DYNAPAC Vibratory roller CC900G Engine Honda GX630R. Operation & Maintenance (2017)
Instruction manual
Operating & Maintenance
Vibratory roller
CC900G
Engine
Honda GX630R
Serial number
10000303x0C003469 - 0C005137
10000303x0C005138 (Improved Frame) -
Translation of original instruction
Reservation for changes
Printed in China
Table of Contents
Introduction
1
The machine
1
Intended use
1
Warning symbols
1
Safety information
1
General
2
Safety - General instructions
3
Safety - when operating
5
Slopes
5
Driving near edges
6
Sitting position
7
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
9
Roll Over Protective Structure (ROPS)
10
Battery handling
10
Jump starting
11
Technical specifications - Noise/Vibrations/Electrical
13
Vibrations - Operator station
13
Noise level
13
Technical specifications - Dimensions
15
Dimensions, side view
15
Dimensions, top view
16
Weights and volumes
17
Working capacity
17
General
18
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Hydraulic system
18
Tightening torque
18
ROPS - bolts
19
Identification
19
Machine plate
19
Product identification number on the frame
20
Engine plates
21
Machine description- Decals
23
Location - decals
23
Safety decals
24
Info decals
25
Instruments/Controls
26
Locations - Instruments and controls
26
Function description
27
Electrical system
28
Relays and fuses on the machine
28
Operation
29
Before starting
29
Operator’s seat - Adjusting
29
Sprinkler - Check
29
Parking brake
30
Emergency stop
30
Operator position
30
Starting
31
Starting the engine
31
Driving
32
Operating the roller
32
Vibration
33
Manual vibration - Switching on
33
Operating - Stopping
35
Braking
35
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Normal braking
35
Reserve brake
36
Switching off
36
Parking
37
Chocking the drums
37
Long-term parking
38
Battery
38
Air cleaner, exhaust pipe
38
Sprinkler system
38
Fuel tank
38
Hydraulic reservoir
39
Steering cylinder, hinges, etc
39
Hoods, tarpaulin
39
Engine
40
Miscellaneous
41
Locking the articulation
41
Lifting the roller
41
Unlocking the articulation
41
Securing CC900G for loading
42
Towing
43
Releasing the brake
43
Towing the roller
45
Operating instructions - Summary
47
Preventive maintenance
49
Acceptance and delivery inspection
49
Warranty
49
Maintenance - Lubricants and symbols
51
Maintenance symbols
53
Maintenance - Maintenance schedule
55
Service and maintenance points
55
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General
56
Every 10 hours of operation (Daily)
56
After the first 20 hours of operation
56
After the FIRST 50 hours of operation
57
Every 50 hours of operation
57
Every 100 hours of operation
57
Every 200 / 400 / 600 / 800 hours of operation
58
Every 500 hours of operation
58
Every 1000 hours of operation
59
Every 2000 hours of operation
60
Maintenance - Maintenance measures, before use
61
Static drum - Filling with water
61
Maintenance, 10h
63
Engine - Checking the oil level
63
Hydraulic reservoir, Level check - Filling
63
Refueling
64
Water tank - Filling
64
Sprinkler system - Check, cleaning
64
Air circulation - Check
65
Scrapers - Check, adjustment
65
Warning lamps - Check
65
Air cleaner - check
66
Maintenance - 20h
67
Engine oil and oil filter - Change
67
Maintenance - 50h
69
Brakes - Check
69
Air cleaner - cleaning
70
Rubber elements and fastening screws - Check
70
Drum bearing seat - Check and lubrication
70
Maintenance - 100h
71
Spark plug - Check and adjustment
71
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Maintenance - 200 / 400 / 600 / 800 h
73
Spark plug - Replace
73
Engine's fuel filter - Check
74
Engine oil and oil filter - Change
75
Forward/Reverse controls and joints - Check and lubrication
76
Maintenance - 500h
77
Front drum - Checking the oil level
77
Hydraulic reservoir - Check/venting
78
Steering joint - Check
78
Air cleaner - replace insert
79
Maintenance - 1000h
81
Spark plug - Replace
81
Engine's fuel filter - Replace
82
Hydraulic fluid cooler - Cleaning (Option)
82
Forward/Reverse controls and joints - Check and lubrication
83
Front drum - Checking the oil level
84
Hydraulic reservoir - Check/venting
84
Steering joint - Check
85
Air cleaner - replace insert
85
Hydraulic fluid filter - Change
86
Engine oil and oil filter - Change
86
Engine's fuel filter - Check
87
Maintenance - 2000h
89
Spark plug - Replace
89
Engine's fuel filter - Replace
90
Hydraulic fluid cooler - Cleaning (Option)
90
Forward/Reverse controls and joints - Check and lubrication
91
Hydraulic reservoir - Check/venting
91
Steering joint - Check
92
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Air cleaner - replace insert
92
Hydraulic fluid filter - Change
93
Engine oil and oil filter - Change
93
Hydraulic reservoir - fluid change
95
Front drum - Changing the oil
96
Water tank - Cleaning
96
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Introduction
Introduction
The machine
Dynapac CC900G is a self-propelled vibratory tandem
roller in the 1,6 metric tonnes class featuring 900 mm
wide drums. The machine is equipped with drive,
brakes, and vibration on both drums.
Intended use
CC900G is primarily used for smaller compaction
works, such as minor roads, sidewalks, cycle ways
and minor parking places.
Warning symbols
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
Safety information
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.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
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Introduction
Prevent persons from entering or remaining in
the danger area, 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 danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
CALIFORNIA
Proposition 65 Warning
Gasolin engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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.
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 normally carried out by the operator.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
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Safety - General instructions
Safety - General instructions
(Also read the safety manual)
1.
The operator must be familiar with the contents of the OPERATION section
before starting the roller.
2.
Ensure that all instructions in the MAINTENANCE section are followed.
3.
Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
4.
Never use the roller if it is in need of adjustment or repair.
5.
Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
6.
The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
7.
Drive slowly in sharp bends.
8.
Avoid driving across slopes. Drive straight up or straight down the slope.
9.
When driving close to edges, ditches or holes, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
10.
Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
11.
Drive particularly carefully on uneven ground.
12.
Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
13.
Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
14.
Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
15.
Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
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Safety - General instructions
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
18. 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. See instructions in the STOP section.
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
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Safety - when operating
Safety - when operating
Prevent persons from entering or remaining in
the danger area, 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 danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
Slopes
This angle has been measured on a hard, flat surface
with the machine stationary.
The steering angle was zero, the vibration was
switched off and all tanks were full.
Always take into consideration that loose ground,
steering the machine, vibration on, machine speed
across the ground and raising the center of gravity can
all cause the machine to topple at smaller slope
angles than those specified here.
It is recommended that the ROPS (Roll Over
Protective Structure) is always used when
Max 20° or 36%
driving on slopes or unsafe ground.
Fig. Operating on slopes
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
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Safety - when operating
Driving near edges
When driving near an edge, minimum 2/3 of the drum
width must be on solid ground.
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.
≥ 2/3
Fig. Position of drum when driving
near an edge
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Safety - when operating
Sitting position
Remain seated at all times when operating the roller.
Always use the seat belt where fitted. Where the
seat belt is not used, there is a great risk that the
operator will be thrown off and land under the
1
machine if the machine topples over.
2
Figure. Seat position
The seat belt is standard equipment on rollers fitted
1. ROPS
with Roll Over Protective Structure (ROPS) (1).
2. Seat belt
ROPS should always be in the raised position
when machines with foldable ROPS are operated
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Safety - when operating
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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).
Higher ambient temperatures, above +40°C
(104°F)
For operation of the machine at higher ambient
temperatures, although maximum +50°C (122°F), the
following recommendations apply:
The petrol 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 T100 or
equivalent.
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.
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. This is particularly important when using a
high-pressure cleaner.
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.
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Special instructions
Roll Over Protective Structure (ROPS)
Never carry out any welding or drilling
operations of any kind on the Roll Over
Protective Structure (ROPS).
Never attempt to repair a damaged ROPS
structure. This must be replaced with new ROPS
structure.
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.
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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
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Special instructions
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Technical specifications - Noise/Vibrations/Electrical
Technical specifications -
Noise/Vibrations/Electrical
Vibrations - Operator station
(ISO 2631)
The vibration levels are measured in accordance with the operational cycle described in
EU directive 2005/14/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 2005/14/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
102 dB (A)
Sound pressure level at the operator's ear (platform), LpA
84 ±3 dB (A)
During operation the above values may differ because of the actual operational
conditions.
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Technical specifications - Noise/Vibrations/Electrical
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Technical specifications - Dimensions
Technical specifications - Dimensions
Dimensions, side view
K
S
A
L
Dimensions
mm
in
A
Wheelbase
1350
53,1
D
Drum diameter
584
23,0
H1
Height, with ROPS
2300
90,5
H2
Height, w/o ROPS
1585
62,4
K1
455
17,9
K2
Ground clearance
261
10,3
L2
Length
2107
83,0
S
Drum shell thickness
13
0,51
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Technical specifications - Dimensions
Dimensions, top view
O1
O2
Dimensions
mm
in
B
Width
970
38,2
O
Overhang
35
1,38
R1
Turning radius, outside
2700
106,3
R2
2660
104,7
W
Drum shell thickness
900
35,4
α
Steering angle
±34°
±34°
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Technical specifications - Dimensions
Weights and volumes
Weights (s/n 003469 - 005137)
Service weight with ROPS
1335 kg
2943 lbs
(EN500)
Weights (Improved Frame, s/n 005138 - )
Operating mass
1250 kg
2767 lbs
(EN500)
Fluid volumes
Fuel tank
23 liters
6,0 gal
Water tank
175 liters/tank
46,2 gal
Working capacity
Compaction data (s/n 003469 - 005137)
Static linear load, front
6,6 kg/cm
37 pli
Static linear load, rear
8,2 kg/cm
45,9 pli
Amplitude
0,4 mm
0,016 in
Vibration frequency
70 Hz
4200 rpm
Centrifugal force
17 kN
3820 lb
Compaction data (Improved Frame, s/n 005138 - )
Static linear load, front
6 kg/cm
33,6 pli
Static linear load, rear
7,8 kg/cm
43,7 pli
Amplitude
0,4 mm
0,016 in
Vibration frequency
70 Hz
4200 rpm
Centrifugal force
16,7 kN
3752 lb
Note: The frequency is measured at high revs. The
amplitude is measured as the real value and not
the nominal.
Propulsion
Speed range
0-8
kph
0-5
mph
Climbing capacity (theoretical)
35
%
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Technical specifications - Dimensions
General
Engine
Manufacturer/Model
Honda GX630
Output at 3,600 rpm (SAE J1349)
15,5 kW / 21 Hp
Electrical system
Battery
12V 60Ah
Charging coil
12V 20A
Fuses
See the Electrical system section - fuses
Hydraulic system
Opening pressure
MPa
Psi
Drive system
27,0
3915
Supply system
2,0
290
Vibration system
22,0
3190
Control systems
7,0
1015
Brake disengagement
2,0
290
Tightening torque
Tightening torque in Nm for oiled, bright galvanized
bolts tightened using a torque wrench.
STRENGTH CLASS
M - thread
8.8
10.9
12.9
M6
8,4
12
14,6
M8
21
28
34
M10
40
56
68
M12
70
98
117
M16
169
240
290
M20
330
470
560
M24
570
800
960
M30
1130
1580
1900
M36
1960
2800
-
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Technical specifications - Dimensions
ROPS - bolts
Bolt dimensions :
M12 (PN 508063)
Strength class :
8.8
Tightening torque :
70 Nm
ROPS-bolts which are to be torque tightened
must be dry.
Identification
Machine plate
1
The machine plate (1) is attached to the front left 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
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, left side
1. Machine plate
Please state the machine’s PIN when ordering
spares.
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Technical specifications - Dimensions
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 Front frame
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Technical specifications - Dimensions
Engine plates
The engine serial number (1) is punched below the
starter.
Please specify the engine serial number when
ordering spares. Refer also to the engine manual.
2
The engine's EPA plate (2).
1
Figure. Engine
1. Serial number
2. EPA plate (USA)
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Machine description- Decals
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Machine description- Decals
Machine description- Decals
Location - decals
3
2
6
8
5
11
10
7
4
8
5
11
10
1, 9
Fig. Location, decals and signs
1.
Warning, Crush zone
4700903422
8.
Lifting point
4700357587
2.
Warning, Rotating engine components
4700903423
9.
Hydraulic fluid level
4700272373
3.
Warning, Hot surfaces
4700903424
10.
Hoisting plate
4700904870
4.
Warning, Instruction manual
4700903459
11.
Fixing point
4700382751
5.
Warning, Locking
4700908229
6.
Handbook compartment
4700903425
7.
Petrol fuel
4700381371
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Machine description- Decals
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.
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.
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.
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Machine description- Decals
Info decals
Handbook compartment
Petrol
Lifting point
Hydraulic oil level
Hoisting plate
Securing point
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Machine description- Decals
Instruments/Controls
12
Locations - Instruments and controls
5
8
9
1. Ignition key
7. Fuse box
11
2. Control, engine speed
8. Sprinkler
3. Parking brake
9. Horn
10
4. Vibration on/off, switch
10. Emergency stop
3
1
5. Fuel level, hour meter
11. Choke
7
6. Forward/reverse lever
4
6
12. Parking brake warning lamp, Hydraulic oil termperature (not in use)
2
2
Fig. Instruments and control panel
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Machine description- Decals
Function description
No
Designation
Symbol
Function
1.
Starter switch
The electric circuit is broken.
All instruments and electrical controls are supplied
with power
Starter motor activation.
2.
Control, engine speed
Pull the lever up to obtain working speed. Move the
lever down to obtain idling speed.
3.
Parking brake
The parking brake is activated if pressed when the
machine is stationary. The brakes are released when
pulled out.
4.
Vibration On/Off. Switch
When the switch for vibrations in the forward/reverse
lever is pressed and released, the vibrations are
engaged. Press the switch again to disengage the
vibrations.
5.
Fuel level, hour meter
6.
Forward/Reverse lever
The lever must be in neutral to start the petrol engine.
The engine cannot be started if the forward/reverse
lever is in any other position.
The forward/reverse lever controls both the roller's
driving direction and speed. When the lever is moved
forward, the roller moves forward etc.
The roller's speed is proportional to the distance the
lever is from the neutral position. The further the lever
is from the neutral position, the higher the speed.
7.
Fuse box (on control column)
Contains fuses for the electrical system. See under
the heading ‘Electrical system’ for a description of
fuse functions.
8.
Sprinkler, control
Turn the knob clockwise to switch on the water flow to
the drum.
9.
Horn, switch
Press to sound the horn.
Brakes the roller and switches off the engine. The
10.
Emergency stop
power supply goes off.
NOTE: The emergency stop must be deactivated
when starting the machine.
11.
Choke
Used in the pulled out position if necessary when the
engine is started.
12.
Parking brake warning lamp,
Hydraulic oil temperature
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Machine description- Decals
Electrical system
Relays and fuses on the machine
The figure shows the positions of the various fuses
and relays. The table below gives their amperage and
function. All fuses are flat pin fuses.
Relays
1
1.
K1
Starting
12V 30A
2.
K2
Start, vibration, brake
12V 15A
3.
K22
Cooling fan, hydraulic system (Option)
12V 30A
5
3
4.
K20
Drive restriction relay
12V 10A
2
6
Fuses
5.
7.5A Start/stop valve
4
Fuel pump
Restriction relay
VBS relay
Vibration
6.
15A Horn
Backup alarm
Fan (Option)
Fig. Control column
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Operation
Operation
Before starting
Operator’s seat - Adjusting
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
Sprinkler - Check
Make sure that the emergency stop knob is
actually pressed in.
8
3
1
Set the knob (8) for the sprinkler in the open position
and check that the drums are watered.
Figure. Instrument panel
1. Ignition key
3. Parking brake
8. Switch, sprinkler
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Operation
Parking brake
Activate parking brake before leaving the machine.
The machine starts with the parking brake deactivated.
3
10
Emergency stop
The machine starts with emergency stop pulled out.
Figure. Control panel
3. Parking brake
10. Emergency stop
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
Ensure that the anti-slip (3) on the platform is in
good condition. Replace where anti-slip friction is
1
poor.
3
If a ROPS (Roll Over Protective Structure) (2) is fitted
to the roller, always wear the seat belt (1) provided
Fig. Operator's station
and wear a protective helmet.
1. Seat belt
2. ROPS (Option)
3. Anti-slip
2017-07-10
30
Operation
Starting
Starting the engine
Make sure that the parking brake knob (3) is activated.
Sit down in the operator's seat and set the
forward/reverse lever (6) in neutral. You cannot start
the petrol engine with the lever in any other position.
11
1
Set the RPM control (2) to idle.
3
6
For cold start: Pull out the choke (11) and turn the
ignition key to position II. Check that the warning
2
lamps on the control panel are working. Turn the
ignition key (1) to the right. As soon as the engine has
started, release the ignition key.
Figure. Control panel
Do not run the starter motor for too long. If the
1. Starter switch
engine does not start immediately, wait a minute
2. Speed control
or so before trying again.
3. Parking brake
6. Forward/Reverse lever
11. Choke
12
Warm up the engine at idling speed for a few minutes,
although longer if ambient temperature is below +10 C
(50 F)
When the engine is warm, check that the parking brake
warning lamp (12) is still lit.
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
until the machine reaches the working temperature.
Fig. Instrument panel
12. Parking brake warning lamp
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
2017-07-10
31
Operation
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
forward/reverse lever and never by changing the
engine speed.
Test the function of the reserve brake by activating
parking brake (3) while the roller is moving slowly
forwards and backwards.
Check when operating that the warning lamps do not
come on.
A hydraulic fluid cooler is recommended for warm
ambient temperatures and long operating periods
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.
8
10
Deactivate parking brake knob (3). Be prepared that
3
1
the roller can move.
Check that the steering is working correctly by turning
6
the steering wheel once to the right and once to the
left while the roller is stationary.
2
When compacting asphalt, remember to turn on the
sprinkler system (8).
Figure. Instrument panel
1. Ignition key
Make sure that the area in front of and behind the
2. Speed control
roller is clear.
3. Parking brake
6. Forward/Reverse lever
8. Sprinkler knob
10. Emergency stop
2017-07-10
32
Operation
Vibration
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.
4
Always switch off vibration before the roller comes to a
standstill.
Fig. Forward/Reverse lever
4. Switch, vibration On/Off
2017-07-10
33
Operation
2017-07-10
34
Operating - Stopping
Operating - Stopping
Braking
Normal braking
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
until the machine reaches the working temperature.
Press the switch (4) to switch off the vibration.
Move the forward/reverse lever (6) to the neutral
position to stop the roller.
3
1
For shorter stopping periods, in which the operator
needs to stand up with the engine running, it is
important to check that the brake light is lit, including
6
when stopping briefly on sloping ground.
4
2
Turn the engine speed control (2) back to idling and
stop the engine. Switch off the machine using the key
Fig. Control panel
(1). Activate parking brake knob (3).
1. Key
2. Engine speed control
3. Parking brake
4. Vibration On/Off
6. Forward/reverse lever
2017-07-10
35
Operating - Stopping
Reserve brake
Braking is normally activated using the
forward/reverse lever. The hydrostatic transmission
retards and slows the roller when the lever is moved
towards the neutral position.
A disc brake in each drum motor acts as reserve brake
when in motion and as a parking brake when
stationary.
To brake in an emergency situation, press in the
3
emergency stop (10), hold the steering wheel
10
firmly and be prepared for a sudden stop.
After braking, return the forward/reverse lever to the
neutral position and activate the parking brake.
Fig. Controls
Activate the parking brake (3) before leaving
3. Parking brake
the machine.
10. Emergency stop
Switching off
Turn the starter switch (1) to the left to shut off position.
1
Fig. Instrument panel
1. Starter switch
2017-07-10
36
Operating - Stopping
Parking
Chocking the drums
Never disembark from the machine when the is
engine running, unless the reserve/parking brake
knob is depressed.
Make sure that the roller is parked in a safe place
with respect to other road users. Chock the drums
1
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.
2017-07-10
37
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.
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 300 hours of
operation') or its opening with plastic or tape. Also
cover the exhaust pipe opening. This is to avoid
moisture entering the engine.
Sprinkler system
* Empty the water tank and all hoses of all water (see
under the heading "Every 2000 hours of operation").
Fuel tank
Fill the fuel tank completely full to prevent
condensation.
Hydraulic reservoir
Fill the hydraulic reservoir to the uppermost level mark
(see under the heading ‘Every 10 hours of operation.’)
38
2017-07-10
Long-term parking
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.
2017-07-10
39
Long-term parking
Engine
* Below description quote from manufacturer’s instructions in the
engine manual that is supplied with the roller.
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40
2017-07-10
Miscellaneous
Miscellaneous
Locking the articulation
Turn the steering wheel to the straight ahead position.
1
Raise the locking arm (1) and turn 180 degrees
downward. Ensure that the cotter pin (2) is guided into
2
its lower position correctly for locking the articulation.
Fig. Steering joint
1. Locking arm
2. Cotter pin in locked position
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,
1
and lifting hooks must be dimensioned and used
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
Unlocking the articulation
1
Remember to unlock the articulation before
operating.
2
Raise the locking arm (1) and turn it 180 degrees
upward. Check that the cotter pin (2) is guided
correctly into position for unlocking the articulation.
Fig. Articulated joint
1. Locking arm
2. Cotter pin in open position
2017-07-10
41
Miscellaneous
Securing CC900G for loading
Securing the CC900G 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.
2017-07-10
42
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
The roller can be moved up to 300 meters (1,000 ft)
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.
Releasing the brake
1. Remove the 2 plugs (191).
2017-07-10
43
Miscellaneous
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.
Restored brake
Undo the two screws (192) alternately, and then insert
the plugs (191).
2017-07-10
44
Miscellaneous
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.
2017-07-10
45
Operating instructions - Summary
2017-07-10
46
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.
Set the reserve/parking brake to its pulled-out position.
4.
Move the forward/reverse lever to the NEUTRAL position.
5.
Set the engine speed control to idle.
6.
Start the engine and allow it to warm up.
7.
Set the engine speed control to the operating position.
8.
Drive the roller. Operate the forward/reverse lever with care.
9.
Test the brakes. Remember that the braking distance will be longer if the
roller is cold.
10. Use vibration only when the roller is in motion.
11. Check that the drums are thoroughly watered when watering is required.
12. IN AN EMERGENCY:
- Press the RESERVE/PARKING BRAKE BUTTON
- Hold the steering wheel firmly.
- Brace yourself for a sudden stop.
13. Parking: - Switch off the machine and chock the drums.
14. When lifting: - Refer to the relevant section in the Instruction Manual.
15. When towing: - Refer to the relevant section in the Instruction Manual.
16. When transporting: - Refer to the relevant section in the Instruction Manual.
17. When recovering - Refer to the relevant section in the Instruction Manual.
2017-07-10
47
Operating instructions - Summary
2017-07-10
48
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 immediately reported
to the transport company.
Warranty
The warranty is only valid if the stiplulated 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
authorisation.
2017-07-10
49
Preventive maintenance
2017-07-10
50
Maintenance - Lubricants and symbols
Maintenance - Lubricants and symbols
Always use high-quality lubricants and the
amounts recommended. Too much grease or
oil can cause overheating, resulting in rapid
wear.
Fluid volumes
Drum
3,5 liters
3,7 qts
Ballast static drum *
65 liters
68,7 qts
Hydraulic reservoir
12 liters
3,2 gal
Petrol engine
1,5 liters without filter
1,6 qts
replacement
1,8 liters with filter
1,9 qts
replacement
* In climates where there is a risk of freezing, see
Coolant under the section Lubricants and Symbols.
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.
Other fuel and lubricants are required when
operating in areas with extremely high or
extremely low ambient temperature. See the
'Special instructions' chapter, or consult
Dynapac.
2017-07-10
51
Maintenance - Lubricants and symbols
ENGINE OIL
Air temperature -15°C - +50°C
P/N 5580020624 (5 litres)
(5°F-122°F)
P/N 5501522700 (20 litres)
HYDRAULIC FLUID
Air temperature -15°C - +40°C
P/N 9106230330 (20 litres)
(5°F-104°F)
P/N 9106230331 (209
litres)
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
,
P/N 4812008274 (5 litres),
(5°F-104°F)
P/N 4812008275 (20 litres)
Air temp. 0°C (32°F) - above
Shell Spirax AX
+40°C (104°F)
85W/140, API GL-5
FUEL
See engine manual.
-
To comply with emission
requirements for Honda GX630
you must use fuel with a low or
extremely low sulphur content.
2017-07-10
52
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
2017-07-10
53
Maintenance - Lubricants and symbols
2017-07-10
54
Maintenance - Maintenance schedule
Maintenance - Maintenance schedule
Service and maintenance points
1
3
7
2
6
4
8
9
17
10
16
15
11
12, 13
18
11
14
Fig. Service and maintenance points
1. Water tank, filling
7. Air cleaner
13. Hydraulic fluid, filling
2. Forward/Reverse lever
8. Battery (maintenance free)
14. Fuel tank, filling
3. Reserve/parking brake
9. Sprinkler
15. Steering joint
4. Hydraulic fluid cooler, (option)
10. Scrapers
16. Front drum, filling with oil
6
Engine
11. Rubber element
17. ROPS, (option)
12. Hydraulic fluid filter
18. Static drum, filling with water.
2017-07-10
55
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.
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 oil level in the engine
Refer to the engine manual
13
Check the hydraulic reservoir level
14
Refuel
1
Fill the water tank
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 engine's air cleaner
Refer to the engine manual
After the first 20 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
6
Change the engine oil
Refer to the engine manual
6
Change the engine's oil filter
Refer to the engine manual
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56
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
12
Change the hydraulic fluid filter
Every 50 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
3
Test the brakes
7
Clean the air cleaner
Refer to the engine manual
11
Check the rubber elements and bolted joints
18
Check and lubricate drum bearing seat
Every 100 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
6
Check and adjust the spark plug
Refer to the engine manual
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57
Maintenance - Maintenance schedule
Every 200 / 400 / 600 / 800 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
6
Replace the spark plugs
Refer to the engine manual.
6
Check idling revs
Refer to the engine manual.
6
Check valve play
Refer to the engine manual.
6
Replace the fuel filter
Refer to the engine manual.
6
Change the engine oil
Refer to the engine manual.
6
Change the oil filter
Refer to the engine manual.
Check lubrication of controls and pivots
Lubricate as necessary
Replace valve cover gasket
Refer to the engine manual.
Every 500 hours of operation
Refer to the contents to find the page number of the
sections referred to !
Pos.
Action
Comment
in fig
6
Clean the combustion chamber
Refer to the engine manual
16
Check the oil level in the front drum
13
Check the hydraulic reservoir cover/breather
15
Check the condition of the articulation
7
Replace the air cleaner insert
Refer to the engine manual
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58
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
6
Replace the spark plugs
Refer to the engine manual.
6
Check idling revs
Refer to the engine manual.
6
Check valve play
Refer to the engine manual.
6
Replace the fuel filter
Refer to the engine manual.
4
Clean the hydraulic fluid cooler
Accessory
Check lubrication of controls and pivots
Lubricate as necessary
Replace valve cover gasket
Refer to the engine manual.
6
Clean the combustion chamber
Refer to the engine manual.
16
Check the oil level in the front drum
13
Check the hydraulic reservoir cover/breather
15
Check the condition of the articulation
7
Replace the air cleaner insert
Refer to the engine manual.
12
Change the hydraulic fluid filter
6
Change the engine oil
Refer to the engine manual.
6
Change the oil filter
Refer to the engine manual.
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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
6
Replace the spark plugs
Refer to the engine manual
6
Check idling revs
Refer to the engine manual
6
Check valve play
Refer to the engine manual
6
Replace the fuel filter
Refer to the engine manual
4
Clean the hydraulic fluid cooler
Accessory
Check lubrication of controls and pivots
Lubricate as necessary
Replace valve cover gasket
Refer to the engine manual
6
Clean the combustion chamber
Refer to the engine manual
13
Check the hydraulic reservoir cover/breather
15
Check the condition of the articulation
7
Replace the air cleaner insert
Refer to the engine manual
12
Change the hydraulic fluid filter
6
Change the engine oil
Refer to the engine manual
6
Change the oil filter
Refer to the engine manual
13
Change the hydraulic fluid
16
Change the oil in the front drum
18
Change the water in the rear drum
1
Drain and clean the water tank
6
Drain and clean the fuel tank
Refer to the engine manual
6
Check the fuel line
Refer to the engine manual
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60
Maintenance - Maintenance measures, before use
Maintenance - Maintenance measures,
before use
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
30°
Static drum - Filling with water
Unscrew the filler plug (1) and fill with pure water.
The recommended volume of water in the drum is
65 liters. Where there is a risk of freezing,
remember to add antifreeze.
1
Only additive: Environmentally-friendly
antifreeze. Dosage according to the
recommendations from the antifreeze supplier.
Fig. static drum
1. Water plug in position for filling.
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Maintenance - Maintenance measures, before use
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62
Maintenance, 10h
Maintenance, 10h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Engine - Checking the oil level
Ensure that the engine cover is fully open when
work is carried out under the cover.
2
Open the engine cover lock and lower the engine
1
cover forwards.
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 plug
Hydraulic reservoir, Level check - Filling
Wipe the sight glass (1) clean. Make sure that the oil
2
level is in the middle of the sight glass. If necessary,
top up with fresh hydraulic fluid through the filler hose
(2).
See under the heading ‘Lubricants’ for the correct fluid
grade.
1
Fig. Hydraulic reservoir
1. Sight glass
2. Filler hose
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63
Maintenance, 10h
Refueling
Refuel the tank every day before starting work. Open
the tank cap and fill through the filler pipe (1).
1
Never refuel while the engine is running. Do not
smoke and avoid spilling fuel.
Stop the engine. Short-circuit (press) the filler gun
against the filler pipe (1) while refuelling.
Fig. Left side
1. Filler pipe/cap
The tank holds 23 liters (31.7 gal) of fuel.
Water tank - Filling
1
Unscrew the tank cap (1), and fill with clean water.
Fill the water tank; it holds 175 liters.
Only additive: A small amount of environmentally
friendly antifreeze.
Fig. Water tank
1. Tank cap
Sprinkler system - Check, cleaning
Check that the holes in the sprinkler pipe (1) are not
clogged, clean if necessary.
1
Fig. Sprinkler system
1. Sprinkler pipes with holes for
water.
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64
Maintenance, 10h
Air circulation - Check
Ensure that the petrol engine has free circulation of
1
cooling air through the vents in the hood.
Fig. Engine cover
1. Cooling air grille/engine
Scrapers - Check, adjustment
2
Make sure that the scrapers are undamaged. Adjust
the scrapers if necessary in the following way:
For firmer application of the scraper, undo the locking
1
nut (2) and turn it to the right until the desired
application is achieved.
Lock this setting by tightening the locking nut against
the frame side (2).
Fig. Front scrapers in transport
position
Adjust the pressure on both scraper brackets.
1. Locking nut
2. Frame side
To set a lower scraper pressure, adjust in the reverse
order to the above.
Warning lamps - Check
Check that the warning lamps (12).
12
3
Figure. Control panel.
3. Parking brake
12. Parking brake warning lamp
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Maintenance, 10h
Air cleaner - check
1
Check that hoses and couplings are not leaking and
that the air cleaner cover is on properly.
Clean the air cleaner when operated in extremely
dusty environments.
Fig. Engine
1. Air filter
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66
Maintenance - 20h
Maintenance - 20h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Engine oil and oil filter - Change
Run the engine until it is warm before draining the oil.
Switch off the engine and push in the
reserve/parking brake knob.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
1,
2
2
3
Fig. Engine compartment, left side
1. Drain hose
2. Plug
Place a receptacle that holds at least 4 liters (1 gal.)
3. Oil filter
under the drain plug (2).
Undo the oil filler cap (4) and remove the plug (2) from
4
the end of the drain hose (1); allow all the engine oil to
run out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Fig. Engine compartment, right side
4. Filler cap
Remove the oil filter (3) and insert a new one.
Collect any spillage.
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Maintenance - 20h
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil (see under Lubricants heading
for the correct oil grade), refit the filler cap (4) and
check the level on the dipstick.
Start the engine and check the tightness around the oil
filter.
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Maintenance - 50h
Maintenance - 50h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Brakes - Check
Check the brakes by carrying out the following:
Drive the roller slowly forwards.
Activate parking brake (3). The parking brake warning
3
lamp (12) should light and the roller should stop.
After testing the brakes, set the forward/reverse lever
in neutral.
Deactivate the parking brake (3).
12
The roller can now be started.
Refer also to the section in the manual on operation.
Figure. Control panel.
3. Parking brake
12. Parking brake warning lamp
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Maintenance - 50h
Air cleaner - cleaning
1
Unclip the four lock catches (1) and lift the air cleaner's
cover (2). Lift out the plastic foam and clean it in warm
soapy water, rinse and dry.
Clean the air filter by tapping it with the palm of the
2
hand or blow compressed air (not exceeding 207 kPa
8
(2,1 kgf/cm2, 30 psi)) through the filter element from
3
the air cleaner case side. Brushing the filter may
cause dust to penetrate the fibres. Replace the filter if
4
it is very dirty.
7
5
Dry the inside of the filter container and its cover with
a damp rag. Make sure that dirt does not enter the
suction pipe.
6
Clean the air cleaner when operated in extremely
Fig. Air cleaner
dusty environments.
1. Cover latch
2. Cover
Refit the filter element and the cover and secure the
3. Wing nut
cover with put the latch (1) to locked position.
4. Filter element
5. Case
6. Seal
7. Air chamber
8. Foam filter element
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
Drum bearing seat - Check and lubrication
Drum bearing seat, which located on the left side of
the rear drum. Check the condition of the bearing seat,
grease the bearing seat through the grease nipple (1).
1
1
Grease the bearing point with twenty to twenty-five
strokes of hand-operated grease gun.
Figure. Drum bearing seat
1. Grease nipple
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70
Maintenance - 100h
Maintenance - 100h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Spark plug - Check and adjustment
Switch off the engine and push in the
reserve/parking brake knob.
Observe care with hot surfaces. Wear gloves.
1
Refer to the engine manual for detailed
instructions.
Fig. Engine compartment left side
1. Spark plug
Dispose of used spark plugs properly.
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Maintenance - 100h
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72
Maintenance - 200 / 400 / 600 / 800 h
Maintenance - 200 / 400 / 600 / 800 h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Spark plug - Replace
Switch off the engine and push in the
reserve/parking brake knob.
Observe care with hot surfaces. Wear gloves.
1
Refer to the engine manual for detailed
instructions.
Fig. Engine compartment left side
1. Location of the spark plug on the
left and right sides of the engine.
Dispose of used spark plugs properly.
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Maintenance - 200 / 400 / 600 / 800 h
Engine's fuel filter - Check
Switch off the engine and push in the
reserve/parking brake knob.
Use caution. Wear gloves.
Replace the fuel filter (1).
1
Refer to the engine manual for detailed
Fig. Engine compartment left side
instructions.
1. Fuel filter
Dispose of the old filter carefully.
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Maintenance - 200 / 400 / 600 / 800 h
Engine oil and oil filter - Change
Run the engine until it is warm before draining the oil.
Switch off the engine and push in the
reserve/parking brake knob.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
1,
2
2
3
Fig. Engine compartment, left side
1. Drain hose
2. Plug
Place a receptacle that holds at least 4 liters (1 gal.)
3. Oil filter
under the drain plug (2).
Undo the oil filler cap (4) and remove the plug (2) from
4
the end of the drain hose (1); allow all the engine oil to
run out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Fig. Engine compartment, right side
4. Filler cap
Remove the oil filter (3) and insert a new one.
Collect any spillage.
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil (see under Lubricants heading
for the correct oil grade), refit the filler cap (4) and
check the level on the dipstick.
Start the engine and check the tightness around the oil
filter.
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Maintenance - 200 / 400 / 600 / 800 h
Forward/Reverse controls and joints - Check
and lubrication
Unscrew the protective plate. Check the friction on the
forward/reverse lever. The friction nut (1) should be
applied with sufficient pressure to keep the
forward/reverse lever in the set position during
operation.
1
If the lever gets stiff after prolonged use, lubricate the
lever at the bearing bushings and at the cable with a
few drops of oil at each place.
Figure. Forward/reverse lever
1. Friction nut
If the forward/reverse lever still is stiff after the above
3
adjustments, lubricate the other end of the control
2
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 lever cable
2. Heat cover
3. Air filter
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Maintenance - 500h
Maintenance - 500h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Front 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 reserve/parking brake knob.
Unscrew the plug and check that the oil level reaches
1
the hole’s lower edge. If necessary, top off with fresh
transmission fluid. See under the heading lubricants
Figure. Front drum, drive side
for correct fluid grade.
1. Oil plug
Clean the magnetic oil plug (1) from any metallic
residue, and refit the plug.
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Maintenance - 500h
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
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
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Maintenance - 500h
Air cleaner - replace insert
1
Pull the air cleaner cover latch (1) to the unlocked
position and remove the cover (2).
Remove the wing nut (3) from the filter element (4).
2
Lift out the foam filter element (8) and the filter
element (4).
3
Dry the inside of the filter container and its cover with
4
a damp rag Make sure that dirt does not enter the
suction pipe.
5
Reinstall with new filter element and secure the cover
6
with put the latch (1) to locked position.
Fig. Air cleaner
1. Cover latch
2. Cover
3. Wing nut
4. Filter element
5. Case
6. Seal
7. Air chamber
8. Foam filter element
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Maintenance - 500h
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80
Maintenance - 1000h
Maintenance - 1000h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Spark plug - Replace
Switch off the engine and push in the
reserve/parking brake knob.
Observe care with hot surfaces. Wear gloves.
1
Refer to the engine manual for detailed
instructions.
Fig. Engine compartment left side
1. Location of the spark plug on the
left and right sides of the engine.
Dispose of used spark plugs properly.
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Maintenance - 1000h
Engine's fuel filter - Replace
Switch off the engine and push in the
reserve/parking brake knob.
Use caution. Wear gloves.
Replace the fuel filter (1).
1
Refer to the engine manual for detailed
Fig. Engine compartment left side
instructions.
1. Fuel filter
Dispose of the old filter carefully.
Hydraulic fluid cooler - Cleaning (Option)
Clean the hydraulic fluid cooler’s cooling flanges,
ideally with compressed air. Blow the cooler clean by
blowing air from the inside outwards.
Wear gloves and eye protectors when working
with compressed air.
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Maintenance - 1000h
Forward/Reverse controls and joints - Check
and lubrication
Unscrew the protective plate. Check the friction on the
forward/reverse lever. The friction nut (1) should be
applied with sufficient pressure to keep the
forward/reverse lever in the set position during
operation.
1
If the lever gets stiff after prolonged use, lubricate the
lever at the bearing bushings and at the cable with a
few drops of oil at each place.
Figure. Forward/reverse lever
1. Friction nut
If the forward/reverse lever still is stiff after the above
3
adjustments, lubricate the other end of the control
2
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 lever cable
2. Heat cover
3. Air filter
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Maintenance - 1000h
Front 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 reserve/parking brake knob.
Unscrew the plug and check that the oil level reaches
1
the hole’s lower edge. If necessary, top off with fresh
transmission fluid. See under the heading lubricants
Figure. Front drum, drive side
for correct fluid grade.
1. Oil plug
Clean the magnetic oil plug (1) from any metallic
residue, and refit the plug.
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
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Maintenance - 1000h
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
Air cleaner - replace insert
1
Pull the air cleaner cover latch (1) to the unlocked
position and remove the cover (2).
Remove the wing nut (3) from the filter element (4).
2
Lift out the foam filter element (8) and the filter
element (4).
3
Dry the inside of the filter container and its cover with
4
a damp rag Make sure that dirt does not enter the
suction pipe.
5
Reinstall with new filter element and secure the cover
6
with put the latch (1) to locked position.
Fig. Air cleaner
1. Cover latch
2. Cover
3. Wing nut
4. Filter element
5. Case
6. Seal
7. Air chamber
8. Foam filter element
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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
makes contact with the filter base. Then rotate a
further ½ turn.
Fig. Engine compartment, left side
Do not over-tighten. The seal can be damaged.
1. Hydraulic fluid filter
Start the engine and check that the filter does not leak.
Engine oil and oil filter - Change
Run the engine until it is warm before draining the oil.
Switch off the engine and push in the
reserve/parking brake knob.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
1,
2
2
3
Fig. Engine compartment, left side
1. Drain hose
2. Plug
Place a receptacle that holds at least 4 liters (1 gal.)
3. Oil filter
under the drain plug (2).
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Maintenance - 1000h
Undo the oil filler cap (4) and remove the plug (2) from
4
the end of the drain hose (1); allow all the engine oil to
run out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Fig. Engine compartment, right side
4. Filler cap
Remove the oil filter (3) and insert a new one.
Collect any spillage.
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil (see under Lubricants heading
for the correct oil grade), refit the filler cap (4) and
check the level on the dipstick.
Start the engine and check the tightness around the oil
filter.
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Maintenance - 1000h
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88
Maintenance - 2000h
Maintenance - 2000h
Park the roller on a level surface.
When checking and making adjustments, the
engine should be switched off and the
emergency/parking brake should be applied, if
not otherwise specified.
Check that the engine cover is fully open before
carrying out work underneath it.
Spark plug - Replace
Switch off the engine and push in the
reserve/parking brake knob.
Observe care with hot surfaces. Wear gloves.
1
Refer to the engine manual for detailed
instructions.
Fig. Engine compartment left side
1. Location of the spark plug on the
left and right sides of the engine.
Dispose of used spark plugs properly.
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Maintenance - 2000h
Engine's fuel filter - Replace
Switch off the engine and push in the
reserve/parking brake knob.
Use caution. Wear gloves.
Replace the fuel filter (1).
1
Refer to the engine manual for detailed
Fig. Engine compartment left side
instructions.
1. Fuel filter
Dispose of the old filter carefully.
Hydraulic fluid cooler - Cleaning (Option)
Clean the hydraulic fluid cooler’s cooling flanges,
ideally with compressed air. Blow the cooler clean by
blowing air from the inside outwards.
Wear gloves and eye protectors when working
with compressed air.
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Maintenance - 2000h
Forward/Reverse controls and joints - Check
and lubrication
Unscrew the protective plate. Check the friction on the
forward/reverse lever. The friction nut (1) should be
applied with sufficient pressure to keep the
forward/reverse lever in the set position during
operation.
1
If the lever gets stiff after prolonged use, lubricate the
lever at the bearing bushings and at the cable with a
few drops of oil at each place.
Figure. Forward/reverse lever
1. Friction nut
If the forward/reverse lever still is stiff after the above
3
adjustments, lubricate the other end of the control
2
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 lever cable
2. Heat cover
3. Air filter
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
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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
1
Air cleaner - replace insert
2
Pull the air cleaner cover latch (1) to the unlocked
position and remove the cover (2).
3
Remove the wing nut (3) from the filter element (4).
4
Lift out the foam filter element (8) and the filter
element (4).
5
Dry the inside of the filter container and its cover with
a damp rag Make sure that dirt does not enter the
6
suction pipe.
Fig. Air cleaner
1. Cover latch
2. Cover
Reinstall with new filter element and secure the cover
3. Wing nut
4. Filter element
with put the latch (1) to locked position.
5. Case
6. Seal
7. Air chamber
8. Foam filter element
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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
makes contact with the filter base. Then rotate a
further ½ turn.
Fig. Engine compartment, left side
Do not over-tighten. The seal can be damaged.
1. Hydraulic fluid filter
Start the engine and check that the filter does not leak.
Engine oil and oil filter - Change
Run the engine until it is warm before draining the oil.
Switch off the engine and push in the
reserve/parking brake knob.
Take great care when draining fluids and oils.
Wear protective gloves and goggles.
1,
2
2
3
Fig. Engine compartment, left side
1. Drain hose
2. Plug
Place a receptacle that holds at least 4 liters (1 gal.)
3. Oil filter
under the drain plug (2).
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Undo the oil filler cap (4) and remove the plug (2) from
4
the end of the drain hose (1); allow all the engine oil to
run out.
Deliver the drained oil to special waste handling.
Refer to the engine manual for detailed
instructions when changing oil and filters.
Fig. Engine compartment, right side
4. Filler cap
Remove the oil filter (3) and insert a new one.
Collect any spillage.
Fit the drain plug (2) to the end of the hose.
Fill with fresh engine oil (see under Lubricants heading
for the correct oil grade), refit the filler cap (4) and
check the level on the dipstick.
Start the engine and check the tightness around the oil
filter.
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Hydraulic reservoir - fluid change
Use an external drainage pump when
draining/emptying the hydraulic reservoir.
Danger of being burned when draining hot oil.
Wear gloves and eye protectors.
1
Unscrew the reservoir cap. Use an external pump and
check that the pump's hose reaches the bottom of the
hydraulic reservoir in order to remove as much of the
oil as possible. Drain the hydraulic oil into a drainage
Fig. Hydraulic reservoir
container.
1. Draining
Use a receptacle that holds at least 15 liters (4
gal).
Collect the oil and deliver to special waste
handling.
Change the hydraulic fluid filter, see under heading
'Every 900 hours of operation'.
Fill with fresh hydraulic fluid (see under Lubricants
heading for the correct grade), refit the filler cap, and
check the level in the tank.
Wipe up any spillage.
Start the engine and operate the various hydraulic
functions. Check the level in the reservoir and top off
as required.
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Maintenance - 2000h
Front drum - Changing the oil
Loosen the oil plug (1) slightly, when it is in position for
level check (2), so that it can subsequently be
unscrewed by hand.
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
2
push in the reserve/parking brake knob.
1
Fig. Drum, Drive side
Place a receptacle that will hold at least 4 liters (1 gal)
1. Oil plug
2. Position for level check
under the plug.
Remove the plug (1) and let the oil run out.
Deliver the drained oil to special waste handling.
See under the section 'Every 500 hours of operation'
for filling oil.
Water tank - Cleaning
1
Keep in mind that there is a risk of freezing in
winter. Drain the tank, pump and lines.
Empty the tank.
Clean the tank with water and a suitable detergent for
plastic surfaces.
Fill the tank with water and check that the sprinkler
works.
The water tank is made of plastic (polyethylene)
Fig. Water tank
and is recyclable.
1. Cap
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