DYNAPAC Vibratory rollers CC425. Operation & Maintenance (2021)

Manual Revisions

Table 1: Revision History

REV.

DATE

REVISION

NO.

June 2021

New release

Customer Acknowledgment

• Dynapac reserves the right to make any changes or modifications without prior

notice and without incurring any liability to retrofit machines previously shipped from

the factory.

• Dynapac will not be held responsible for any damages caused by unauthorized

modification of the machine and its associated equipment.

• The manufacturer is not liable for damages caused by inappropriate use.

• Damage that occurs as a result of substandard repairs, as well as injury to personnel

or damage to equipment that is attributable to older un-repaired damage, is not

covered by the customer warranty policy. Always refer to your customer warranty

policy.

• Always refer to equipment documentation for correct operation and repair

procedures.

Table of Contents

Section 1: Introduction

1.1 General Information

Instruction Manual Location

Receiving the Roller

Identification Data

Roller Identification

Engine Identification

1.2 Roller Description

Identification of Major Components

Diesel Engine

Electrical System

Main and Light Fuses

Propulsion System/Transmission

Brake system

Secondary/Parking Brake

Steering System

Roller Applications

Designated Applications

Non-Designated Applications

Section 2: Safety First

2.1 General Information

Warnings and Cautions

Personnel Protective Equipment

Tools and Equipment

Operating Safety

Before Starting the Engine

Starting the Roller

Parking the Roller

Driving Near Edges

Slopes

Hydraulic Maintenance Safety

Cylinder Repairs or Replacement

Handling Fluids and Oil

Transporting

2.2 Equipment Safety Decals

Table of Contents

Section 3: Special Instructions

3.1 Operational Limitations

Standard Lubricants and Other Recommended Oils and Fluids

Higher Ambient Temperatures

Lower Ambient Temperature - Freeze Risk

Temperatures

High Pressure Cleaning

Ambient Temperature Range

Operating Conditions For Stability

Grade Limitations

Fire Fighting

Battery Handling

Jump Starting

Section 4: Specifications

4.1 Weight and Dimensions

Diesel Engine

Fluid Volume

Working Capacity

Hydraulic System

Section 5: Operation Controls

5.1 Instruments and Controls

Functional description - Keypad

Starter Switch

Speed selector

Work Transport mode

Emergency Stop

Forward/Reverse (FNR) Lever

Sprinkler Switch

Seat Buzzer

Horn Button

Vibration High/Low Switch

Drum Selector Switch

Fuse Box

Driving Lights Switch

Working Light Switch

Hazard Warning Lights Switch

Table of Contents

Rotating Beacon Switch (Optional)

Direction Indicator Switch

Parking Brake On/Off Switch

Electrical Control Panel

Functional description - Display

Transport mode

Direction of work

Hour meter

Fuel level

User settings

Work mode vibration

Vibration status

Automatic vibration control - AVC

Function description

Control Panel Warnings Symbols

Control Panel Notification Symbols

Section 6: Inspections and Operations

6.1 General Information

General Checks

Operator Areas

Check Engine Oil Level

Check Engine Coolant Level

Check Fuel Level

Check Batteries

Verify the Controls

6.2 Before Starting the Engine

Seat(Standard) Adjustment

Check the Instruments and Lamps

Interlock

6.3 Operating the Roller

Operation

Vibration on Selected Drum

Braking

Normal Braking

Emergency Braking

Switching Off

6.4 Lifting and Handling

Locking the Articulation

Lifting the Roller

6.5 Towing the Roller

Towing Information

Table of Contents

Towing

6.6 Transporting the Roller

Transportation Procedures

Safety Precautions

Operator Checklist

Start Up

Before Driving

Roller preparation for Transport

6.7 Special Conditions

Cold Weather Conditions

Hot Weather Conditions

High Altitude Conditions

Long-term Parking

Section 7: Maintenance

7.1 General Information

7.2 Maintenance Schedule

Maintenance Schedule Information

7.3 Refill Capacities/Lubricants

General Information

Lubrication Chart

Refill Capacities

7.4 Standard Torque Values

Head Markings

Recommended Torques

7.5 Maintenance as Required

Service as Required

Clean the Roller

Loose Bolted Connections

Air Cleaners

Connections and Ducts

Air Cleaner Pre-Cleaner

Air Cleaner Main Filter

Cleaning the Filter Element

Air Circulation

Hose and Clamps

Engine

Batteries

Check Electrolyte Level

Section 1: Introduction

1.1 General Information

This manual contains basic safety information, basic operation instructions, and preventive

maintenance information of the Dynapac CC425 roller.

The purpose of this manual is to provide the knowledge of the fundamental rules and criteria to be

followed for on-site use and maintenance of the CC425 roller for the operator and site maintenance

personnel.

The operator and site maintenance personnel must read and fully understand this instruction manual

before operating or servicing the roller. This manual has been organized to present the safety

precautions, operation requirements, and appropriate information needed to:

•

Safely operate the CC425 roller while achieving optimum production.

•

Understand the operating principal of each system associated with the CC425 roller.

•

React effectively and safely to emergency and alarm conditions.

•

Perform the necessary pre-operational and post-operational checks on the roller.

If any part of this manual cannot be understood, contact the supervisor or local Dynapac distributor.

This is an essential condition for working safely with the roller. The correct roller operation, use, and

regular maintenance are also essential elements to provide the highest performance and safety.

N o t e Always keep the Safety and Instruction manuals on the roller and available to the

operator and the helper. Always provide the model and serial number of the roller when

contacting the local Dynapac service or parts office.

Introduction

Instruction Manual Location

Identification Data

The instruction manuals are located behind the

An exact description of the model type and the

operator seat within easy access.

serial number of the roller facilitates fast and

efficient response from our parts and service

support operations.

Figure 1-1: Instruction manual Location

Provide the model type and serial number while

contacting the local Dynapac service or parts

office.

Enter the roller data on the following lines to

maintain the roller and engine information

necessary to facilitate fast and efficient response

from our parts and service support operations:

Model:

Roller Serial

Number:

Chassis VIN

Number:

Year of

A Manual location

Manufacture:

Engine (Mfg. and Type of

Receiving the Roller

Engine):

The roller has been tested, accurately checked,

Engine Serial

and prepared for shipment. Every part of the roller

Number:

is accurately checked before being shipped from

the factory.

When receiving the roller and before unpacking

the equipment, check if damage has occurred

during transport and if any parts are missing.

Check the equipment by consulting the shipment

documents.

If the goods are damaged or if parts are missing,

inform the freight agent and raise a complaint

against it.

Introduction

Roller Identification

The roller product identification number (PIN) plate is located on left hand side of the engine frame. The

PIN number is a 17 digit number which provides information about manufacturer, family model, check

letter, no coding, production unit, and serial number.

Figure 1-2: Location PIN

Manufacturer

Family/Model

C Check letter

D No coding

Production unit

Serial number

A Serial number

The pin number is punched on top-right side of the side plate

Figure 1-3: Location PIN

A Pin number

Introduction

Engine Identification

Figure 1-4: Identification Plate

A Engine identification plate

The engine identification plate is affixed to the right side of the engine. The engine identification plate

provides model identification and other important data about the engine. Refer to the engine operation

and maintenance manual for further information on the identification information. Have the following

engine data available when communicating with an authorized repair location or engine dealer. The

data on the engine identification plate is mandatory when sourcing service parts:

•

Engine serial number

•

Model

Introduction

1.2 Roller Description

The roller is a two self-propelled vibratory tandem rollers in the nine-metric tonnes class featuring

1690-mm wide drums. The roller is equipped with drive, brakes, and vibration on both drums.

To permit optimum performance on a wide range of applications and site requirements, the roller is

equipped with:

•

Diesel engine

•

Electrical system

•

Propulsion system/transmission

•

Brake system

•

Secondary/parking brake

•

Steering system

•

Canopy

Identification of Major Components

Figure 1-5: Major Components Right Side

A Rear light

E Mirror

J Vibration motor

B Water tank

F Steering console

K ROC

C Hydraulic tank

G Fuel tank

M Drum

D Canopy

H Head Light

Q Drive motor

Introduction

Figure 1-8: Fuses-View A

Electrical System

The roller is equipped with 12V DC electrical

system and 90A alternator.

Figure 1-7: Electric System

10A -Fuse

D and E

40A - Main and Light

fuse

30A - Mini Relay

Battery Disconnector

Switch

100A - Starter Relay

30A- Engine ECU fuse

A Battery disconnector

Component

Rating

Battery

12V, 150AH

Alternator

12V, 90amps

Starter

12V, 2.7kw

Main and Light Fuses

The main fuse and light fuse are placed near to a

100A starter relay on battery disconnector

bracket.

Table 1-1:Placement of Fuses

F10

Main fuse

40 A

F11

Light fuse

40 A

F13

Engine ECU fuse

30 A

Introduction

Figure 1-9: Fuses- View B

Figure 1-10: Fuse Boxes in Switch Box

A Fuse box

C Fuse for Driving Lights

B Fuse

The flat pin, type C (medium) fuses and 20A

fuse are used for driving lights.

Table 1-2: Fuse Function and Amperage

Sl.

Function

Amperage

Main fuse

15 A

(Ignition/emergency/

Parking brake/vibration

A and B Main and light

10A- fuse for back up

Drum selection)

fuse

alarm

Working light

15 A

Engine ECU

F Starter Relay

relay/Dyn@link/Ignition

terminal

Mini Relay

Battery

Sprinkler pump/USB

10 A

disconnector

charger

switch

Rotating beacon relay

10 A

Mini Relay

Drum Speed & Back up

15 A

Mini Relay

alarm switch

Engine Diagnostic tool

10 A

ECU battery +ve & flasher

20 A

relay

ECU battery supply before

30 A

ignition

Table 1-3: Driving light Fuse

Sl.

Function

Amperage

Driving lights

20 A

Spare

10 A

Introduction

Roller Applications

Propulsion system/

The roller is built in accordance with international

Transmission

standards and recognized safety rules.

The propulsion system is a hydrostatic system

Nevertheless, misuse may constitute a risk to the life

with a hydraulic pump supplying two motors with

and limb of the user or third parties, and may cause

gear box connected in parallel. The motors drive

the front and rear drums.

damage to the roller or other material property.

The speed of the roller is proportional to the

The roller must be used in accordance with its

deflection of the control lever from neutral.

designated use as described in this manual. The

roller must only be operated by trained, safety-

conscious persons who are fully aware of risks

involved in operating the roller. Any functional

disorders, especially those affecting the safety ofthe

roller, must be corrected immediately.

Brake system

The brake system consists of a service brake,

secondary brake and parking brake. The service

Designated Applications

brake is hydrostatic and is activated by moving the

The roller is designed primarily to compact thin

control lever to neutral.

and thick asphalt layers with respect to dual

vibration amplitudes optimized for this purpose.

Secondary/Parking Brake

Non-Designated Applications

The secondary and parking brake system

consists of spring multiple disc brakes in the drive

The roller is not designed to use as a ladder,

gear box. The brakes are released with hydraulic

support, or a work surface. it is not used to carry

pressure and are operated with a switch on the

or transport passengers or equipment. The

instrument panel.

manufacturer/supplier cannot be held liable for

any damage resulting from such use. The risk of

such use lies entirely with the user.

Steering System

The steering system is a hydrostatic system.The

Operating the roller within the limits of its

control valve on the steering column distributes

designated use also involves compliance with the

the flow to the control cylinder, which actuates the

inspection and maintenance directives contained

articulation.

in the operating manual.

The steering angle is proportional to the deflection

of the steering wheel.

Introduction

Section 2:Safety First

2.1 General Information

This information is intended as a guide for trained and qualified personnel who are aware of the dangers

involved in handling potentially hazardous equipment. It is not intended to contain a complete list of all

safety precautions which should be observed by personnel using this equipment.

Before you operate, maintain, work around, or in any other way use this equipment:

N o t e Read and study the Safety Manual, and this Instruction Manual.

N o t e Ensure that all instructions in the maintenance section are followed. Failure to obey

instructions or warnings could result in injury or death.

•

Those who operate, maintain, and work on roller must be competent.

•

The maintenance and service of this roller involves risks both to personnel and roller and must be

performed only by qualified personnel exercising caution.

•

Personnel engaged in the operation, maintenance, or servicing of this roller are urged to become

familiar with First Aid theory and practices.

•

During operation of this roller, local safety, and fire protection standards must be observed.

•

Do not use the roller in need of adjustment or repair. 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 roller. Do not jump on or off

a moving roller.

•

Drive slowly and carefully during the sharp bends or during the uneven ground.

•

Avoid driving across slopes. Drive straight up or straight down the slope.

•

Fasten the seat belt while driving.

•

Replace all the lost and damaged safety labels.

•

Keep the roller in good working condition.

•

Safety measures during refueling:

• Make sure to stop the engine.

• Do not smoke.

• Do not use naked flames in the vicinity.

• Ground the nozzle of the filling device against the tank to prevent sparks.

This safety summary includes general safety precautions and instructions that must be understood and

applied during operation and maintenance to make sure personnel safety and protection of equipment.

Before performing any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be

reviewed and understood.

Safety First

Warnings and Cautions

Personnel Protective

Equipment

Throughout the manual, Warnings, Cautions, and

Notes symbols are used to designate instructions

Anyone working around the roller must wear

of particular importance. Look for these symbols

approved safety equipment (safety shoes or

which point out items of extreme importance to

protective footwear, safety glasses, hearing

you and your co-workers’ safety. Read and

protection, hard hat, gloves, respirator, and the

understand thoroughly. Heed the warning and

like) when operating or maintaining the roller.

follow the associated instructions. In this manual,

Wear close fitting clothing and confine long hair.

these terms have the following significance:

Operating requires full attention of the operator.

Do not wear radio or music headphones while

operating.

WARNING! Marks a danger or a

hazardous procedure that can result in

life threatening or serious injury if the

Tools and Equipment

warning is ignored.

Tools, lifting gear, fastening devices,

jacks, and other working equipment must

CAUTION! Marks a danger or hazardous

be in safe operational working

procedure that can result in damage to

conditions.

the roller or property if the warning is

ignored.

Equipment or components which are

being fitted or removed or where their

N o t e Note is used for supplementary

installation position is being changed,

information not directly effecting

must be secured against unintentional

safety or damage to equipment. Note

movement, slipping, or falling over. Use

can also refer to special information

suitable lifting gear or suspension/

on the efficient use of the roller.

support devices.

Systems and units (tensioning units)

Modifications

must be depressurized in an appropriate

manner before opening.

The roller is designed for safe operation. Do not

do anything that may hamper the safety features

or structural integrity of the roller.

Damaged hydraulic or mechanical pre-

tensioned spring elements must be

Do not make any unauthorized modifications to

exchanged as a completed unit. Further

this roller. Dynapac cannot be held responsible for

information can be found in the

any accidents, incidents, or damage to persons or

respective component descriptions and/

property that are related to the use of modified

or fitting and removal instructions.

roller.

Safety First

Driving Near Edges

Operating Safety

Know the working area. Familiarize with work site

While driving near an edge make sure to maintain

obstructions and any other potential hazards in

2/3 of the drum width on the solid ground.

the area.

N o t e The roller's center of gravity moves

Before Starting the Engine

outwards when steering. For example,

the center of gravity moves to the right

•

Inspect the roller for potential hazards.

when you steer to the left.

•

Adjust the rear view mirrors for good visibility.

N o t e Never operate roller on side slopes.

The roller may roll over, even on

•

Make sure that the controls are in the neutral

stable ground. Always operate the

position and the parking brake is applied.

roller parallel to the slope; never

•

Make sure that there is no one in the immedi-

perpendicular.

ate vicinity and there are no obstructions

around the roller.

Figure 2-1:Position of the Drum

Starting the Roller

•

Do not start the engine or move any of the

controls if there is a warning tag attached to

the controls. Check with the person who

attached the tag before starting.

•

Read and follow all the instruction decals.

•

Before starting the engine, check that all the

gear controls are in neutral position.

•

Always inspect the motor before and after

starting.

•

Check all the safety devices. Report any

defects immediately.

•

Listen for unusual noises.

•

Engage hydraulic controls slowly in cold

weather to avoid shock loading.

Parking the Roller

•

Select the level and hard ground. If necessary

to park on the slope, block the front of the

drums on the downside of the slope.

•

Apply break in emergency conditions.

Safety First

Slopes

Hydraulic Maintenance

Safety

The slope angle is measured on a hard, flat

surface with the roller stationary. The steering

The normal operating temperature of hydraulic oil

angle was zero, the vibration was switched OFF

is hot enough to cause serious burns. Use

and all tanks were full.

precautions when working on any hot fluid lines or

changing filters.

Always take into consideration that loose ground,

steering the roller, vibration on, roller speed

across the ground and raising the centre of gravity

Hot oil or components can burn. Avoid

can cause the roller to topple at smaller slope

contact with hot oil or components. Do

not allow used oil to drain into the

angles than those specified here.

ground. Dispose the used oil properly in

accordance with the local guidelines.

N o t e It is recommended that Roll Over

Protective Structure (ROPS) or a

ROPS approved cab, is always used

Cylinder Repairs or Replacement

when driving on slopes or unsafe

•

When repairing cylinders, make sure to block

ground.

them up to prevent dropping or rolling off the

roller.

Figure 2-2: Operating on the Slopes

Handling Fluids and Oil

•

When draining fluids, make sure that

adequate sealable containers are available,

and take care to prevent spillage.

•

Always make sure waste fluids are disposed

in an environmentally safe manner.

•

Always make sure that used filters are stored

in secure containers and disposed of in an

environmentally safe manner.

•

Do not use used oil for oil change.

Safety First

Transporting

•

Use only appropriate means of transport and lifting gear of adequate capacity.

•

Fastening of loads and instructing the crane operators should be entrusted to the

experienced persons only. The person giving the instructions must be within sight or sound of the

operator.

•

Do not attempt to load the roller on the transport vehicle without knowledge and experience with

the operation of the roller.

•

Use proper chock blocks in front and rear of the wheels of the transport vehicle when

loading the roller.

•

Position the roller on the transport vehicle centered from side to side and use proper chock blocks

in front and rear of the tracks.

•

Secure the roller to the deck of the transport vehicle with adequate chains or cables and blocks to

meet local regulations.

•

When moving the roller on public access roads, obey all traffic regulations and make sure that pro-

per clearance flags, lights, and warning signs are properly displayed. Never turn corners at exces-

sive speeds. Look in all directions before reversing the travel direction.

•

Make sure that hitch of the transport vehicle is properly locked before transporting the roller.

Safety First

2.2 Equipment Safety Decals

Before you operate, maintain, work around, or in any other way use this roller, read and understand the

safety decals and safety labels located on the roller. Follow all directions on the labels. Do not remove

or deface the labels. Replace them if they become damaged or lost

Table 2-1:Decal List

Decal

Message

Location

Warning - Crush zone

Quantity 2: Engine frame left and

right bottom side.

Warning - Rotating engine

Quantity1: Engine frame left top

components

side.

Warning: Hot surfaces

Quantity 1: Engine frame front

center side on grill.

Warning: Instruction manual

Quantity 1:- Center of cancol

cover below steering wheel.

Warning - Risk of crushing

Quantity 2: Front left and right

side plate.

Warning: Combustible Gas

Quantity 1: Engine frame rear

top side.

Warning: Brake

Quantity 1: Engine frame rear

Disengagement

bottom left side.

Safety First

Section 3:Special Instructions

3.1 Operational Limitations

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 of 4°C to +50°C (39.2°F to 122°F)

•

Cold start in the range of 4°C to -15°C (39.2°F to 5°F)

Higher Ambient Temperatures

For operation of the roller at higher ambient temperatures, however maximum +50°C (122°F).

The diesel engine can be run at this temperature using normal oil.

Hydraulic system - mineral oil Dynapac Hydraulic 300 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.

Special Instructions

N o t e Specifications represented are

High Pressure Cleaning

calculated values at 100% efficiency.

Do not spray water directly onto electrical

components or the instrument panels.

Operator life may be endangered if the

following is not complied with. Do not add

attachments to the roller that intrude into

Place a plastic bag over the fuel filler cap and

the operator protective area, reduce

secure with a rubber band. This is to avoid high

visibility, restrict emergency exits, or add

pressure water entering the vent hole in the filler

weight exceeding certification weight.

See the operation manual or contact the

cap. This could cause malfunctions, such as the

dealer for complete inspection

blocking of filters.

requirements and maintenance

instructions.

Do not spray with high-pressure cleaner directly

onto gaskets and bearing spacings in steering

Grade Limitations

hitch.

Exceeding the slope or grade limitations of the

roller and its configuration can cause the roller to

Do not spray water directly onto electrical

tip over. Prior to moving the roller into position,

components or the instrument panels.

always determine the safe operating grade of the

Place a plastic bag over the fuel filler cap

and secure with a rubber band. This is to

roller.

avoid high pressure water entering the

vent hole in the filler cap. This could

Fire Fighting

cause malfunctions, such as the blocking

of filters.

If the roller catches fire, use an ABC-class powder

fire extinguisher.

Ambient Temperature

A BE-class carbon dioxide fire extinguisher can

Range

also be used.

The ambient temperature working range between

Battery Handling

limits of 4°C to +50°C (39.2°F to 122°F).

When removing batteries, always

disconnect the negative cable first.

Operating Conditions For

Stability

When fitting batteries, always connect the

Stability is affected by the orientation of the roller,

positive cable first.

surface stability (bearing strength), and wind

conditions.

Dispose old batteries in an

environmentally friendly way. Batteries

Travel at a safe speed relevant to

contain toxic lead.

surrounding conditions.

Do not use a quick-charger for charging

Contact the local Dynapac distributor, dealer, or

the battery. This may shorten the battery

service office for further information.

life.

Special Instructions

Jump Starting

Do not connect the negative cable to thenegative

terminal on the dead battery. Aspark can ignite

the oxy-hydrogen gas formed around the

battery.

Check the battery used for jump startinghas

the same voltage as the dead battery.

Turn off the ignition and all power consuming

equipment.

Switch off the engine on the roller which is

providing jump start power.

Connect the jump start battery's positive

Fig. Ignition key & battery disconnector

terminal (A) to the flat battery's positive

1. Ignition key

terminal(B).

2. Battery disconnector

Connect the jump start battery's negative

terminal (C) to, for example, a bolt (D) or the

lifting eye on the roller with the flat battery.

Ignition key & Battery Dis-connector key

Start the engine on the power providing roller.

removal In transit

Let it run for a while. Now try to start the other

While transporting the machine on the trailer or

roller.

container or in long-term parking always ensure

Disconnect the cables in the reverse order.

that

1. Ignition key should be removed from the

Ignition switch

Figure 3-1: Jump Starting

2. Battery dis-connector key should be

removed.

This will avoid static parasitic current

consumption & saves the battery life & potential

battery drain issue

Battery's positive terminal one

Battery's positive terminal two

Battery's negative terminal three

Battery's negative terminal four

Special Instructions

Fluid Volume

Table 4-4:Fluid Volumes

Fuel tank

180 L (47.5 gal)

Water tank

Front side

400 L (105.6 gal)

Rear side

400 L (105.6 gal)

Hydraulic tank

62 L (16.3 gal)

Hydraulic system

13 L (3.4 gal)

Drum oil

14 L (3.7 gal) each

Coolant - Premixed coolant

18.5 L (4.89 gal)

Working Capacity

Table 4-5:Working Capacity

Static linear load front

28.4 kg/cm

Static linear load rear

26.0 kg/cm

Amplitude

0.9 mm / 0.4 mm (0.036 / 0.01 in)

Vibration frequency

36 Hz / 54 Hz

Centrifugal force

130 kN / 60 kN

Hydraulic System

Table 4-6:Hydraulic System

Opening pressure (Absolute pressure)

MPa

Bar

Psi

Drive system

35.0

350

5076.3

Vibration system

35.0

350

5076.3

Steering system

17.5

175

2538

Charge pressure

2.5

365.5

Brake release

2.5

365.5

Table 4-7: Machine speed

Mode

Km/hr

Transport speed

Working speed

Specifications

Section 5: Operation Controls

5.1 Instruments and Controls

This section provides basic information about the operating controls, instruments, and indicators

located on the consoles and around the roller.

The operator console is located in front of the operator seat under the steering wheel. The slim profile

and quick opening side panels provide easy access for maintenance and service.

Figure 5-1: CC425 Console

A High Beam

Parking brake On/Off

B Driving lights

Keypad

C Dual Speed

D Hazard warning lights

E Display

F Direction indicators

G Emergency

Operation Controls

Functional Description - Keypad

Working mode

Amplitude, hight/low

Working lights

Rotating beacon

(Not Applicable)

Sprinkler Timer

Sprinkler Manual/Auto

Engine speed selector

Horn

Symbol

Designation

Function

LED

LED color

LED OFF → Transport mode

Work mode

LED LEFT → Working mode,

Red

vibration

LED LEFT → Low amplitude

Amplitude

Red

selector

LED RIGHT → High amplitude

Turns on the working lights of canopy.

Working lights

LED OFF

LED LEFT → Working lights, ON

Red

LED LEFT → Sprinkler manual

Red

Sprinkler

Manual/Auto

LED RIGHT → Sprinkler auto

Red

LED LEFT → Sprinkler spray low

Red

Sprinkler

LED CENTER → Sprinkler spray

Red

Timer

medium

LED RIGHT → Sprinkler spray

Red

high

LED LEFT → Speed low

Red

Engine speed

selector

LED RIGHT → Speed High

Red

Operation Controls

Starter Switch

Speed selector

The Starter switch starts and stops the engine.

The Speed selector regulates the speed of the

There are three positions in the starter switch:

engine. In the ON LED Left position, the engine

idles and in the ON LED Right position the

•

OFF: All the electric systems and the engine

engine runs at full speed.

are switched off, and the key can be remo-

ved.

Figure 5-3:Speed selector

•

ON: Engine is on Run mode. Charging circuit

and lamp circuit are energized.

•

Start: The engine cranks. Make sure to allow

the switch to ON position until the engine is

started.

Figure 5-2:Starter Switch

A Speed selector

Work/Transport mode

The 1^st number button is used for work or transport

mode selection. Press the button to turn on the

work mode with Red illumination in button and

press again to turn On the transport mode.

Figure 5-4: Vibration On/Off Switch

1 Off position

Start position to supply power

to the instruments and controls

2 On position

Hold position

50 a Starter motor activation.

A Work/Transport mode

Operation Controls

Sprinkler Switch

Emergency Stop

Figure 5-7: Sprinkler Manual/Auto

The Emergency stop button is used to stop the

A. Sprinkler Manual/Auto

engine in an emergency situation which cannot be

B. Sprinkler timer

shut off in an usual manner. It switches off the

engine and activates the brakes. The emergency

stop aborts the entire control operation in a

quicker way for the personnel safety.

Figure 5-5: Emergency Stop

5^th Button for Sprinkler manual/auto mode selection,

First press manual mode is activated with red

illumination in Left side button.

On second press auto mode is activated with red

illumination in right side button, Machine running

condition water flow comes on drum.

6^th Button for sprinkler timer to adjust water spray in

three mode.

A Emergency stop button

Forward/Reverse (FNR)

Lever

The direction of travel and speed of the roller is

regulated with the forward/reverse (FNR) lever.

Seat Buzzer

The roller speed increases or decreases in

The Seat buzzer beeps if the operator is not

proportion to the lever position.

seated during the operation of the roller and it

continues to beep until the operator sits on the

Figure 5-6: FNR Lever

seat. If the buzzer beeps for long the brakes are

activated and engine is forced to stop.

A FNR lever

Operation Controls

Horn Button

Drum Selector Switch

Depending on the Drum selector, the vibration is

The Horn button is located on the

activated in the following places.

keypad button no 7

Press the button to activate the horn.

Left side button

Activates vibration for front

drum.

Figure 5-9: Horn Button

Right side button

Activates vibration for rear

drum.

Figure 5-11: Drum Selector Switch

Vibration High/Low Switch

In the one press, the High amplitude is activated

with the red illumination in left side button.The

function is activated with the switch. In the

second press the Low amplitude is activated

with Red illumination in right side button.

Figure 5-10: Vibration Hi/Low Switch

Fuse Box

The fuse box is located on the control column that

contains the fuses for the electrical system. Fuses

protect the electrical components from short

circuit damage. Refer to electrical system for the

description and function of fuses.

Driving Lights Switch

Push Up position

Turns on driving lights.

Intermediate position

Turns off all lights.

Depress position

Turns on parking lights.

Figure 5-12: Driving Lights Switch

A Push up position

B Intermediate position

C Depressed position

Operation Controls

Depress the switch to turn on the rotating beacon.

Working Light

Switch

Figure 5-15: Rotating Beacon Switch

Depress the Working light switch to turn on the

working lights.

Figure 5-13: Working Lights

Direction Indicator Switch

The direction indicators are blinking lamps

mounted near the left and right, front and rear

corners of the roller. Depress the Direction

Hazard Warning Lights

indicator switch to either left or right to turn on the

Switch

left or right indicators. In the intermediate position

the function is shut off.

The hazard warning lights are primarily used to

warn other vehicles that there is a problem either

Figure 5-16: Directional Indicator Lights

with the roller, or there is a hazard in front of roller

causing the operator to reduce the speed quickly.

Depress the switch to turn on the hazard warning

lights.

Parking Brake On/Off

Figure 5-14: Hazard Warning Lights

Switch

The Parking brake On/Off switch is used to

activate the parking brake.

N o t e Parking brake must be activated while

starting the engine. Always activate

the parking brake when the roller is

stationary on a sloping surface.

Figure 5-17: Parking Brake On/Off Switch

Rotating Beacon Switch

(Optional)

The rotating beacon lighting is generally used to

warn the approaching vehicle of potential

hazards, such as roller that is stopped or moving

slower than the rate of the traffic.

Operation Controls

Electrical control system

Functional Description - Display

When the ignition key is activated to position 1, the start screen appears on

the display (Fig. 1). This is shown for a two seconds and then switches over

to the status screen.

Transport mode

Fig. Start screen

The transport mode menu is shown when one of the three function keys to

the right on the display is activated.

The status screening provides information about travel direction (2), Hour

meter (3), fuel level (4) and Engine RPM (12).

Direction of work

The icon has three options (F, N, R) and is located in the top left corner of

the Display (2).

➔ N (Neutral) - Indicates that the lever is in Neutral position.

➔ F (Forward) - A left arrow is shown in front of "F" on the display.

➔ R (Reverse) - A right arrow is shown after "R" on the display.

Hour meter

An icon (hour-glass) is shown on the left-hand side of the display for machine

hours. The number of hours is shown to the right of the icon (3).

Fuel level

The fuel level is indicated as a no of lines of on the bar to the right of the

Fig. Transport mode

display.

Once the first fuel bar is reached (bottom to top), it means the system has 10%

of its total capacity, and the warning LED lights glow, indicating that you

should refuel (5).

User settings

Users can change the lighting configurations (6), Brightness & contrast.

SW: - 4812330900_A- Display

4812330901_A - ECU software

Fig. User setting

Working mode - Vibration

Different Vibration modes are chosen by pressing the corresponding button (2)

on the Keypad.

Operation Controls

Vibration status

Vibration status activated on the drum (8).

Automatic Vibration Control - AVC

If AVC is activated from display selector switch, machine will runs with

automatic vibration meaning that every time you don’t need to press vibration

switch on FNR lever. Refer beside snap for this & follow below conditions.

1) Select button of display in front of AVC=it will appear on display as shown

in beside-encircled snap.

2) Activate work mode from Keypad.

3) Select either low or high amplitude from Keypad.

4) Switch 'ON' Vibration Sw.on FNR lever=only once.

5) Whenever machine comes in neutrl-vibration will stops & whenever it

moves away from neutral=vibration will automatically starts .This time you

dont need to select anything-thus its AVC.

Fig. FNR lever

A. Front Drum selector

B. Rear Drum selector

Function Description

Operation Controls

Control Panel Warnings Symbols

Warning lights turn on when the starter switch is turned to the on position and turn off when the

engineis started. If the lights turn on even when the engine is running indicates a faulty condition.

Table 5-1:Warning Lights

Designation

Function

Description

Battery

When battery voltage is low i.e.<12.5V,the

charging

charging symbol should come with Orange

indicator.

red alert as per beside snap.

Diesel engine

When engine oil press. Level is low;

lubricating oil

immediately symbol should come with RED

pressure indicator.

colour alert.

Diesel engine

When engine temp. high; immediately symbol

Coolant

should come with RED colour alert.

temperature

indicator.

Low fuel level

The lamp illuminates if the oil level is low inthe

indicator.

fuel tank.

Hydraulic oil filter

When Hydraulic Oil filter clogged; immediately

pop up symbol should come.

Operation Controls

Control Panel Notification Symbols

Notifications are displayed when the starter switch is turned to the on position and notifies that

corresponding systems are operating.

Table 5-2:Notification Lights

Designation

Function

Description

The lamp illuminates when the parking brake is

Parking brake indicator

activated.

The fuel level gauge monitors the fuel level in

the fuel tanks of the roller.

The fuel level gauge

1. Total 10Nos.lines are appearing for fuel

level indication as full. It’s solid or dark

when tank is full.

2. It’s hollow or blank when tank is

empty/less fuel.

Hour meter

Ensure hour meter should clocked every

after 1 hour with change in hour digits.

Glow Plug indicator illuminates momentarily (for

approximately 5 seconds.) once ignition is

Glow plug indicator

switched on.

When glow plug is active ;immediately the

glow plug LED should be on.

Air filter indicator

When Air filter clogged; immediately symbol

should come with RED colour alert.

Hydraulic oil

The indicator illuminates when hydraulic oil

temperature

temperature increases beyond 103 to 106 °C

indicator

(217.4 to 222.8 °F). When this indicator

illuminates, stop the engine and find the fault.

Operation Controls

Control Panel Notification Symbols

Table 5-2:Notification Lights

Designation

Function

Description

If by mistake P-Brake Sw.is ON (disabled) & if

Cranking Attempt when P-

anyone trying to crank the engine-then beside

Brake disabled

warning symbol should appear on display.

Whenever FNR lever either in forward or

Cranking Attempt when FNR

reverse direction & attempting to crank the

lever away from Neutral

machine-then beside symbol should appear

on display.

Enabling Vibration in

When operator tries to enable the vibration

transport mode

from the transport mode, display will show

this pop up.

Driver away from seat

When operator stands from seat while

machine is moving, display will show this pop

up.

Water in Fuel

When water detected in fuel; immediately

symbol should come with yellow colour alert.

Malfunction Indicator

During malfunction indicator error from engine:

Immediately symbol should come with yellow

color alert

Check Engine

During check engine error from engine:

Immediately symbol should come with yellow

color alert.

When high beam is on ;immediately the high

beam LED should be on.

High Beam

Operation Controls

Control Panel Notification Symbols

Table 5-2:Notification Lights

Designation

Function

Description

Symbolic representation of

machine position (in Neutral

Check & ensure Neutral symbol as 'N' &

'N', Non neutral: Check &

whenever FNR lever comes in correct neutral

ensure Neutral symbol as 'N'

position.

& whenever FNR lever comes

in correct neutral position.

Symbolic representation of

Switched 'ON' vibration in low amplitude &

Vibration 'ON' in low

check symbol as per beside snap with single

amplitude

curve below drum (this needs to be checked

whenever machine running in Vibration low

mode only)

Symbolic representation of

Switched 'ON' vibration in high amplitude &

Vibration 'ON' in high

check symbol as per beside snap with dual

amplitude

curves below drum (this needs to be checked

whenever machine running in Vibration high

mode only)

Inspections and Operations

Section 6: Inspections and Operations

6.1 General Information

N o t e If you are not experienced with the roller controls, read and understand

Section 5 - Operation Controls.

The following operational hints should be observed:

•

Do not speed the engine when it is cold.

•

Do not lubricate the roller while the engine is running.

•

Always perform safety checks prior to starting the roller.

•

Never stop the roller on a slope or surface that is liable to collapse.

•

Never stop the roller against a high wall that is liable to collapse or cause a crushing risk.

•

Before starting the engine, make sure all operator controls are either in off or neutral positions and

the parking brake is applied.

•

Always sound the horn before moving the roller in any direction to alert the personnel and to allow

sufficient time before putting the roller in motion.

•

Always judge when driving on unstable surfaces where there may be a risk of overturning or when

loading onto a transporter where there is a risk of overturning. Always use a spotter.

General Checks

•

Do general checks for any wear and tear on the roller.

•

Check for broken or cracked welds, loose or missing bolts broken or inoperative gauges, or any

other irregularities which could lead to more costly breakdowns.

•

Check oil levels before starting the roller.

•

Check all bolted assemblies for tightness.

•

Check the entire roller for any loose, worn, or missing parts and replace them as needed.

•

Check fluid lines, hoses, filler openings, drain plugs, pressure caps, tires, tower cables, hoist wire

cables, muffler, engine, safety shrouds, and the area under the roller for signs of leakage.

N o t e Frequently walk around the roller and inspect for leaks, loose or missing parts,

damaged parts or parts out of adjustment. Perform all recommended daily

maintenance.

Operator Areas

• Keep operator areas, mirrors, and all lights clean. Check for all lights function.

• Make sure the operator areas, steps, and grab rails are clean. Oil, grease, snow, ice, or mud in

these areas can be slippery. Clean the boots of excess mud before getting on the roller.

Inspections and Operations

Check Engine Oil Level

Check Engine Coolant Level

•

Hot oil and hot components can cause

Check the coolant level through transparent

personal injury. Do not allow hot oil or

plastic of expansion tank. Fill the cooling system

hot components to contact the skin.

when coolant is empty. With the engine cold, top

•

Never operate the engine with the oil

off with premixed coolant of the desired freeze

level below the low (L) mark or above the

high (H) mark.

protection concentration. Add coolant through the

pressure cap neck of the surge tank.

N o t e Wait for at least five minutes after

shutting off the engine to check the oil

Always shut off the engine and allow to

level. This allows time for the oil to

cool before removing the radiator cap.

drain into the oil pan.

Remove cap slowly to relieve pressure.

Avoid contact with steam or escaping

Level the roller. The roller must be level when

fluid.

checking the oil level to make sure the

measurement is correct.

Shut off the engine.

Removing the radiator cap on a hot

radiator can cause scalding coolant to

spray out and burn the body badly. If the

Check the engine oil level by viewing the

engine has been in operation within the

engine dipstick.

previous 30 minutes, be very careful in

removing the radiator cap. Protect face,

If the oil level is low, add oil through the fill cap.

hands, and arms against escaping fluid

and steam by covering the cap with a

large, thick rag. If you see any steam or

Figure 6-1: Engine Oil Dipstick

coolant escaping, do not try to remove it

until the radiator cools down. If nothing is

escaping, remove the cap very slowly

and be careful. Be ready to step away if

any steam or coolant begins to escape.

Inhibitor contains alkali. Avoid contact

with skin and eyes.

Engine coolant must be properly

maintained to protect against engine

damage. Coolant must be tested at

regular intervals to make sure it can

provide adequate protection against

freezing, boiling, and corrosion. It is the

owner’s responsibility to know the type of

coolant used and to maintain it properly.

If coolant must be added, use K-cool super plus. It

must be used year round in all climates. Refer to

A Engine Oil Dipstick

instructions in 7.5 Maintenance as Required for

the correct procedures.

Inspections and Operations

Check Fuel Level

Check Batteries

Fuel is flammable and may cause serious

Batteries contain an acid and can cause

injury or death. Shut off the engine,

injury. Battery fumes can ignite and

extinguish all open flames, and do not

explode. Do not smoke when observing

smoke while filling the tank. Always wipe

battery fluid level. Skin and eye contact

any spilled fuel.

with battery fluid can cause injury. Avoid

skin and eye contact with battery fluid. If

contact occurs, flush area immediately

Check fuel level on the fuel level gauge, located

with water.

on the roller dashboard. Refill the tank when the

indicator needle moves to below 1/4 tank. Refer to

Check the battery posts and cables for corrosion.

the maintenance procedures in

Check and keep the electrolyte levels above the

Section 7 - Maintenance. Select the proper

battery plates or to the bottom of the fill holes.

grade of fuel oil in accordance with the

Refer to Section 7 - Maintenance for the correct

instructions given in the Lubrication Table in

procedures.

Section 7 - Maintenance.

Verify the Controls

Maintain fuel tank(s) at a high level to minimize

water condensation inside the tank(s). This is best

Before starting the roller, check that the Warning

accomplished by filling the fuel tanks at the end of

lights, Backup alarm, Horn and Emergency stop

each shift or day. Check the fuel tank for possible

controls are functioning properly. This inspection

leaks. Because of the potential fire hazard, leaks

should be performed before each shift and at

must be corrected as soon as they are spotted.

every startup.

1. Check the fuel level by reading the fuel level

gauge.

If any controls, instruments, or devices do

not function correctly, report the defects

2. Do not allow fuel tank to get emptied,

to the proper personnel. Defects must be

otherwise the entire fuel system will require

corrected before starting and operating

bleeding.

the roller.

3. If the fuel level is low, add clean-filtered fuel.

4. Fill the tank with the correct grade of fuel.

Refer to Lubrication Table for more fuel

details.

Inspections and Operations

6.2 Before Starting the

If any controls, instruments, or devices do

Engine

not function correctly report the defects

to the proper personnel. Defects must be

corrected before starting and operating

Remember to carry out daily maintenance before

the roller.

starting the engine.

Refer to Section 7 - Maintenance.

Seat (Standard) Adjustment

Consider the following points before starting the

Adjust the operator seat to the comfortable

engine:

position so that the controls are within easy reach.

1. Before starting the engine, check inside,

The seat is adjusted in the following way:

outside, and underneath the roller for people

or obstructions.

• Length adjustment: Pull the length

adjustment lever and move the seat forward

2. Turn the Battery disconnector key (located on

or back.

the right side of the operator compartment) to

the on position. This supplies the roller with the

power.

Figure 6-3: Seat Adjustments

Figure 6-2: Battery Disconnector

A Battery disconnecter

A Length adjustment

3. Check for warnings on the controls.

4. Start the engine only from the operator

position.

Do not leave the operator platform when

running the engine and roller.

Inspections and Operations

Check the Instruments and Lamps

N o t e Make sure that the Emergency stop is pulled out and the parking brake is activated. If

the forward/reverse lever is in neutral, the automatic brake function is engaged.

1. Turn on the switch.

2. Check that the warning lamps in the warning panel illuminates.

3. Set the sprinkler switch to the operating position and check for the system is functioning.

Interlock

The roller is equipped with interlock. The diesel engine switches off after 10 seconds, if the operator

gets off the seat during tramming. If the operator is not seated during tramming a buzzer goes on until

the parking brake is activated.

Inspections and Operations

6. Make sure the Engine RPM switch is

6.3 Operating the Roller

turned to low position.

Operation

Figure 6-5: Engine RPM

1. Before the roller start up, a pre-operational

general inspection of the roller must be

performed in accordance with those

instructions previously mentioned and in the

instructions found in

Section 7 - Maintenance.

2. Make sure all operator controls are either Off

or in the neutral position and all control

console gauges read zero.

Figure 6-4: Operator Consoles

Figure: Engine RPM

7. Set the vibration switch for high/low vibration

position. The operator must activate the

vibration using the switch on the forward/

reverse lever grip.

Figure 6-6: Vibration High/Low

Switches

A Emergency stop

C Ignition switch

B FNR lever

D Engine RPM

3. Make sure the Emergency stop button is not

activated.

4. The FNR lever must be in neutral position.

5. The Parking brake switch must be in the

engaged condition.

A Vibration high/low

B Vibration selector

switch

Inspections and Operations

N o t e As a general rule, do not operate the

Vibration on Selected Drum

starter motor more than 30 seconds at

a time without pausing to allow the

1. Activate the Working mode and High/low

starter motor to cool for at least two

amplitude from keypad button 1 and 2.

minutes. Overheating caused by

excessive cranking will seriously

2. Vibration is activated by using the switch

damage the starter motor.

in the FNR Lever.

• In the Left button the vibration is

8. Turn on the Ignition switch. Check all the

activated on front drum.

warning lamps and then crank the engine.

• In the Right button the vibration is

9. Allow the engine to warm up at idle speed for

activated for rear drum.

few minutes. Warm up time should be

• In both button the vibration is activated

extended when extremely low ambient

for front and rear drums

conditions (cold weather) occur or when

battery power is depleted during initial start-up.

•

10. Check the engine air cleaner indicator gauge

Braking

to determine if the elements require servicing.

Normal Braking

11. Make sure the parking brake is released and

the parking lights goes off.

1. Turn off the vibration by pressing the Vibration

control button on the FNR lever.

Figure 6-7:Parking Brake

2. Set the FNR lever to the neutral position and

apply brake to stop the roller.

N o t e In cold climatic condition braking

distances can be longer than the

normal distance.

N o t e Never leave the operator platform

without activating the parking brake.

Emergency Braking

Parking brake button

To hold the roller in the Stop position (parked),

Parking brake indicator

use the mechanical parking brake on each drum

drive motor. The mechanical parking brakes are

spring-activated and hydraulically released type

brakes.

1. In case of emergency, push in the Emergency

stop button, hold the steering wheel firmly and

be prepared for a sudden stop. The diesel

engine stops.

2. After emergency braking, reset the FNR lever

to neutral position, pull out the Emergency

stop and activate the parking brake. Restart

the engine.

Inspections and Operations

Switching Off

1. Press the Vibration control button to the off

position.

2. Set the FNR lever to the neutral position.

3. Turn the Engine RPM switch to low and allow

the engine to idle for a few minutes to cool.

4. Press the Parking brake button to activate the

parking brake. Always activate the parking

brake before leaving the roller.

N o t e If the roller must be parked on a

sloping surface, chock the drums with

wedges to prevent any movement.

5. Check instruments and warning lamps to see

if any faults are indicated. Switch off all lights

and other electrical functions.

6. Turn the Starter switch to the off position to

stop the engine.

7. Switch off the battery disconnector and

remove the key.

Inspections and Operations

6.4 Lifting and Handling

Lifting the Roller

• Use a crane/forklift to lift the equipment.

Locking the Articulation

• Pay attention when lifting and balancing the

N o t e Lock the steering joint, before lifting

equipment.

the roller.

• Seek a person to guide the way when lifting

1. Turn the steering wheel to the straight ahead

and moving the equipment.

position.

• An experienced crane/forklift driver should

2. Switch off the roller and activate the parking

drive the crane/forklift.

brake.

• When lifting, add a pad at the joint of steel

3. Pull out the lowermost locking pin which has a

cable of the crane and the hook hole and

a wire attached. Pull up the locking dowel

secure the hole.

which also has a wire attached.

N o t e The weight of the roller is shown on

4. Fold out the locking arm and secure it to the

the lifting plate. Refer to

upper locking lug on steering joint.

Section 4 - Specifications.

5. Fit the locking stub in the holes through the

locking arm and locking lug and secure the

Figure 6-9:Lifting the roller

stud in position with the locking pin.

N o t e Remember to refit the lock bar in its

holder after operation.

Figure 6-8:Locking the articulation

A Lifting belt

A Lock bar

Inspections and Operations

Towing

6.5 Towing the Roller

The roller can be moved up to 300 meters

Towing Information

(1,000 ft) using the instructions below.

Proper equipment must be used to prevent

N o t e Chock the drum to prevent the roller

damage to the vehicle and the roller during any

from moving when the brakes are

tow. Follow the state and local laws applying to

hydraulically disengaged.

vehicles.

Release the Brakes

If the vehicle is to be towed by a wrecker, use only

equipment designed for this purpose following the

The disc brake in each drive motor must be

instructions of the wrecker manufacturer. A safety

disengaged mechanically, according to the

chain system must be used.

following instructions, before the roller can be

towed.

Personal injury or death could result

1. Open the right door of the engine compartment

when towing a disabled roller incorrectly.

to access the propulsion pump.

2. Unscrew the nut 1 by holding the Allan screw

Block the drums of the roller to prevent

movement before releasing the

emergency brake system or the disc brake

3. Unscrew the Allen screw 2.

in each drive motor must be disengaged

mechanically, before the roller can be

towed. The roller can roll free if drum is

Figure 6-10:Unscrew Step

not blocked.

Follow the recommendations below to

properly perform the towing procedure.

Make sure to block the drums of the roller

and reapply the emergency brake system

before disconnecting from the towing

vehicle.

N o t e Maximum towing speed is 2 mph

(3 Kmph).

A Nut 1

B Allen screw 2

Inspections and Operations

Start Up

6.6 Transporting the

Roller

1. Before starting the engine, check inside,

outside, and underneath the roller for people

or obstructions.

Transportation Procedures

2. Always horn before starting the roller to alert

Safety Precautions

everyone in the area.

Before moving the roller on public roads, check for

3. Check all the gauges (including fuel).

instructions and information with respect to traffic

regulations regarding construction machinery.

4. Check for excessive noise or vibration.

Before Driving

The roller must be driven and transported only in

accordance with the operating instructions.

Fasten the seat belts.

1. When driving the roller, observe the prescribed

Adjust each mirror so that the side of the

transport position, admissible speed, and

vehicle is visible in the side of the mirror

itinerary.

closest to the vehicle. This helps you

determine the relation to objects seen in the

2. Do not attempt to drive unless knowledgeable

mirror.

and experienced.

Release the parking brake.

3. Always know the overall height, weight, width,

and length of the roller. Make sure there is

sufficient clearance when crossing

underpasses, bridges, and tunnels or when

passing under overhead lines.

4. When moving the roller on public access

roads, obey all traffic regulations and make

sure that proper clearance flags, lights, and

warning signs, including the slow moving

vehicle emblem, are properly displayed. Know

your approximate stopping distance at any

given speed. Never turn corners at excessive

speeds. Look in all directions before reversing

the direction of travel.

Operator Checklist

•

Make sure to know the vehicle and its

equipment and how to use it safely.

•

See that mirrors, and lights are clean and

unobstructed.

•

Check for fluid leaks.

•

Check lights and reflectors.

•

Check oil and coolant levels.

Inspections and Operations

Figure 6-15: Securing the Vibratory Roller For Transport

Table 6-1:Lashings' Permitted Distance

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.

Inspections and Operations

6.7 Special Conditions

Cold Weather Conditions

•

Refer to Section 7 - 7.3 Refill Capacities/Lubricants in the maintenance section for information

regarding cold weather lubricants, hydraulic fluids, coolants, fuel, and the like.

•

Use winter grade diesel fuel for operation at subzero temperatures.

•

Be extremely careful when using cold weather starting aids. Starting aids are very flammable and

should only be used if needed.

•

Remove batteries and store in a warm area to about 20 °C68 °F (68 °F).

Hot Weather Conditions

•

Monitor temperature gauges.

•

Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.

High Altitude Conditions

•

Be aware that engine power will be reduced.

•

Keep cooling fins on radiator and oil cooler clean and free of accumulated dirt.

N o t e Contact the engine dealer for fuel system adjustment before working on high altitude

condition.

Long-term Parking

Observe the following when storing the roller for short periods of time.

•

Remove the battery/batteries from the roller, clean and charge once a month.

• Cover the air cleaner (Refer Section 7 - Maintenance) or its opening with plastic or tape.

• Also cover the exhaust pipe opening. This is to avoid moisture entering the engine.

• Fill the fuel tank fully to prevent condensation.

• Fill the hydraulic reservoir to the uppermost level mark.

• Empty the water tank completely to avoid fouling.

Inspections and Operations

Section 7:Maintenance

7.1 General Information

Safety should be the main concern for anyone working on or around the roller. Do not perform any

function that could put someone in danger.

Always wear proper safety gear while working on or around the roller. This includes an approved hard

hat, safety glasses, steel toe shoes, gloves, respirator, and ear protection. Do not wear loose fitting

clothing that can get caught in rotating components.

N o t e If not experienced with the roller controls and instruments, read and understand

Operation Controls.

The following operational hints are observed:

•

Do not speed the engine when it is cold.

•

Always chock the drum if there is a possibility of uncontrolled movement.

•

Do not lubricate the roller while the engine is running.

•

Always perform safety checks prior to starting and using the roller.

•

Always operate the roller at the full engine power.

•

Never propel or stop the roller on a slope or surface that could possibly collapse.

•

Never stop the roller against a high wall that could possibly collapse or cause a crushing risk.

•

Before starting the engine all the controls are in the off or neutral position on the operator control

panel.

•

Always sound the attention horn before moving the roller in either direction to alert personnel and

allow sufficient time before putting the roller in motion.

Maintenance

7.2 Maintenance Schedule

Maintenance Schedule Information

The maintenance schedule shows those items requiring regular service and the interval at which they

are performed. A regular service program is geared to the items listed under each interval. These

intervals are based on average operating conditions. Before each consecutive interval is performed, all

of the maintenance requirements from the previous interval must also be performed.

N o t e In the event of extremely severe, dusty, or wet operating conditions, more frequent

maintenance than specified is necessary.

Table 7-1: Maintenance Daily/Every 10 Hours

Description

Action

Lubrication

Engine oil

Check level

Engine primary air filter

Check Vacuum Indicator - change it if

shows Chocking.

Radiator coolant

Check level

Hydraulic oil

Check level

Greasing

Grease

See lubrication chart

Table 7-2: Maintenance at First 50 Hours

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Pre fuel filter element

Change

See engine manual

Main fuel filter

Change

See engine manual

Hydraulic oil filter

Change

Drum gear oil

Change

Table 7-3: Maintenance at 50 Hours or Weekly

Description

Action

Lubrication

Drum gear oil

Check level

Battery and lead connection

Check

Maintenance

Table 7-4: Maintenance at 250 Hours/750 Hours/Three Months

Description

Action

Lubrication

See engine manual

Engine V Belt Condition

Check

Table 7-5: Maintenance at 500 Hours/Six Months

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Pre fuel filter element

Change

See engine manual

Main fuel filter

Change

See engine manual

Drum oil

Check level

AVM bolts

Check for tightness.

Drum AVM

Check for any crack and

deformation.

Hydraulic reservoir cover

Check for any leakage.

See engine manual

Engine V Belt

Change

Fuel tank

Drain and clean

Table 7-6: Maintenance at 1,000 Hours/One Year

Description

Action

Lubrication

Engine oil filter element

Change

See engine manual

Engine oil

Change

See engine manual

Pre fuel filter element

Change

See engine manual

Main fuel filter

Change

See engine manual

Engine primary air filter

Change

See engine manual

Safety filter

Change

See engine manual

Engine drive V-belt

Change

Valve cover gasket

Check

ROC cleaning

Check Delta T (clean if

required internally).

Fuel pipe and clamps

Check for tightness of

clamps.

Valve clearance

Check

See engine manual

Hydraulic oil filter element

Change

Drum oil & Drum gear oil

Change

Fuel tank

Drain and clean

Maintenance

7.3 Refill Capacities/Lubricants

General Information

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of

the unit. Periodic lubrication of the moving parts reduces to a minimum the possibility of the mechanical

failures.

The lubrication chart that follows in this section shows those items requiring regular service and the

interval at which they should be performed. Details concerning the oil and other lubricants follow the

lubrication chart. A regular service program should be geared to the items listed under each interval.

These intervals are based on the average operating conditions. In the event of extremely severe, dusty,

or wet operating conditions, more frequent lubrication than specified may be necessary.

•

Specific recommendations of the brand and grade of lubricants are not made here due to regional

availability, operating conditions, and also the continual development of the improved products.

For more information, refer to component manufacturer’s manual.

•

All the oil levels are to be checked with the roller parked on a level surface and while the oil is cold,

unless otherwise specified.

•

On plug type check points, the oil levels are to be at the bottom edge of the check port.

•

All the grease fittings are SAE standard unless otherwise indicated. Grease the non-sealed fittings

until the grease is seen extruding from the fitting. One ounce (28 grams) of EP-MPG equals one

pump on a standard one pound (0.45 kg) grease gun.

•

Over lubrication on the non-sealed fittings will not harm the fittings or components, but under

lubrication will definitely lead to a shorter lifetime.

•

Grease fittings that are worn and do not hold the grease gun or those that have a stuck check ball

must be replaced.

To prevent the minor irregularities from developing into serious conditions, several other services or

checks are recommended for the same intervals as the periodic lubrication:

•

Thoroughly wash all fittings, caps, plugs, and the like with a non-flammable and non-toxic cleaning

solution before servicing to prevent dirt from entering while performing the service. During the

regular lubrication service, visually check the entire unit with regard to cap screws, nuts, and

boltsbeing properly secured.

•

Spot check the several cap screws and the nuts for proper torque. If any are found loose, a

morethorough investigation must be made.

•

If a defect is detected, that requires special service, stop the roller operation until the defect has

been corrected. If necessary, contact the Dynapac representative for assistance.

Maintenance

Lubrication Chart

Periodic lubrication requirements are listed in the following Lubrication Chart. These requirements

include lubricant checks and greasing designated areas of the roller.

Description

Part Number

Remarks

Quantity

Engine oil

4812161866

Dynapac engine oil 50

5 L (1.3 gallons)

Hydraulic oil

D971800001

Dynapac hydraulic 300

20 L (5.3 gallons)

Drum oil

4812161862

Dynapac Drum oil 500

5L (1.3 gallons)

Coolant

2658449097

Dynapac coolant 150

20 L (5.3 gallons)

Drum gear oil

4812161858

Dynapac Gear oil 400

5L (1.3 gallons)

Refill Capacities

The following fluid capacities are provided for the servicing personnel who must perform roller

maintenance in the remote locations where complete shop facilities and resources are not available.

These capacities will give the servicing personnel an approximation of the fluid capacities of the

components to be serviced. Always use the specified method to check for accurate fluid levels.

Component

Approx. Quantity

Systems

Hydraulic Tank

65 L (14.5 gallons)

Water tank front side

400 L (125.4 gallons)

Water tank rear side

400 L (125.4 gallons)

Engine

Engine Coolant (Premixed)

18.5L (4.9 gal)

Engine Oil Capacity

12 L (3.2 gallons)

Fuel Tank

180 L (66 gallons)

Drum

14 L (3.7 gallons) each

Maintenance

7.4 Standard Torque Values

Use only the proper tools (inches) on hardware. Other tools may not fit properly and may slip

and cause injury.

Head Markings

Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners are

used, these should only be tightened to the strength of the original grade fastener.

Do not use these values if a different torque value or the tightening procedure is listed for a specific

application. Torque values listed are for general use only. All values are suggested maximum with dry

plated hardware.

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them

from falling when tightening.

The following pages list the recommended tightening torques for the various size bolts used for the

roller. Proper torque specifications should be used at all times.

Recommended Torques

This page lists the recommended tightening torques, in foot/pounds (ft·lb), for the various size bolts and

nuts that are used. Proper torque specifications should be used at all times. Dry means clean dry

threads and lube means a light film of oil. Excess oil in a threaded dead end hole can create a hydraulic

lock giving false torque readings. Suggested assembly torque values are per engineering

specifications.

Metric coarse screw thread, bright galvanized (fzb):

M-thread

Size

12.9,

8.8 Oiled

8.8 Dry

10.9 Oiled

10.9, Dry

12.9, Dry

Oiled

8,4

9,4

13,4

14,6

16,3

M10

M12

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

Maintenance

Metric coarse screw thread, bright galvanized (fzb):

M-thread

Size

12.9,

8.8 Oiled

8.8 Dry

10.9 Oiled

10.9, Dry

12.9, Dry

Oiled

M24

570

640

800

900

960

1080

M30

1130

1260

1580

1770

1900

2100

Metric coarse thread, zinc-treated

(Dacromet/GEOMET)

M-thread Size

10.9 Oiled

10.9 Dry

12.9 Oiled

12.9 Dry

120

150

146

183

M10

M12

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

Bolt dimensions

M16 (PN 902889)

Strength class

10.9

Tightening torque

192 Nm, torque class 2

(Dacromet treated)

Maintenance

Loose Bolted Connections

7.5 Maintenance as

Required

If any loose nuts or bolts are found during the

frequent walk-around and the daily inspections,

make sure they are properly torqued. Refer to 7.4

Service as Required

Standard Torque Values for the required torque

The preventive maintenance and service in this

for all bolt sizes and grades. Always replace self-

section requires attention on the need basis,

locking nuts if they have been loosened.

before, during, and after the operation shift. This

is in addition to the 8 to 10 hour daily routine

Air Cleaners

maintenance procedures. Performance of this

inspection can result in longer life and maximum

The following are detailed instructions for

productivity from the roller. Refer to the

performing routine maintenance procedures on

manufacturer’s service manuals for maintenance

the air cleaner.

and service on the carrier.

Raw, unfiltered air can damage the

Clean the Roller

roller. Never service the air cleaner

while the roller is running.

Clean the complete roller weekly. Daily cleaning is

required if material is adhering to the roller

working parts.

Airborne dust may be hazardous. Wear

proper personal protective equipment

•

Make sure that the operator areas, steps, and

while handling air cleaners and

grab rails are clean. Oil, grease, snow, ice, or

elements.

mud in these areas can cause to slip and fall.

Clean the boots of excess mud before getting

in the roller.

Connections and Ducts

•

Thoroughly wash all fittings, caps, plugs, and

Check air cleaner and ducts for leaks before every

the like with a nonflammable, nontoxic clea-

shift, during every shift, and after every shift. Make

ning

solution before servicing to prevent dirt from

sure all connections are tight and sealed.

entering while performing the service.

•

After cleaning, check for defects in the air cle-

N o t e Dust that gets by the air cleaner

aner ducts.

system can often be detected by

looking for dust streaks on the air

a. Check intake for accumulation of

transfer tubing or just inside the intake

debris that could restrict air flow.

manifold inlet.

b. Check the air cleaner mounting

hardware for security.

c. Check all hoses for cracks, chafing, or

deterioration and replace at the first

sign of probable failure.

Maintenance

Air Cleaner Pre- Cleaner

Figure 7-2: Air Cleaner Elements

Wipe clean the inside of the cover and the filter

housing. Wipe also both surfaces for the outlet

pipe.

N o t e Check that the hose clamps between

the filter housing and the suction hose

are tight and that the hoses are intact.

A Cover

D Backup filter

Inspect the entire hose system, all the

way to the engine.

B Main filter

E Clips

C Filter housing

F Dust valve

Figure 7-1: Pre-Cleaner

When the choking (air filter) indicator illuminates

do the following maintenance steps.

1. Unclip the clamps holding the main filter.

2. Carefully withdraw the main filter.

N o t e Do not clean the air filter until the

indicator illuminates on the control

panel. Cleaning the filter when there is

no indication is not recommended.

Never clean Donoclone tubes with

N o t e Make sure new elements arrive

compressed air unless both the safety

enclosed in plastic or in a protective

and primary elements are installed in the

membrane. Do not install elements

air cleaner. Do not steam clean the tubes

that are unprotected. This is a dust

in the pre-cleaner.

hazard.

Air Cleaner Main Filter

N o t e Never attempt to clean a backup filter.

Change the backup filter whenever

The air cleaner is the dry type with two elements;

main filter replaced.

a main filter that is replaceable and can be

3. Examine the new or newly cleaned main filter

cleaned, and a backup filter that should only be

for torn or damaged pleats, bent end covers,

replaced and never cleaned.

liners, and gaskets.

4. The backup filter should be replaced if the air

cleaner indicator is red after servicing the

main filter.

5. Clean the inside of the air cleaner housing

before removing backup filter.

6. To replace the backup filter, remove the old

filter from the holder. Dispose of the used

element properly.

7. Install new backup filter into the holder.

Maintenance

8. Carefully install the cleaned or new main

N o t e Replace air filter element after two

filter.

cleaning interval

Air Circulation

Figure 7-3: Air Filter

Check that the engine has free circulation of

cooling air through the grille in the engine

compartment.

Figure 7-5: Air Circulation

A Backup filter

9. Re-install the back cover, make sure the dust

valve is positioned downwards.

10. Inspect all air intake piping and joints

between the air cleaner and inspect the air

inlet to make sure that no dusty air can enter.

A Cooling air grille

N o t e Never leave the air cleaner open

longer than necessary.

Hose and Clamps

N o t e The two most common servicing

problems are over servicing and

1. Periodic clamping bolts re-tightening is

improper servicing.

necessary due to cold-flow present in all

rubber hoses. Tighten the boss clamps.

Cleaning the Filter Element

2. Examine and change out worn hoses and

weakened Boss clamps. If hoses are to be

Figure 7-4: Filter Element Cleaning

changed out, change the Boss clamps also.

Boss clamps hold the hose connections

under a large amount of pressure. Boss

clamps (including nuts and bolts) are for

single use only. Do not reuse. Once

removed, discard them.

Clean the air filter element from inside to outside

using compressed air.

Maintenance

Engine

Batteries

Refer to the engine service and maintenance

The following battery maintenance must be

manuals for specific information on the engine

carried out as part of the 250 hour routine

maintenance.

maintenance schedule.

N o t e Switch off the engine before filling the

oil.

Batteries contain an acid and can cause

injury. Skin and eye contact with battery

N o t e Care must be taken while draining the

fluid can cause injury. Avoid skin and eye

oil. Wear protective gloves and eye

contact with battery fluid. If contact

glasses.

occurs, flush area immediately with

water.

Change the engine oil first 50 hours and then

every 500 hours of operation.

Battery fumes can ignite and explode. Do

not smoke when observing battery fluid

Remove the oil filler cap and oil drain plug.

level.

Drain the oil into a suitable container.

N o t e When disconnecting the battery,

Reinstall the drain plug and tighten.

always disconnect the negative cable

first. When connecting the battery,

Remove and replace the oil filter.

always connect the positive cable first.

N o t e Always wear protective glasses when

Figure 7-6: Fuel Filters

working with batteries. Wash hands

after touching batteries and

connectors. Use of gloves

recommended.

Batteries, Clamps, and Cables

The standard batteries supplied are heavy duty

lead acid type, requiring the following

maintenance.

1. Keep the top of the batteries clean.

2. Clean the terminals.

3. Keep battery connections tight.

Main fuel filter

Pre Fuel filter

4. Apply a small amount of grease to the

terminal connections to prevent corrosion.

C Engine oil filter

5. Inspect the cables, clamps, and hold down

Remove the oil filler cap and fill the engine

brackets. Replace if necessary.

crank case with recommended oil.

Start the engine and allow it to idle for a few

minutes. During this time, check around the

oil filter and drain plug for leaks.

Install the oil filler cap.

Maintenance

Check Electrolyte Level

Fuel Tank

1. Shut off the engine.

Refuel the tank every day before starting the

roller.

2. Lockout/tagout the roller as per the site

specific procedure.

1. Unscrew the lockable tank cap.

3. Check the electrolyte level and keep the

electrolyte level above the plates. Fluid level

2. Fill diesel fuel to the lower edge of the filler

is low when below ring or ring is visible and

pipe.

too high when slots are not visible.

Check fuel tanks and fuel lines for possible leaks.

4. Refill with distilled water, if necessary.

Because of the potential fire hazard, leaks must

be corrected as soon as they are spotted.

Over filling can cause poor performance

or early failure.

Fuel is flammable. May cause serious

injury or death. Shut off the engine,

extinguish all open flames, and do not

smoke while filling the fuel tanks. Always

5. Remove lockout / tagout.

wipe up any spilled fuel immediately.

Figure 7-7: Battery Location

•

Check the fuel level by reading the fuel level

gauge.

•

Never allow fuel tanks to completely empty.

N o t e Fill tank with the correct grade of fuel.

The fuel tank holds 250 liters.

Figure 7-8: Fuel Tank

A Battery location

A Fuel tank

Maintenance

Coolant System

Water Tank

Unscrew the tank cap and fill with clean water. Do

Check that all hoses/hose connectors are intact

not remove the strainer. See technical

and tight. Fill with coolant as specified in the

specifications for the tank volume.

lubricants specification.

N o t e A small amount of environment-

Change the coolant every year. Failure to cool the

friendly antifreeze is added.

engine properly can result in engine failure or

severely reduce engine life.

Figure 7-10: Water Tank

Figure 7-9: Coolant Level Gauge

A Tank cap

A Coolant level gauge

Fixed Scrapers

Personal injury can occur when removing

the radiator cap. Steam or fluid escaping

Make sure that the scrapers are undamaged.

from the radiator can burn. Inhibitor

Adjust the scrapers so that they are 1-2 mm from

contains alkali. Avoid contact with skin

the drum. For special asphalt compounds, it may

and eyes. Wear protective gloves and

eye glasses.

be better if the scraper blades lie lightly against

the drums.

Always shut off the engine and allow it to

cool down before removing the radiator

Asphalt remnants can accumulate on the scraper

cap. Remove the radiator cap slowly to

and affect the contact force. Clean as required.

relieve pressure. Avoid contact with

steam or escaping fluid.

1. Loosen the screws to adjust the contact

pressure of the scraper blade against the

drum.

2. Lock this setting by tightening the lock nut

against the mounting plate.

3. Adjust the contact surface on both scraper

attachments.

Maintenance

4. Tighten all the screws after adjustment.

Sprinkler System

Start the sprinkler system and make sure that

Figure 7-11: Drum

nozzles are clogged. If necessary, clean

clogged nozzles and the coarse filter located by

the water pump.

The sprinkler system should be drained if

there is a risk of freezing.

Wear protective eye glases when working

with compressed air.

Dismantle the blocked nozzle by hand. Blow the

nozzle and fine filter clean with compressed air, or

install replacement parts and clean the clogged

parts later.

Scraper blade

Drum

Figure 7-12: Sprinkler Pump

The scrapers must be lifted from the drum during

transport.

Brakes

Run the roller very slowly forward. Hold the

steering wheel firmly and brace yourself for a

sudden stop. Press in the emergency stop. The

roller will stop abruptly and the engine will switch

A Sprinkler pump

off. After testing the brakes, set the forward/

reverse lever in neutral. Pull out the emergency

stop. Start the engine. The roller is now ready for

operation.

Maintenance

Check Hydraulic Oil Level

7.6 Lubrication and

Filters

If the hydraulic oil level is low, add hydraulic oil.

Level the roller.

Hydraulic Reservoir

Check the reservoir oil level by viewing the

The hydraulic reservoir oil level must be checked

sight gauge. Verify that fluid level is near the

daily as part of the 8 to 10 hour routine

maximum level indicated on the sight glass.

maintenance procedure.

Figure 7-13: Hydraulic Reservoir

Excessive hydraulic oil can rupture

hydraulic tank and cause injury or

property damage.

N o t e Take extra care when working around

or on the hydraulic system to make

sure its complete cleanliness. When

operating, the oil level must be

between the maximum and minimum

levels. Top up with hydraulic fluid as

per lubricant specifications if level is

too low.

N o t e Dirt in the hydraulic system will lead to

Level Guage

premature component failure. A clean,

contaminant free system is extremely

important for the roller to function

Open the engine hood and unscrew the filler

properly.

cap, top up with hydraulic fluid (as per

lubricant specification) if the level is too low.

Figure 7-14: Hydraulic fluid Refilling

A Hydraulic oil filling

Oil level guage

Maintenance

Steering Cylinder and

Drum - Oil Level

Steering Joint

1. Run the roller slowly until the oil plug is

opposite to one of the inspection holes.

The steering cylinder is located under the operator

platform. There is a grease fitting near the base

2. Unscrew the plug and check that the oil level

and rod ends of the cylinder.

reaches up to the bottom of the hole. Top up

with new oil if necessary. Use oil as per the

1. To access the four grease nipples, turn the

lubricant specification.

steering wheel fully to the counterclockwise

direction.

3. Clean the magnetic oil plug from any metallic

residue, and refit the plug.

2. Wipe the grease nipples.

3. Apply five strokes of grease to each nipple

Figure 7-16: Drum Oil Filling

using the hand-operated grease gun. Make

sure that grease penetrates into the bearing.

If grease does not penetrate into bearings, it

may be necessary to relieve the articulation

joint with a jack while repeating the greasing

process.

Figure 7-15: Greasing

A Oil filling

B Oil level check

C Oil drain

A Grease nipple

Maintenance

Check Drum Gear Oil Level

Housekeeping

Move the roller until the inspection/filling

The complete roller must be given a weekly

holes are in position for filling.

cleaning. Daily cleaning will be required if material

is adhering to the roller working parts.

Refill the oil about 1.1 L (0.3 gallons). Use

transmission oil as per lubrication

specification.

1. Make sure the operator areas, steps, and

grab rails are clean. Oil, grease, snow, ice, or

Make sure that oil level reaches up to the

mud in these areas can be slippery. Clean

lower edge of the plug hole.

the boots of excess mud before getting in the

cab or on the roller operator platform.

Clean and refit the plugs.

2. Check the tower feed installation for debris

buildup around the sheaves.

Figure 7-17: Drum Gear

3. Thoroughly wash all fittings, caps, plugs, and

the like with a nonflammable, nontoxic

cleaning solution before servicing to prevent

dirt from entering while performing the

service.

N o t e Protect all electrical components and

control panels against entry of water

or steam when using high pressure

cleaning methods. Cover the fuel and

hydraulic fill cap breathers located on

each tank.

After cleaning, check for defects in the air

cleaner ducts.

•

Check intake for accumulation of debris that

could restrict air flow.

•

Check air cleaner mounting hardware for

security.

Oil filling plug

•

Check all hoses for cracks, chafing, or

deterioration and replace at the first sign of

Oil level plug

probable failure.

Oil Drain plug

Controls

If the lever gets stiff after a prolonged period of

use, remove the cover of the lever and lubricate.

Lubricate the forward/reverse lever in the engine

compartment with a few drops of oil.

Maintenance