
Fig. Forward/Reverse lever
1. Plate
2
If the forward/reverse lever still is stiff after the above
adjustments, lubricate the other end of the control
cable with a few drops of oil. The cable is located on
the top of the propulsion pump.
1
Fig. Engine compartment
1. F/R-control cable
2. Propulsion pump
86
Maintenance measures - 500 h
Maintenance measures - 500 h
Every 500/1500
hours of operation (every six
months)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Ensure that the engine cover is fully open when
work is being carried out under it
Hydraulic fluid cooler - Cleaning
Clean the hydraulic fluid cooler’s cooling flanges,
ideally with compressed air. Blow the cooler clean by
blowing air from the inside outwards.
1
Wear gloves and eye protectors when working
with compressed air.
Fig. Engine compartment
1. Hydraulic fluid cooler
87
Maintenance measures - 500 h
Forward/Reverse controls and joints - Check
and lubrication
Remove the plate (1). Check the friction of the
forward/reverse controls. The friction screws should be
set so that the forward/reverse lever remains in the
position in which it is set whilst the machine is
operated. The control’s ‘0 position’ is determined by a
screw which engages with the groove on the shaft
between the controls.
If the control begins to be stiff after a longer period of
use, lubricate the controls by the bearings and the
1
control cable with a few drops of oil.
Fig. Forward/Reverse lever
1. Plate
2
If the forward/reverse lever still is stiff after the above
adjustments, lubricate the other end of the control
cable with a few drops of oil. The cable is located on
the top of the propulsion pump.
1
Fig. Engine compartment
1. F/R-control cable
2. Propulsion pump
88
Maintenance measures - 500 h
Air cleaner - Cleaning - Change
2
Clean the air cleaner. Remove the main filter (3) by
undoing the catches (1), and then the cover (2).
Check that the filter element is undamaged. Clean the
element by banging it against your hand or other soft
5
object.
1
3
4
Then blow clean with compressed air (max 5 bars)
from the inside of the filter. Also clean the filter
Fig. Air cleaner
housing (5) and the cover (2).
1. Catches
2. Cover
Replace the filter cartridge after 5 cleanings or
3. Main filter
more frequently.
4. Backup filter
5. Filter housing
89
Maintenance measures - 500 h
Engine oil and oil filter - Change
3
Run the engine until it is warm before draining the oil .
Switch off the engine and push in the emergency
brake button.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
4
1
2
Fig. Engine compartment left side
Set a container which can hold at least 5 liters (1,3
1. Drain hose
gal) under the drain plug (2).
2. Plug
3. Filler cap
Undo the oil filler cap (3), and undo the plug (2) in the
4. Oil filter
end of the drain hose (1). Let all the engine oil flow out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Remove the oil filter (4) and fit a new filter.
Collect any spillage.
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil. See under the heading
lubricants, for the correct oil grade. Fit the filler cap (3)
and check that the oil level is correct using the dipstick.
Start the engine and allow it to idle for a few minutes.
During this time, check around the oil filter for leaks.
Switch off the engine, wait for a minute or so and then
check the oil level. Top up with more oil if necessary.
90
Maintenance measures - 500 h
Check - Coolant system
Check that all hoses/hose connectors are intact and
1
tight. Fill with coolant as specified in the lubricants
specification.
Take great care when opening the radiator cap
while the engine is hot. Wear protective gloves and
goggles.
2
Also check the freezing point. Change the coolant
every other year.
Figure. Cooling water container
1. Filler cap
2. Level marking
Drum - Checking the oil level
Park the roller on a level surface, and drive the roller
slowly until the oil plug (1) is in the middle of the
semicircle shaped notch in the drum suspension.
Switch off the engine, disconnect the power and
push in the emergency stop button.
1
Unscrew the plug and check that the oil level reaches
the hole’s lower edge. If necessary, top off with fresh
transmission fluid. See under the heading lubricants
Fig. Drum drive side
for correct fluid grade.
1. Oil plug
Clean the magnetic oil plug (1) from any metallic
residue, and refit the plug.
91
Maintenance measures - 500 h
Hydraulic reservoir - Check/venting
Unscrew and make sure that the reservoir cap is not
1
blocked. Air must have unobstructed passage through
the cap in both directions.
If blocked in either direction, clean with a little diesel oil
and blow with compressed air until unblocked or
replace the cap with a new one.
Wear eye protectors and gloves when working
with compressed air.
Figure. Engine compartment, right side
1. Hydraulic fluid tank cap
Belt tension on the hydraulic vibration and
steering pump drive belt - Check
If the hydraulic pump drive belt can be pressed in 5-6
mm between the pulleys with a force of 50 Nm, then
the belt is correctly tensioned.
Do as follows to tension the belt:
- Undo the screws (1) and (2).
- Press over the hydraulic pump so that the belt
tensions to the specified extent.
1
- Tighten screw (1) and then screw (2).
2
- Check that the belt still has the correct tension after
tightening.
Fig. Engine compartment
1. Screw
Replace the belt when necessary, or after 2000 h.
2. Screw
92
Maintenance - 1000h
Maintenance - 1000h
Performed after 1000 operating hours (each year)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Ensure that the engine cover is fully open when
work is being carried out under it
Hydraulic fluid cooler - Cleaning
Clean the hydraulic fluid cooler’s cooling flanges,
ideally with compressed air. Blow the cooler clean by
blowing air from the inside outwards.
1
Wear gloves and eye protectors when working
with compressed air.
Fig. Engine compartment
1. Hydraulic fluid cooler
93
Maintenance - 1000h
Forward/Reverse controls and joints - Check
and lubrication
Remove the plate (1). Check the friction of the
forward/reverse controls. The friction screws should be
set so that the forward/reverse lever remains in the
position in which it is set whilst the machine is
operated. The control’s ‘0 position’ is determined by a
screw which engages with the groove on the shaft
between the controls.
If the control begins to be stiff after a longer period of
use, lubricate the controls by the bearings and the
1
control cable with a few drops of oil.
Fig. Forward/Reverse lever
1. Plate
2
If the forward/reverse lever still is stiff after the above
adjustments, lubricate the other end of the control
cable with a few drops of oil. The cable is located on
the top of the propulsion pump.
1
Fig. Engine compartment
1. F/R-control cable
2. Propulsion pump
94
Maintenance - 1000h
Air cleaner - Cleaning - Change
2
Clean the air cleaner. Remove the main filter (3) by
undoing the catches (1), and then the cover (2).
Check that the filter element is undamaged. Clean the
element by banging it against your hand or other soft
5
object.
1
3
4
Then blow clean with compressed air (max 5 bars)
from the inside of the filter. Also clean the filter
Fig. Air cleaner
housing (5) and the cover (2).
1. Catches
2. Cover
Replace the filter cartridge after 5 cleanings or
3. Main filter
more frequently.
4. Backup filter
5. Filter housing
95
Maintenance - 1000h
Engine oil and oil filter - Change
3
Run the engine until it is warm before draining the oil .
Switch off the engine and push in the emergency
brake button.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
4
1
2
Fig. Engine compartment left side
Set a container which can hold at least 5 liters (1,3
1. Drain hose
gal) under the drain plug (2).
2. Plug
3. Filler cap
Undo the oil filler cap (3), and undo the plug (2) in the
4. Oil filter
end of the drain hose (1). Let all the engine oil flow out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Remove the oil filter (4) and fit a new filter.
Collect any spillage.
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil. See under the heading
lubricants, for the correct oil grade. Fit the filler cap (3)
and check that the oil level is correct using the dipstick.
Start the engine and allow it to idle for a few minutes.
During this time, check around the oil filter for leaks.
Switch off the engine, wait for a minute or so and then
check the oil level. Top up with more oil if necessary.
96
Maintenance - 1000h
Check - Coolant system
Check that all hoses/hose connectors are intact and
1
tight. Fill with coolant as specified in the lubricants
specification.
Take great care when opening the radiator cap
while the engine is hot. Wear protective gloves and
goggles.
2
Also check the freezing point. Change the coolant
every other year.
Figure. Cooling water container
1. Filler cap
2. Level marking
Drum - Checking the oil level
Park the roller on a level surface, and drive the roller
slowly until the oil plug (1) is in the middle of the
semicircle shaped notch in the drum suspension.
Switch off the engine, disconnect the power and
push in the emergency stop button.
1
Unscrew the plug and check that the oil level reaches
the hole’s lower edge. If necessary, top off with fresh
transmission fluid. See under the heading lubricants
Fig. Drum drive side
for correct fluid grade.
1. Oil plug
Clean the magnetic oil plug (1) from any metallic
residue, and refit the plug.
97
Maintenance - 1000h
Hydraulic reservoir - Check/venting
Unscrew and make sure that the reservoir cap is not
1
blocked. Air must have unobstructed passage through
the cap in both directions.
If blocked in either direction, clean with a little diesel oil
and blow with compressed air until unblocked or
replace the cap with a new one.
Wear eye protectors and gloves when working
with compressed air.
Figure. Engine compartment, right side
1. Hydraulic fluid tank cap
Check the hydraulic oil level in the sight glass (1) and
top off where necessary. See under the heading
‘Every 10 hours of operation’.
1
Fig. Engine compartment, right side
1. Sight glass
98
Maintenance - 1000h
Hydraulic fluid filter - Change
Remove the filter (1) and deliver to special waste
handling. This is a single-use filter and cannot be
cleaned.
Thoroughly clean the filter holder sealing surface.
1
Apply a thin coat of fresh hydraulic fluid to the rubber
gasket on the new filter.
Screw the filter on by hand, firstly until the filter gasket
Fig. Engine compartment, left side
makes contact with the filter base. Then rotate a
1. Hydraulic fluid filter
further ½ turn.
Do not over-tighten. The seal can be damaged.
Start the engine and check that the filter does not leak.
Alternator belt - Checking tension - Change
Switch off the engine, disconnect the power and
switch on the emergency brake button.
1
3
Undo the two hexagonal socket screws (1) and (2).
2
Bend off the old alternator belt and replace with a new
Press the alternator across so that the alternator belt
is tensioned to the measurement given below.
When the alternator belt (3) can be pressed by hand in
around 10 mm halfway between the pulleys, it is
correctly tensioned.
Fig. Alternator viewed from the front
Tighten first screw (1) and then screw (2). Check that
1. Mounting screw
the belt still has the correct tension after tightening.
2. Mounting screw
3. Alternator belt
99
Maintenance - 1000h
Belt tension on the hydraulic vibration and
steering pump drive belt - Check
If the hydraulic pump drive belt can be pressed in 5-6
mm between the pulleys with a force of 50 Nm, then
the belt is correctly tensioned.
Do as follows to tension the belt:
- Undo the screws (1) and (2).
- Press over the hydraulic pump so that the belt
tensions to the specified extent.
1
2
- Tighten screw (1) and then screw (2).
- Check that the belt still has the correct tension after
tightening.
Fig. Engine compartment
1. Screw
Replace the belt when necessary, or after 2000 h.
2. Screw
100
Maintenance - 2000h
Maintenance - 2000h
Performed after 2000 operating hours (every two
years)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Ensure that the engine cover is fully open when
work is being carried out under it
Hydraulic fluid cooler - Cleaning
Clean the hydraulic fluid cooler’s cooling flanges,
ideally with compressed air. Blow the cooler clean by
blowing air from the inside outwards.
1
Wear gloves and eye protectors when working
with compressed air.
Fig. Engine compartment
1. Hydraulic fluid cooler
101
Maintenance - 2000h
Forward/Reverse controls and joints - Check
and lubrication
Remove the plate (1). Check the friction of the
forward/reverse controls. The friction screws should be
set so that the forward/reverse lever remains in the
position in which it is set whilst the machine is
operated. The control’s ‘0 position’ is determined by a
screw which engages with the groove on the shaft
between the controls.
If the control begins to be stiff after a longer period of
use, lubricate the controls by the bearings and the
1
control cable with a few drops of oil.
Fig. Forward/Reverse lever
1. Plate
2
If the forward/reverse lever still is stiff after the above
adjustments, lubricate the other end of the control
cable with a few drops of oil. The cable is located on
the top of the propulsion pump.
1
Fig. Engine compartment
1. F/R-control cable
2. Propulsion pump
102
Maintenance - 2000h
Air cleaner - Cleaning - Change
2
Clean the air cleaner. Remove the main filter (3) by
undoing the catches (1), and then the cover (2).
Check that the filter element is undamaged. Clean the
element by banging it against your hand or other soft
5
object.
1
3
4
Then blow clean with compressed air (max 5 bars)
from the inside of the filter. Also clean the filter
Fig. Air cleaner
housing (5) and the cover (2).
1. Catches
2. Cover
Replace the filter cartridge after 5 cleanings or
3. Main filter
more frequently.
4. Backup filter
5. Filter housing
103
Maintenance - 2000h
Engine oil and oil filter - Change
3
Run the engine until it is warm before draining the oil .
Switch off the engine and push in the emergency
brake button.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
4
1
2
Fig. Engine compartment left side
Set a container which can hold at least 5 liters (1,3
1. Drain hose
gal) under the drain plug (2).
2. Plug
3. Filler cap
Undo the oil filler cap (3), and undo the plug (2) in the
4. Oil filter
end of the drain hose (1). Let all the engine oil flow out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Remove the oil filter (4) and fit a new filter.
Collect any spillage.
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil. See under the heading
lubricants, for the correct oil grade. Fit the filler cap (3)
and check that the oil level is correct using the dipstick.
Start the engine and allow it to idle for a few minutes.
During this time, check around the oil filter for leaks.
Switch off the engine, wait for a minute or so and then
check the oil level. Top up with more oil if necessary.
104
Maintenance - 2000h
Check - Coolant system
Check that all hoses/hose connectors are intact and
1
tight. Fill with coolant as specified in the lubricants
specification.
Take great care when opening the radiator cap
while the engine is hot. Wear protective gloves and
goggles.
2
Also check the freezing point. Change the coolant
every other year.
Figure. Cooling water container
1. Filler cap
2. Level marking
Drum - Checking the oil level
Park the roller on a level surface, and drive the roller
slowly until the oil plug (1) is in the middle of the
semicircle shaped notch in the drum suspension.
Switch off the engine, disconnect the power and
push in the emergency stop button.
1
Unscrew the plug and check that the oil level reaches
the hole’s lower edge. If necessary, top off with fresh
transmission fluid. See under the heading lubricants
Fig. Drum drive side
for correct fluid grade.
1. Oil plug
Clean the magnetic oil plug (1) from any metallic
residue, and refit the plug.
105
Maintenance - 2000h
Hydraulic reservoir - Check/venting
Unscrew and make sure that the reservoir cap is not
1
blocked. Air must have unobstructed passage through
the cap in both directions.
If blocked in either direction, clean with a little diesel oil
and blow with compressed air until unblocked or
replace the cap with a new one.
Wear eye protectors and gloves when working
with compressed air.
Figure. Engine compartment, right side
1. Hydraulic fluid tank cap
Check the hydraulic oil level in the sight glass (1) and
top off where necessary. See under the heading
‘Every 10 hours of operation’.
1
Fig. Engine compartment, right side
1. Sight glass
106
Maintenance - 2000h
Hydraulic fluid filter - Change
Remove the filter (1) and deliver to special waste
handling. This is a single-use filter and cannot be
cleaned.
Thoroughly clean the filter holder sealing surface.
1
Apply a thin coat of fresh hydraulic fluid to the rubber
gasket on the new filter.
Screw the filter on by hand, firstly until the filter gasket
Fig. Engine compartment, left side
makes contact with the filter base. Then rotate a
1. Hydraulic fluid filter
further ½ turn.
Do not over-tighten. The seal can be damaged.
Start the engine and check that the filter does not leak.
107
Maintenance - 2000h
Hydraulic reservoir - fluid change
Use an external drainage pump when
draining/emptying the hydraulic reservoir.
Risk of burn injuries when draining hot oil. Wear
protective gloves and goggles.
1
Unscrew the tank cap. Place the pump's suction hose
in the filler/drain outlet in the hydraulic tank. Place the
other hose in a container.
Use a receptacle that holds at least 15 liters (4
Fig. Hydraulic reservoir
gal).
1. Draining
Start the pumpen so that it sucks out the fluid from the
tank.
Check that the hose to the pump reaches the bottom
of the hydraulic reservoir to ensure that as much of the
fluid as possible is drained.
Collect the oil and deliver to special waste
handling.
Fill up with the recommended hydraulic fluid to the
correct level. Replace the cap on the tank and wipe
clean.
Change the hydraulic fluid filter, see under 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.
108
Maintenance - 2000h
Alternator belt - Checking tension - Change
Switch off the engine, disconnect the power and
switch on the emergency brake button.
1
3
Undo the two hexagonal socket screws (1) and (2).
2
Bend off the old alternator belt and replace with a new
Press the alternator across so that the alternator belt
is tensioned to the measurement given below.
When the alternator belt (3) can be pressed by hand in
around 10 mm halfway between the pulleys, it is
correctly tensioned.
Fig. Alternator viewed from the front
Tighten first screw (1) and then screw (2). Check that
1. Mounting screw
the belt still has the correct tension after tightening.
2. Mounting screw
3. Alternator belt
Water tank - Cleaning
Keep in mind that there is a risk of freezing in
winter. Drain the tank, pump and lines.
3
2
Drain the tank through the drainage tap (1) alongside
the filter.
1
Clean the tanks with water and a suitable detergent for
plastic surfaces.
Fig. Bay under the floor
1. Drainage tap
Clean the water filter (2). Fill the tank with water and
2. Water filter
check that the sprinkler functions.
3. Water pump
The water tanks are made of plastic
(polyethylene) and are recyclable.
109
Maintenance - 2000h
Drum - Changing the oil
Park the roller on a level surface, and drive the roller
slowly until the plug (1) is in the bottom position.
Switch off the engine, disconnect the power and
push in the emergency stop button.
Place a receptacle that will hold at least 4 liters (1 gal)
2
under the plug.
1
Fig. Drum, vibration side
Remove the plug (1) and let the oil run out.
1. Oil plug (1) in position
Deliver the drained oil to special waste handling.
for draining the oil.
2. The oil plug position for level
check and filling.
Refit the plug. Top up with new oil in position 2. See
'Every 500 hours of operation' for filling oil.
Fuel tank - Cleaning
It is easiest to clean the tank when it is almost empty.
Pump out any bottom sediment using an external
pump.
To remove any additional bottom sediment, fill the tank
with two liters of diesel, and then pump it out using the
external pump.
Collect in a container which holds at least 28
liters and deliver to special waste handling.
1
Fig. Fuel tank
1. Hose from external pump
Keep in mind fire risk when handling fuel.
The fuel tank is made of plastic (polyethylene)
and is recyclable.
110
Maintenance - 2000h
Steering joint - Check
Inspect the steering joint to detect any damage or
cracks.
Check and tighten any loose bolts.
Check also for any stiffness and play in the steering
joint. Rectify if necessary.
Fig. Steering joint
Belt tension on the hydraulic vibration and
steering pump drive belt - Check
If the hydraulic pump drive belt can be pressed in 5-6
mm between the pulleys with a force of 50 Nm, then
the belt is correctly tensioned.
Do as follows to tension the belt:
- Undo the screws (1) and (2).
- Press over the hydraulic pump so that the belt
tensions to the specified extent.
1
- Tighten screw (1) and then screw (2).
2
- Check that the belt still has the correct tension after
tightening.
Fig. Engine compartment
1. Screw
Replace the belt when necessary, or after 2000 h.
2. Screw
111