DYNAPAC Vibratory roller CC4000 VI, CC4200 VI (Engine Cummins QSF 3.8 (Stage IV/T4F) / Cummins F 3.8 (Stage V)). Instruction manual - page 5
Maintenance - 1000h
Seat bearing - Lubrication
5
Keep in mind that the chain is a vital part of the
steering mechanism.
6
Remove the covers (5) to access the lubrication nipple
(1). Lubricate the driver seat slew bearing with three
strokes of a hand-operated grease gun.
2
3
Clean and grease the chain (3) between the seat and
the steering column.
Also grease the seat slide rails (6).
If the chain is slack on the sprocket (2), loosen the
screws (4) and move the steering column forward.
4
Tighten the screws and check chain tension.
1
7
No not tension the chain too tightly. It should be
possible to move the chain about 10 mm (0.4 in) to the
Figure. Seat bearing
side with a forefinger/thumb at the marking (7) in seat
1. Grease nipple
2. Gearwheel
frame. Fit the chain lock at the bottom.
3. Steering chain
If the seat starts to be stiff when adjusting, it
4. Adjusting screw
5. Covers
should be lubricated more often than specified
6. Slide rails
here.
7. Marking
Steering hitch - Tightening
Nobody must be allowed near the steering joint
when the engine is running. Risk of being
crushed when the steering is operated. Switch
off the engine and activate the parking brake
1
before lubricating.
The easiest way to identify if you have this type of
steering hitch is that it has a new type of nut (1) at the
top, as shown.
Fig. Steering hitch
1. Nut
Actual torque (Nm) should be when the machine's
position is straight ahead.
M14
174 Nm
M16
270 Nm
149
Maintenance - 1000h
Air conditioning (Optional)
Fresh air filter - Change
Use a step ladder to reach the filter (1).
1
2
There is a fresh air filter (1), located at the rear of the
cab.
Loosen the quick lock (2) and open the protective
cover.
Remove the filter insert and replace with a new filter
Fig. Cab
insert.
1. Fresh air filter
2. Quick lock
The filter may need to be changed more often if the
machine is operated in a dusty environment.
Do not drive in contaminated areas, as the air filter
is not intended for air contaminated with, for
example, gas, radioactive particles or similar.
The filter is of disposable type and cannot be
cleaned. Dispose of the replaced filter in an
environment-friendly manner.
Edge cutter (Optional)
- Lubrication
Refer to the operation section for information on
2
how to operate the edge cutter.
1
Grease the two points as shown in the figure.
Grease should always be used for lubrication, see the
lubricant specifications.
Grease all bearing points with five strokes of a
Figure. Two grease points for
hand-operated grease gun.
lubricating the edge cutter
150
Maintenance - 2000h
Maintenance - 2000h
Performed after 2000 operating hours (every two
years)
Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.
Ensure that there is good ventilation (air
extraction) if the engine is run indoors. Risk of
carbon monoxide poisoning.
Cooler
Check - Clean
The water and hydraulic fluid coolers are accessible
when the cooler grill (4) is removed.
Make sure that the air flow through the coolers is
unobstructed. Clean a dirty cooler using compressed
air or wash with a high-pressure washer.
Blow or wash the coolers in the reverse order to the
cooling air.
Take care when using a high-pressure water jet.
Do not hold the nozzle too near the cooler.
3
4
2
1
Figure. Cooler
1. Charge air cooler
When working with compressed air or a
2. Water cooler
3. Hydraulic fluid cooler
high-pressure washer, use the following protective
4. Cooler grill
equipment:
Eye protection
Protective gloves
Ear protectors
151
Maintenance - 2000h
Air cleaner
Checking - Change the main air filter
Change the air cleaner's main filter when the
warning lamp on the display lights when the
diesel engine is operating at full speed.
2
3
Release the clips (1), pull off the cover (2), and pull out
the main filter (3).
Do not remove the backup filter (4).
Clean the air cleaner if necessary, see section Air
cleaner - Cleaning.
When replacing the main filter (3), insert a new filter
1
4
5
6
and refit the air cleaner in the reverse order.
Fig. Air cleaner
Check the condition of the dust valve (6); replace if
1. Clips
necessary.
2. Cover
3. Main filter
4. Backup filter
When refitting the cover, make sure that the dust valve
5. Filter housing
is positioned downwards.
6. Dust valve
Backup filter - Change
1
Change the backup filter with a new filter after every
second replacement of the main filter.
To change the backup filter (1), pull the old filter out of
its holder, insert a new filter and reassemble the air
cleaner in the reverse order.
Clean the air cleaner if necessary, see section Air
cleaner - Cleaning.
Fig. Air filter
1. Backup filter
152
Maintenance - 2000h
Air cleaner
- Cleaning
Wipe clean on both sides of the outlet
pipe.
Wipe clean the inside of the cover (2) and the filter
housing (5). See the previous illustration.
Wipe also both surfaces for the outlet pipe; see
adjacent figure.
Inner edge of
Outer edge of outlet
outlet pipe.
pipe.
Check that the hose clamps between the filter
housing and the suction hose are tight and that
the hoses are intact. Inspect the entire hose
system, all the way to the engine.
153
Maintenance - 2000h
Diesel engine
Oil change
The engine's oil drain plug is located under the rear
frame on the machine on the right side.The drain plug
is accessed by first removing the rubber plug on the
underside of the frame.
Observe care when draining hot engine oil. Use
the following protective equipment:
Protective gloves
Eye protection
1
Figure. Underside of rear frame
Drain the oil when the engine is warm. Place a
1. Oil draining of diesel engine
receptacle that holds at least 14 liters (15 qts) under
the drain plugs.
Unscrew the drain plug (1). Allow all the oil to drain out
and refit the plug.
Deliver the drain oil for environmentally correct
handling.
Fill with fresh engine oil, see Lubricant specification or
the engine manual for the correct grade of oil.
Fill with the requisite volume of engine oil. See
technical specifications before starting the machine.
Allow the engine to idle for a few minutes, and then
switch off the engine.
Check the dipstick to ensure that the engine oil level is
correct. Refer to the engine manual for details. Top up
with oil if necessary to the max mark on the dipstick.
154
Maintenance - 2000h
Engine
Replacing oil filter
The oil filter (1) is located at the front of the engine and
is accessible in the engine compartment inside the
right engine door.
See the engine manual for information about replacing
the filter.
1
Figure. Engine compartment, right side
1. Oil filter
The engine fuel filter - replacement/cleaning
The fuel prefilter is placed on the right side of the
engine compartment.
Unscrew the bottom and drain off any water, and then
1
replace the filter unit.
Figure. Engine compartment, right side
1. Fuel prefilter
Replace the fuel filter, located on the right side of the
engine compartment.
Start the engine and check that the filter is well sealed.
1
Figure. Engine compartment, right
side.
1. Fuel filter
155
Maintenance - 2000h
Drum - oil level
Inspection - filling
Position the roller with the filler plug (1), the large plug,
at the highest point in its rotation.
Wipe clean around the level plug (2), the small plug,
1
and remove the plug.
Make sure that the oil level is up to the lower edge of
the hole. Top off with fresh oil if the level is low. Use oil
as specified in the lubricants specification.
2
When removing the filler plug, wipe any metal
accumulated on the plug magnet off. Make sure that
plug seals are intact and replace with new seals if not.
Refit the plugs and check that they are tight by driving
Fig. Drum, vibration side
the roller and then rechecking.
1. Filler plug
2. Level plug
Rubber elements and attachment screws
Check
Check all rubber elements (1). Replace all elements if
25% or more than 25% of the number on one side of
1
the drum have cracks deeper than 10-15 mm (0.4-0.6
in).
Check using a knife blade or pointed object.
2
Check also that the attachment screws (2) are
tightened.
Fig. Drum, vibration side
1. Rubber element
2. Attachment screws
156
Maintenance - 2000h
Hydraulic reservoir
Fluid change
Take care when draining the hydraulic fluid. Use
the following protective equipment:
Protective gloves
Eye protection
1
Drain plug (1) is located under the left-hand side of the
rear frame.
Fig. Rear frame left side
1. Oil drain
Place a receptacle that holds at least 50 liters (13.2
gal) under the drain plug.
Unscrew the drain plug (1). Allow all the oil to drain out
and refit the plug, change the hydraulic fluid filter at
the same time (2).
Deliver the drained fluid to environmentally
correct handling.
Fill with fresh hydraulic fluid. Refer to the lubricant
specification for grade information.
Start the diesel engine and operate the hydraulic
3
functions. Check the fluid level (3) in the reservoir and
top up as required.
2
Fig. Left engine compartment
2. Hydraulic fluid filter
3. Sight glass
157
Maintenance - 2000h
Hydraulic filter
Change
Filter is accessible from the left side of the machine, in
the engine compartment.
(1) Hydraulic fluid filter (Main filter)
Remove the hydraulic oil filter (1) and deliver to
environmentally correct handling. The filter is of
4
disposable type and cannot be cleaned.
2
Make sure that the old sealing ring is not left on
the filter holder. Otherwise, this could cause
leakage between the new and old seals.
3
1
Thoroughly clean the filter holder sealing surface.
Apply a thin coat of fresh hydraulic fluid to the rubber
gasket on the new filter.
Screw the filter on by hand, firstly until the filter gasket
Fig. Engine compartment left
1. Hydraulic oil filter (Main filter)
makes contact with the filter base. Then rotate a
2. Hydraulic reservoir cap
further 1/5 turn.
3. Sight glass
4. High pressure filter - electronic
steering (Optional)
(4) High pressure filter - electronic steering
(Optional)
Unscrew the filter bowl and empty any liquid into a
container.
Remove the filter element and deliver to
environmentally correct handling.
Clean the filter bowl and filter head, also check the
o-rings and replace them if necessary.
Apply a thin layer of pure hydraulic oil to sealing
surfaces and threads.
Place a new filter element carefully on the filter head
guide pin.
Screw in the filter bowl completely, then unscrew with
1/4 turn.
Check the hydraulic fluid level in the sight glass (3)
and top off as required. See under the heading 'Every
10 hours of operation' for more information.
Start the engine and check that the filter does not leak.
158
Maintenance - 2000h
Hydraulic reservoir cap - Check
The cap is accessible from the left side of the
machine, in the engine compartment.
Unscrew and make sure that the reservoir cap is not
clogged. Air must have unobstructed passage through
the cap in both directions.
1
If passage in either direction is blocked, clean the filter
with a little diesel oil and blow through with
compressed air until the block is removed, or replace
the cap with a new one.
When working with compressed air, use the
Fig. Engine compartment, left side
following protective equipment:
1. Tank cap
Eye protection
Protective gloves
Ear protectors
Pivot bearing (OFFSET) - Lubrication
1
Grease each nipple (1) with five strokes of a
hand-operated grease gun.
Use grease as specified in the lubricant specification.
Fig. Front drum, left side
1. Grease nipples, 4 off
159
Maintenance - 2000h
Seat bearing - Lubrication
5
Keep in mind that the chain is a vital part of the
steering mechanism.
6
Remove the covers (5) to access the lubrication nipple
(1). Lubricate the driver seat slew bearing with three
strokes of a hand-operated grease gun.
2
3
Clean and grease the chain (3) between the seat and
the steering column.
Also grease the seat slide rails (6).
If the chain is slack on the sprocket (2), loosen the
screws (4) and move the steering column forward.
4
Tighten the screws and check chain tension.
1
7
No not tension the chain too tightly. It should be
possible to move the chain about 10 mm (0.4 in) to the
Figure. Seat bearing
side with a forefinger/thumb at the marking (7) in seat
1. Grease nipple
2. Gearwheel
frame. Fit the chain lock at the bottom.
3. Steering chain
If the seat starts to be stiff when adjusting, it
4. Adjusting screw
5. Covers
should be lubricated more often than specified
6. Slide rails
here.
7. Marking
Steering hitch - Tightening
Nobody must be allowed near the steering joint
when the engine is running. Risk of being
crushed when the steering is operated. Switch
off the engine and activate the parking brake
1
before lubricating.
The easiest way to identify if you have this type of
steering hitch is that it has a new type of nut (1) at the
top, as shown.
Fig. Steering hitch
1. Nut
Actual torque (Nm) should be when the machine's
position is straight ahead.
M14
174 Nm
M16
270 Nm
160
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 or play in the steering joint.
Fig. Steering joint
Fuel tank (STD) - Drainage
Water and sediment in the fuel tank are drained via a
drainage hose.
Be very careful during draining. Do not drop the
plug or else all the fuel will flow out.
Drain the roller after it has been stationary for a long
time, e.g. after standing overnight. The fuel level
1
should be as low as possible.
Fig. The machine’s front frame, right
rear
Drain as follows:
1. Fastening, drain hose
2. Drain plug
Loosen the screws holding the drain (1), so that it can
be lifted out of the groove and becomes available for
drainage.
Undo the drain plug (2) and drain the water and
sediment until only pure diesel fuel comes out at the
plug. Screw in the plug again and refit the bracket in
the front frame.
2
161
Maintenance - 2000h
Fuel tank (OFFSET)
- Cleaning
1
It is easiest to clean the tank when it is almost empty.
Drain the tank with a suitable pump, for example, an
oil drain pump, to bring up any bottom sediment.
Collect the fuel and sediment in a container and
deliver to environmentally correct handling.
Keep in mind fire risk when handling fuel.
Fig. Fuel tank (OFFSET)
1. Oil emptying pump
Watering system
- Draining
3
Remember that there is a risk of freezing during
the winter. Empty the tank, pump, filter and lines,
or mix antifreeze in the water.
There is a drain cock (2) located on the central water
tank. This can be used to drain both the tank and parts
of the pump system.
2
1
Fig. Sprinkler system
1. Pump system
2. Drain cock
3. Filler cap
162
Maintenance - 2000h
Watering system
- Watering, rear tank
Remember that there is a risk of freezing during
the winter. Empty the tank, pump, filter and lines,
or mix antifreeze in the water.
The water tank is drained by opening the ballvalve (1)
on the tank.
1
Fig. Water tank rear, draining
1. Ball valve
The power button for the pump system can supply the
sprinkler system with anti-freeze.
The shut-off valve to the system must be closed first
and the drain valve for the water filter opened. The
end of the hose can then be put into a container
containing antifreeze, and by activating the power
button for the pump system this can be run through
the pump(s)/filter out to the sprinkler nozzles.
Water tank - Cleaning
Clean the tank/tanks with water and a suitable
detergent for plastic surfaces.
Close the drain cock (2), fill with water and check for
leaks.
The water tanks are made of plastic
(polyethylene) and are recyclable.
2
Fig. Water tank
2. Drain cock
163
Maintenance - 2000h
Replacing the urea tank suction filter
The urea tank is located on the right-hand side of the
1
machine. For access, the overlying plastic cap (1) and
cover plate (2) must be removed.
2
Fig. Guard, right-hand rear frame
1. Plastic cap
2. Cover plate
1
Loosen and remove the tank multifunction unit (1),
then remove the suction filter (2) that is located in the
bottom of the unit.
Hand in the filter to an environment-friendly waste
2
disposal station.
Install the new suction filter (2) and refit the
multifunction unit (1) in the tank.
Fig. Urea tank
1. Multifunction unit
2. Suction filter
164
Maintenance - 2000h
Replacing the urea pump filter
The urea pump is located on the right-hand side of the
machine, in the compartment alongside the urea tank.
Release the cover plate and heat guard (2) for access
to the urea pump (1), then dismount the filter at the
bottom of the unit.
To reach the filter, undo the lid with a 27 mm socket
and remove the filter with the tool supplied with the
1, 2
filter spare.
Replace with the new filter and remount the lid with a
Fig. Urea tank volume
torque of 20 Nm. Replace the urea pump in its original
1. Urea pump
2. Cover plate/heat guard
position in the urea tank compartment.
Hand in the filter to an environment-friendly waste
disposal station.
165
Maintenance - 2000h
Edge cutter (Optional)
- Lubrication
Refer to the operation section for information on
2
how to operate the edge cutter.
1
Grease the two points as shown in the figure.
Grease should always be used for lubrication, see the
lubricant specifications.
Grease all bearing points with five strokes of a
Figure. Two grease points for
hand-operated grease gun.
lubricating the edge cutter
Automatic Climate Control (Optional)
- Overhaul
1
Regular inspection and maintenance are necessary to
ensure satisfactory long-term operation.
Clean all dust from the condenser element (1) using
compressed air. Blow from underneath.
The air jet can damage the element flanges if it is
too powerful.
Fig. Rear frame
1. Code element
When working with compressed air, use the
following protective equipment:
Safety glasses
Protective gloves
Ear protectors
Inspect the condenser element attachment.
166
Maintenance - 2000h
Drying filter - Check
1
The compressor will be damaged if the unit is run
with too little refrigerant.
2
Do not disconnect or undo the hose couplings.
The cooling system is pressurized. Incorrect
handling can result in serious personal injury.
The system contains pressurized refrigerant. It is
Fig. Drying filter in engine
forbidden to release refrigerants into the
compartment
atmosphere. Work on the refrigerant circuit is only
1. Sight glass
to be carriedd out by authorized companies.
2. Moisture indicator
With the unit in operation, open the engine hood and
check using the sight glass (1) that bubbles are not
visible on the drying filter. If bubbles are visible
through the sight glass, it is a sign that the refrigerant
level is too low. If so, stop the unit. The unit may be
damaged if it is run with insufficient refrigerant.
Check the moisture indicator (2). It should be blue. If it
is beige, the dryer cartridge should be changed by an
authorized service company.
167