Dynapac CC1000 e Instruction Manual Download Page 9

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2000h-

Maintenance

4812164901_A.pdf

2022-11-14

Maintenance - 2000h ........................................................................................................... 113

Hydraulic oil cooler - Cleaning ................................................................ 113

Forward/Reverse controls and joints - Check and lubrication................. 114

Hydraulic reservoir - Check/venting ........................................................ 114

Hydraulic fluid filter - Change .................................................................. 115

Hydraulic reservoir - fluid change............................................................ 116

Water tank - Cleaning ............................................................................. 117

Drum - Changing the oil .......................................................................... 117

Drum - Checking the oil level .................................................................. 118

Steering joint - Check.............................................................................. 118

Summary of Contents for CC1000 e

Page 1: ...atory roller CC900 e CC900 e CC1000 e CC1000 e Electric powered Electric powered Serial number Serial number 10000615xxA034264 10000615xxA034264 10000618xxA034278 10000618xxA034278 Translation of orig...

Page 2: ......

Page 3: ...tions 7 Standard lubricants and other recommended oils and fluids 7 Higher ambient temperatures above 40 C 104 F 7 Lower ambient temperature Freeze risk 7 Temperatures 7 Battery pack 8 High pressure c...

Page 4: ...21 Product and component plates 21 Product identification number on the frame 21 Machine plate 22 Explanation of 17PIN serial number 22 Decals 23 Location decals 23 Safety decals 24 Info decals 25 In...

Page 5: ...External fuses and relay 40 Electrical system 40 ECU Circuit board 40 Fuses and relays on the steering column s circuit board 41 Power source Battery system 42 Safety 42 Intended use 42 Safety instru...

Page 6: ...position 63 Rear view mirror Adjustment 64 Starting 65 Start up procedure 65 Driving 66 Operating the roller 66 Interlock Emergency stop Parking brake Check 67 Parking brake Check 67 Vibration 68 Manu...

Page 7: ...arranty 85 Maintenance Lubricants and symbols 87 Maintenance symbols 88 Maintenance Maintenance schedule 89 Service and maintenance points 89 General 90 Every 10 hours of operation Daily 90 After the...

Page 8: ...onnectors and leads 100 Battery system Inspecting the battery system 101 Battery system Cleaning 101 Maintenance measures 250 h 103 Hydraulic oil cooler Cleaning 103 Forward Reverse controls and joint...

Page 9: ...113 Forward Reverse controls and joints Check and lubrication 114 Hydraulic reservoir Check venting 114 Hydraulic fluid filter Change 115 Hydraulic reservoir fluid change 116 Water tank Cleaning 117...

Page 10: ...e 4812164901_A pdf 2022 11 14...

Page 11: ...RNING Indicates potential hazardous situation procedure which if not avoided could result in death or serious injury CAUTION Indicates potential hazardous situation procedure which if not avoided coul...

Page 12: ...e connections are discovered at as early a point in time as possible Inspect the machine every day before starting Inspect the entire machine so that any leakages or other faults are detected Check th...

Page 13: ...own the slope Avoid driving across slopes Drive straight up or straight down the slope Never operate with the drum outside the edge the substrate might not have full bearing strength or the edge is cl...

Page 14: ...ight compromise safety including visibility are not allowed Any modifications are only to be made after written approval has been given by Dynapac Avoid using the roller before the hydraulic fluid has...

Page 15: ...own sloping ground Work driving Dynapac always recommends mounted ROPS Roll Over Protective Structure and seat belt usage Dynapac always recommends mounted ROPS Roll Over Protective Structure and seat...

Page 16: ...um outside the edge the substrate might not have full bearing strength or the edge is close to a slope Keep in mind that the machine s center of gravity moves outwards when steering For example the ce...

Page 17: ...ve 40 C 104 F For operation of the machine at higher ambient temperatures however maximum 45 C 113 F the following recommendations apply Hydraulic system mineral oil Shell Tellus S2V100 or similar Low...

Page 18: ...ttery system The battery shall be charged every month when in storage Use designated chargers only See section Chargers Use designated chargers only See section Chargers NOTE The battery system should...

Page 19: ...n the other cells Fire extinguishers with class AB can be used for preventing external re from spreading to nearby materials but capability of putting out Li ion battery re is limited If specially des...

Page 20: ...any welding or drilling in the Roll Over Protective Structure ROPS Never carry out any welding or drilling in the Roll Over Protective Structure ROPS Never repair a damaged ROPS structure it must be...

Page 21: ...s specified in the same directive Limit is 5 m s Measured hand arm vibrations also were below the action level of 2 5 m s specified in the same directive Limit is 5 m s Noise level The noise level is...

Page 22: ...ance 465 18 3 D Diameter drum 584 23 D Diameter drum 584 23 H1 Height with ROPS 2300 90 6 H1 Height with ROPS 2300 90 6 H2 Height without ROPS 1520 59 8 H2 Height without ROPS 1520 59 8 K Ground clear...

Page 23: ...42 3 CC1000 e 1070 42 3 O1 Overhang right 35 1 4 O1 Overhang right 35 1 4 O2 Overhang left 35 1 4 O2 Overhang left 35 1 4 R1 Turning radius outer R1 Turning radius outer CC900 e 2810 110 6 CC900 e 28...

Page 24: ...kg 1 819 lbs CC1000 e 865 kg 1 907 lbs CC1000 e 865 kg 1 907 lbs Module weight rear frame Module weight rear frame CC900 e 865 kg 1 907 lbs CC900 e 865 kg 1 907 lbs CC1000 e 910 kg 2 007 lbs CC1000 e...

Page 25: ...4 11 4 Engine speed 2700 2550 Engine speed 2700 2550 Electrical system Electrical system Battery type Lithium ion Battery type Lithium ion Battery voltage 48V Battery voltage 48V Battery capacity 14 6...

Page 26: ...lt dimensions M12 PN 4700508063 Bolt dimensions M12 PN 4700508063 Strength class 8 8 Strength class 8 8 Tightening torque 70 Nm Tightening torque 70 Nm ROPS bolts which are to be torque tightened must...

Page 27: ...0 470 520 560 620 M22 446 497 626 699 752 839 M22 446 497 626 699 752 839 M24 570 640 800 900 960 1080 M24 570 640 800 900 960 1080 M30 1130 1260 1580 1770 1900 2100 M30 1130 1260 1580 1770 1900 2100...

Page 28: ...Technical specifications 4812164901_A pdf 2022 11 14 18...

Page 29: ...ne As well as checking and control units for drive and vibration packages electricity Propulsion system Transmission The propulsion system is a hydrostatic system with a hydraulic pump that supplies t...

Page 30: ...entric shaft is driven by a hydraulic motor An electric hydraulic pump supplies the hydraulic motors with oil ROPS ROPS is the abbreviation for Roll Over Protective Structure ISO 3471 If any part of t...

Page 31: ...product and serial number 2 Battery plate Type description product and serial number 3 ROPS plate Certification product and serial numbers 3 ROPS plate Certification product and serial numbers 4 Comp...

Page 32: ...IN product identification number serial number 4 maximum weight 5 service weight 6 engine power 7 year of manufacture 8 On machines supplied to outside the EU there are no CE markings and in some case...

Page 33: ...5 Warning Locking 4700908229 12 Hydraulic fluid level 4700272373 5 Warning Locking 4700908229 12 Hydraulic fluid level 4700272373 6 Sound power level 4700791271 13 Bio hydraulic oil PANOLIN 470079277...

Page 34: ...nes on machines fitted with pivotal steering 4812130433 Warning High voltage Avoid contact When performing servicing work under the battery hood switch off the battery pack s service switch See sectio...

Page 35: ...Lifting point 4812134256 4700903425 4700357587 4812134256 4700903425 4700357587 Hydraulic oil level Biological hydraulic fluid PANOLIN Securing point Hydraulic oil level Biological hydraulic fluid PAN...

Page 36: ...ing brake 12 Driving lights 3 Ignition key instrument panel 8 Membrane panel Function keys 13 Direction selector indicator 3 Ignition key instrument panel 8 Membrane panel Function keys 13 Direction s...

Page 37: ...gage the brakes press down the red part at the same time as the switch and change the position of the lever NOTE When starting the machine the parking brake must be activated Always use the parking br...

Page 38: ...LED color LED Designation Function LED LED color Work mode vibration permitted Activates working mode which makes it possible to use vibration Work mode vibration permitted Activates working mode whi...

Page 39: ...prinkler system LED OFF No function LED OFF No function LED LEFT Manual sprinkler Red LED LEFT Manual sprinkler Red LED RIGHT Automatic sprinkler LED RIGHT Automatic sprinkler Sprinkler timer Sprinkle...

Page 40: ...en is lit ECO medium drive speed is selected If the LED on the right is lit the high drive speed is selected Function description buttons on Forward Reverse lever Mode Button LED Button 1 Button 2 Mod...

Page 41: ...here are 3 buttons on the right hand side of the display for navigating in menus and submenus Level 1 Level 2 Level 1 Level 2 1st press Transport mode Working mode 1st press Transport mode Working mod...

Page 42: ...a message in the display In the event of a warning that is instead linked to an error code this is read out in the display s submenu for error codes 2 Warning lamp Yellow 2 Warning lamp Yellow Less s...

Page 43: ...nd it s not possible to run with vibration Warning symbol ventilation fan The ventilation fan must always rotate when the ignition is on The symbol is shown if the fan is not rotating This means it is...

Page 44: ...battery level is indicated in a bar divided into ten segments to the right of the display 3 Direction of travel The icon has three options F N R and is shown in the top left of the display Only curren...

Page 45: ...istance is available respective symbols are shown on the display during attempted start up Operator help Workmode Working mode must be selected and the parking brake button must be deactivated in orde...

Page 46: ...C selected 2 Compaction status off on on front rear drum Press one of the buttons 7 on the far right of the panel The side menu 8 will then appear on the display The lowermost button 7 activates AVC m...

Page 47: ...se do not result in any of the warning lamps lighting but are intended as information Yellow alarm The middle degree of severity Together with the error code or popup the yellow warning light will als...

Page 48: ...on of installed software for display 11 and ECU 12 Fig User settings 9 Light settings Day mode 10 Light settings Night mode 11 Software version Display 12 Software version ECU 13 To service test site...

Page 49: ...AL 3 Move the control lever back to the neutral position 4 Press Enter 12 to save the value The calibration indication now moves to REVERSE 5 Move the control lever back to the reverse position 6 Pres...

Page 50: ...onverters F 10A Motor controls forward drive F 10A Motor controls forward drive F 10A Motor controls vibration F 10A Motor controls vibration F 40A Main fuse circuit board F 40A Main fuse circuit boar...

Page 51: ...anel Parking brake switch 5A F10 Ignition key ECU 5A F4 Joystick Push Button Seat switch 3A F11 ECU 12V socket Dyn link 15A F4 Joystick Push Button Seat switch 3A F11 ECU 12V socket Dyn link 15A F5 N...

Page 52: ...re you understand the instructions before starting any work on the machine No work is allowed to be done on the battery system itself Obey all the instructions Wear eye protection protective gloves an...

Page 53: ...ry system and machine frame when lowering the battery system Safety instructions for connecting cables The battery pack must be fully mechanically installed before connecting cables In order to preven...

Page 54: ...ting valve Do not spray high pressure waterjet to pack lid seams power terminals signal interface terminal and venting valve Make sure that power terminals and signal interface terminal are clean befo...

Page 55: ...t damaging the battery packs thermally Handle a damaged battery pack with care Wear personal protective equipment safety goggles gloves and apron when handling a damaged battery system Handle a damage...

Page 56: ...e equipment against heat splashes and toxic smoke Only if it is safe use re extinguisher to cool down the battery or limit re from spreading to materials nearby 5 Guide Guide the re brigade to the are...

Page 57: ...tention immediately Respiratory tract If there is an intensive smoke build up or release of gas leave the area immediately Smoke and gases irritate the respiratory tract Seek medical attention immedia...

Page 58: ...ystem weighs 135 kg Use lifting device when handling the battery system The battery system weighs 135 kg Fig Lifting points 1 Attach 4 slings 1 4 to the lifting points 5 8 Use four point lifting devic...

Page 59: ...tery system 1 4 11mm for mounting 5 Attach the battery system to the vehicle using the four fastening points 1 4 Attach a vibration damper to every fastening point below the battery Attach a vibration...

Page 60: ...automatically if the batteri is initiated 2 Charge the battery to a full 100 SOC Dismounting and disposal Disconnecting the battery system 1 Shut down the machine Fig Disconnecting cables 2 Disconnec...

Page 61: ...ry system Falling object hazard Do not stand under the hoisted battery system Make sure that the dismounting area is clear before dismounting the battery system from machine Make sure that the dismoun...

Page 62: ...d watt hour limits exceed the permitted limits Surface transportation is allowed and the following codes shall be obeyed ADR The European Agreement concerning the International Carriage of Dangerous G...

Page 63: ...ng any maintenance or repair on the charger No user serviceable parts are inside Do not remove the cover due to the risk of electrical shock Unplug the charger from both AC and DC sources when cleanin...

Page 64: ...shock If the charger is provided with a plug connect it only to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances Risk of electric shock If the...

Page 65: ...r or become entangled in them Ensure all ventilation ports are not obstructed Ensure all ventilation ports are not obstructed Only operate the charger in accordance with the degree of protection shown...

Page 66: ...Machine description 4812164901_A pdf 2022 11 14 56...

Page 67: ...procedure 1 Fig Frame left side 1 Charging socket Connect the charger s charging cable to the charging socket on the machine 1 Connect the charger s 1 phase plug to the wall socket Fig Control panel 1...

Page 68: ...ee the current charging level in and also the estimate remaining charge time until fully charged After the charging is completed the green status lamp on the machine s sterring column goes out Disconn...

Page 69: ...system will still have the anti drive away function active and the machine will not be driveable Also the machine display will have an appearance which indicates that the charger is still connected t...

Page 70: ...in the OFF position OFF 1 Fig Frame left side 1 Charging socket Connect the charger s charging cable to the charging socket on the machine 1 Connect the charger s 3 phase plug to the wall socket Fig C...

Page 71: ...e 2 Flashing red and green lights indicate that the charge is in phase 3 and is approaching full charge The green light indicates that the battery is fully charged If you during the charging procedure...

Page 72: ...lows Length adjustment 1 Weight adjustment 2 Back support angle 3 Always make sure that the seat is secure before beginning operation Always make sure that the seat is secure before beginning operatio...

Page 73: ...operations Operator position 1 4 5 2 Fig Operator s seat 1 Seatbelt 2 ROPS 4 Rubber element 5 Anti slip If a ROPS Roll Over Protective Structure or a cab is fitted to the roller always wear the seat b...

Page 74: ...n is poor Ensure that the anti slip 5 on the platform is in good condition Replace where anti slip friction is poor Rear view mirror Adjustment 1 Fig Rear view mirror The rear view mirror adjustment i...

Page 75: ...battery start up sequence is now initiated for 2 3 seconds When the start up sequence is complete the status light is solid When the status light is constant the ignition key 1 can be turned to positi...

Page 76: ...und The operator must be seated inside the machine during all operation 5 2 4 3 1 Fig Instrument panel 1 Parking brake 2 Motor speed selector drive 3 Emergency stop 4 Forward Reverse lever 5 Sprinkler...

Page 77: ...ting the emergency stop rectify the fault immediately Check the function of the emergency stop by pressing the emergency stop button when the roller is moving slowly forward backward Check in both dir...

Page 78: ...bration of one or both drums has been selected using the buttons on the control lever See the Display chapter to active Deactivation of vibration takes place automatically when the preset deactivation...

Page 79: ...fluid is also cold and that braking distances can be longer than normal until the machine reaches the working temperature Never leave the operator platform without activating the parking brake 4 Never...

Page 80: ...utton 1 Restart the machine in accordance with the start up procedure see section on Start up Switching off 2 3 1 6 5 4 Fig Instrument panel 1 Ignition key 2 Battery OFF 3 Battery ON 4 Instrument cove...

Page 81: ...the drums if the roller is parked on sloping ground Make sure that the roller is parked in a safe place with respect to other road users Chock the drums if the roller is parked on sloping ground Make...

Page 82: ...Operation 4812164901_A pdf 2022 11 14 72...

Page 83: ...the heading Every 2000 hours of operation Drain all hoses filter housings and the water pump Remove all sprinkler nozzles see under the heading Every 10 hours of operation Hydraulic reservoir Fill th...

Page 84: ...e will increase cell unbalance and decrease the battery performance Recommended to be stored in environment with humidity no more than 85 altitude below 1500m air pressure 86kPa 106kPa Temperature for...

Page 85: ...m Secure the position of the locking arm by refitting the locking pin 1 Lifting the roller 2 Weight refer to the machine plate on the roller 1 Fig Roller prepared for lifting 1 Lifting point 2 Machine...

Page 86: ...raps and lifting hooks must be dimensioned in accordance with the applicable safety regulations for lifting devices 3 Stand well clear of the hoisted machine Make sure that the lifting hooks are prope...

Page 87: ...ere the transport takes place Never lash over the machine s articulated joint nor over the machine s operator platform Never lash over the machine s articulated joint nor over the machine s operator p...

Page 88: ...d to two different lashing mounts symmetrically located on the right and left sides 3 rubber fiction pads 3 rubber fiction pads The lashings permitted distance interval in meters The lashings permitte...

Page 89: ...nt lashing points on the platform Each of lashings 1 2 is either a double or two single lashings A double lashing runs in a sling through a lashing point or around a machine part and down into two dif...

Page 90: ...hes the brake 107 inner thread 3 Tighten the two screws 192 alternately a little at a time so that the brake piston 107 loose screw approximately 2 turns Tightening the screws 192 too hard can damage...

Page 91: ...roller has no brakes and can only be slowed and stopped by the vehicle towing the roller The roller must be towed slowly max 3 km h 2 mph and for short distances only max 300 m 1000 ft The roller must...

Page 92: ...Operating instructions Summary 4812164901_A pdf 2022 11 14 82...

Page 93: ...aking distance will be longer if the roller is cold Check the brakes drive slowly Remember that the braking distance will be longer if the roller is cold Use vibration only when the roller is in motio...

Page 94: ...Operating instructions Summary 4812164901_A pdf 2022 11 14 84...

Page 95: ...k list in the warranty document Any transport damage must be reported immediately to the transport company as this is not covered by the product warranty Warranty The warranty is only valid if the sti...

Page 96: ...Preventive maintenance 4812164901_A pdf 2022 11 14 86...

Page 97: ...DRAULIC FLUID Air temperature 15 C 50 C 5 F 122 F Dynapac Hydraulic 300 P N 4812161868 20 liter P N 4812161869 209 liter Air temperature over 50 C 122 F Shell Tellus S2 V100 Air temperature over 50 C...

Page 98: ...tenance symbols Battery Battery Hydraulic reservoir level Sprinkler Hydraulic reservoir level Sprinkler Hydraulic fluid filter Sprinkler water Hydraulic fluid filter Sprinkler water Drum oil level Rec...

Page 99: ...ling 1 Water tank filling 13 Hydraulic fluid filling 2 Forward Reverse lever 2 Forward Reverse lever 3 Emergency brake 9 Sprinkler 3 Emergency brake 9 Sprinkler 4 Hydraulic fluid cooler 10 Scrapers 15...

Page 100: ...ion Comment Pos in fig Action Comment Before starting up for the first time on that day Before starting up for the first time on that day 13 Check the hydraulic reservoir level 13 Check the hydraulic...

Page 101: ...250 1750 hours of operation Refer to the contents to find the page number of the sections referred to Pos Action Comment Pos Action Comment 4 Clean the outside of the radiator core In dusty environmen...

Page 102: ...urs of operation Refer to the contents to find the page number of the sections referred to Pos Action Comment Pos Action Comment 4 Clean the outside inside of the radiator core In dusty environments a...

Page 103: ...when checking or adjusting the roller unless otherwise specified Ensure that the hood is fully open when work is being carried out under it Ensure that the hood is fully open when work is being carrie...

Page 104: ...with clean water Fill the water tank The tank holds 105 liters 28 gal Only additive A small amount of environmentally friendly antifreeze Only additive A small amount of environmentally friendly anti...

Page 105: ...Option red 1 31 0 40 Option red 1 31 0 40 Option brown 1 63 0 50 Option brown 1 63 0 50 After inspecting and carrying out any necessary cleaning start the system and check that it works When working w...

Page 106: ...e is free air circulation through the hood s air openings Scrapers spring action Checking Adjustment Fig Spring action scrapers 1 Scraper blade 2 Nut 3 Spring 2 3 1 Loosen the nut 2 to allow the sprin...

Page 107: ...rk is being carried out under it After the first 50 working hours replace the hydraulic oil filter After the first 50 working hours replace the hydraulic oil filter Rubber elements and fastening screw...

Page 108: ...Maintenance 50h 4812164901_A pdf 2022 11 14 98...

Page 109: ...re that the hood is fully open when work is being carried out under it Ensure that the hood is fully open when work is being carried out under it Do not open the cover of the battery system Do not ope...

Page 110: ...g with the battery system Check that the external cables are not worn NOTE If cables are worn contact the manufacturer Battery system Inspecting power connectors and leads Wear eye protectors and glov...

Page 111: ...ion dampers are in place NOTE If the vibration dampers are missing install them 3 Check that the battery system does not have any cracks or other kind of mechanical damage and wear NOTE If the battery...

Page 112: ...Maintenance measures every other month 4812164901_A pdf 2022 11 14 102...

Page 113: ...ified Ensure that the hood is fully open when work is being carried out under it Ensure that the hood is fully open when work is being carried out under it Hydraulic oil cooler Cleaning Fig Engine com...

Page 114: ...trols The friction screws should be set so that the forward reverse lever remains in the position in which it is set whilst the machine is operated The control s 0 position is determined by a screw wh...

Page 115: ...d Ensure that the hood is fully open when work is being carried out under it Ensure that the hood is fully open when work is being carried out under it Hydraulic oil cooler Cleaning Fig Engine compart...

Page 116: ...after a longer period of use lubricate the controls by the bearings and the control cable with a few drops of oil Drum Checking the oil level Fig Drum drive side 1 Oil plug 1 Park the roller on a lev...

Page 117: ...ted passage through the cap in both directions If blocked in either direction clean with a little diesel oil and blow with compressed air until unblocked or replace the cap with a new one When working...

Page 118: ...Maintenance measures 500 h 4812164901_A pdf 2022 11 14 108...

Page 119: ...at the hood is fully open when work is being carried out under it Ensure that the hood is fully open when work is being carried out under it Hydraulic oil cooler Cleaning Fig Engine compartment 1 Hydr...

Page 120: ...a little diesel oil and blow with compressed air until unblocked or replace the cap with a new one When working with compressed air use the following protective equipment When working with compressed...

Page 121: ...le with a few drops of oil Hydraulic fluid filter Change Fig Front frame rear part 1 Hydraulic oil filter 1 Remove the filter 1 and recycle at your local waste disposal station This is a disposable fi...

Page 122: ...gal under the plug Remove the plug 1 and let the oil run out Hand in the drained oil to a waste disposal station Hand in the drained oil to a waste disposal station Refit the plug Top up with new oil...

Page 123: ...that the hood is fully open when work is being carried out under it Ensure that the hood is fully open when work is being carried out under it Hydraulic oil cooler Cleaning Fig Engine compartment 1 H...

Page 124: ...ger period of use lubricate the controls by the bearings and the control cable with a few drops of oil Hydraulic reservoir Check venting Fig Beneath hood right hand side 1 Hydraulic oil tank cap 1 Uns...

Page 125: ...ilter and cannot be cleaned Remove the filter 1 and recycle at your local waste disposal station This is a disposable filter and cannot be cleaned Thoroughly clean the filter holder sealing surface Ap...

Page 126: ...a receptacle that holds more than 15 liters 4 gallons Use a receptacle that holds more than 15 liters 4 gallons Start the pumpen so that it sucks out the fluid from the tank Check that the hose to the...

Page 127: ...e of plastic polyethylene and is recyclable Drum Changing the oil Park the roller on a level surface and drive the roller slowly until the plug 1 is in the bottom position Fig Drum vibration side 1 Oi...

Page 128: ...off the battery and press down the emergency stop Unscrew the plug and check that the oil level reaches the hole s lower edge If necessary top off with fresh transmission fluid See under the heading l...

Page 129: ......

Page 130: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden www dynapac com...

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