Dynapac CC1000 Page 1 Instruction Manual Download

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Instruction manual

Operating & Maintenance

4812160801_D.pdf

Vibratory roller

CC800/900/1000

Engine

Kubota D1105-E4B

Kubota D1105-E4B T4F / Stage 5

Serial number

10000357xxA012892 -

10000358xxA012889 - xA023346

10000358xxA012889 - xA023346
10000360xxA012890 - xA023344

10000360xxA012890 - xA023344

10000440xxA023605 -

10000440xxA023605 -
10000441xxA023347 -

10000441xxA023347 -
10000443xxA023345 -

10000443xxA023345 -

Translation of original instruction

Reservation for changes

Reservation for changes
Printed in Sweden

Printed in Sweden

Summary of Contents for CC1000

Page 1: ...ota D1105 E4B T4F Stage 5 Serial number Serial number 10000357xxA012892 10000357xxA012892 10000358xxA012889 xA023346 10000358xxA012889 xA023346 10000360xxA012890 xA023344 10000360xxA012890 xA023344 10000440xxA023605 10000440xxA023605 10000441xxA023347 10000441xxA023347 10000443xxA023345 10000443xxA023345 Translation of original instruction Translation of original instruction Reservation for change...

Page 2: ......

Page 3: ...s 8 Special instructions 9 Standard lubricants and other recommended oils and fluids 9 Higher ambient temperatures above 40 C 104 F 9 Lower ambient temperature Freeze risk 9 Temperatures 9 High pressure cleaning 9 Fire fighting 10 Roll Over Protective Structure ROPS 10 Battery handling 10 Jump starting 11 Technical specifications 13 Vibrations Operator station 13 Noise level 13 Electrical system 1...

Page 4: ...g system 21 ROPS 21 Identification 22 Product identification number on the frame 22 Machine plate 23 Explanation of 17PIN serial number 23 Engine plates 24 Decals 25 Location decals 25 Safety decals 27 Info decals 28 Instruments Controls 29 Locations Instruments and controls 29 Locations Control panel and controls 30 Function description 31 Electrical system 33 Fuses 33 Fuses in engine compartment...

Page 5: ...7 Operator position 38 Starting 39 Starting the engine 39 Driving 41 Operating the roller 41 Interlock Emergency stop Parking brake Check 42 Vibration 42 Manual Automatic vibration 42 Manual vibration Switching on 43 Braking 43 Normal braking 43 Emergency braking 44 Switching off 44 Parking 45 Chocking the drums 45 Master switch Optional 45 PLUS version 45 CC version 45 Long term parking 47 Engine...

Page 6: ...easing the brake 53 Towing the roller 54 Operating instructions Summary 55 Preventive maintenance 57 Acceptance and delivery inspection 57 Warranty 57 Maintenance Lubricants and symbols 59 Maintenance symbols 61 Maintenance Maintenance schedule 63 Service and maintenance points 63 General 64 Every 10 hours of operation Daily 64 After the FIRST 50 hours of operation 65 Every 50 hours of operation W...

Page 7: ... Warning lamps Check 76 Air cleaner indicator 76 Brakes Check 77 Maintenance 50h 79 Air cleaner emptying 79 Rubber elements and fastening screws Check 80 Belt tension on the hydraulic pump drive belt Check 80 Maintenance measures 250 h 81 Air cleaner Cleaning Change 81 Hydraulic fluid cooler Cleaning 82 Forward Reverse controls and joints Check and lubrication 82 Maintenance measures 500 h 83 Hydr...

Page 8: ...hange 95 Alternator belt Checking tension Change 95 Belt tension on the hydraulic pump drive belt Check 96 Maintenance 2000h 97 Hydraulic fluid cooler Cleaning 97 Forward Reverse controls and joints Check and lubrication 98 Air cleaner Cleaning Change 99 Engine oil and oil filter Change 100 Check Coolant system 101 Drum Checking the oil level 101 Hydraulic reservoir Check venting 102 Hydraulic flu...

Page 9: ... machine in accordance with the instruction manual It is recommended to at least train operators in handling and daily maintenance of the machine in accordance with the instruction manual Passengers are not allowed on the machine and you must sit in the seat when operating the machine Passengers are not allowed on the machine and you must sit in the seat when operating the machine The safety manua...

Page 10: ...r he she must be attentive and operate the machine only when the person is fully visible or has given a clear indication of where he or she is The operator may allow a person to remain in the risk zone however he she must be attentive and operate the machine only when the person is fully visible or has given a clear indication of where he or she is CALIFORNIA Proposition 65 General This manual con...

Page 11: ...engine manual Additional instructions for the engine can be found in the manufactuer s engine manual Specific maintenance and checks on diesel engines must be carried out by the engine supplier s certified personnel Specific maintenance and checks on diesel engines must be carried out by the engine supplier s certified personnel CE marking and Declaration of conformity Applies to machines marketed...

Page 12: ...Introduction 4812160801_D pdf 2018 12 17 4 ...

Page 13: ...ide the edge if the substrate does not have full bearing strength or is close to a slope Avoid operating close to edges and ditches and the like as well as on poor ground conditions that influence the bearing strength and capacity to support the roller 9 Never operate with roller outside the edge if the substrate does not have full bearing strength or is close to a slope Avoid operating close to e...

Page 14: ... approval has been given by Dynapac 18 Avoid using the roller before the hydraulic fluid has reached its normal working temperature Braking distances can be longer than normal when the fluid is cold See instructions in the STOP section 18 Avoid using the roller before the hydraulic fluid has reached its normal working temperature Braking distances can be longer than normal when the fluid is cold S...

Page 15: ...or stands up during operation a buzzer sounds After 4 seconds the brakes are activated and the engine stops Brace yourself for a sudden stop Always use the seat belt where fitted Where the seat belt is not used there is a great risk that the operator will be thrown off and land under the machine if the machine topples over Always use the seat belt where fitted Where the seat belt is not used there...

Page 16: ...ROPS approved cab is always used when driving on slopes or unsafe ground Always wear a seat belt Driving near edges Never operate with roller outside the edge if the substrate does not have full bearing strength or is close to a slope Never operate with roller outside the edge if the substrate does not have full bearing strength or is close to a slope Keep in mind that the machine s center of grav...

Page 17: ...lus S2V100 or similar Lower ambient temperature Freeze risk Make sure that the watering system is empty drained of water sprinkler hoses tank s or that anti freeze has been added to prevent the system freezing Temperatures The temperature limits apply to standard versions of rollers Rollers equipped with additional equipment such as noise suppression may need to be more carefully monitored in the ...

Page 18: ...ructure or cabs Battery handling When removing batteries always disconnect the negative cable first When removing batteries always disconnect the negative cable first When fitting batteries always connect the positive cable first When fitting batteries always connect the positive cable first Dispose of old batteries in an environmentally friendly way Batteries contain toxic lead Dispose of old bat...

Page 19: ...ion and all power consuming equipment off Switch off the engine on the machine which is providing jump start power First connect the jump start battery s positive terminal 1 to the flat battery s positive terminal 2 Then connect the jump start battery s negative terminal 3 to for example a bolt 4 or the lifting eye on the machine with the flat battery Start the engine on the power providing machin...

Page 20: ...Special instructions 4812160801_D pdf 2018 12 17 12 ...

Page 21: ...1 15 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 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 measured in accordance with the operational cycle described in EU directive 2000 14 EC on machines equipped for the EU m...

Page 22: ...D Diameter drum 588 23 2 H Height with ROPS 2300 90 6 H Height with ROPS 2300 90 6 h Height without ROPS 1520 59 8 h Height without ROPS 1520 59 8 K1 465 18 3 K1 465 18 3 L1 2095 82 5 L1 2095 82 5 L2 2040 80 3 L2 2040 80 3 S Thickness drum amplitude Nominal S Thickness drum amplitude Nominal CC800 14 0 55 CC800 14 0 55 CC900 15 0 59 CC900 15 0 59 CC1000 13 0 51 CC1000 13 0 51 14 ...

Page 23: ...ning radius outer R1 Turning radius outer CC800 2650 104 3 CC800 2650 104 3 CC900 2700 106 3 CC900 2700 106 3 CC1000 2750 108 3 CC1000 2750 108 3 R2 Turning radius outer drum edge R2 Turning radius outer drum edge CC800 2610 102 8 CC800 2610 102 8 CC900 2660 104 7 CC900 2660 104 7 CC1000 2710 106 7 CC1000 2710 106 7 W Drum width W Drum width CC800 800 31 5 CC800 800 31 5 CC900 900 35 4 CC900 900 3...

Page 24: ...l Large Plus version 190 liters 50 gal Large Plus version 190 liters 50 gal Working capacity Compaction data Compaction data Static linear load Front Rear Static linear load Front Rear CC800 8 8 10 1 kg cm CC800 8 8 10 1 kg cm 49 3 56 6 pli 49 3 56 6 pli CC900 8 6 8 9 kg cm CC900 8 6 8 9 kg cm 48 2 49 9 pli 48 2 49 9 pli CC1000 8 1 8 4 kg cm CC1000 8 1 8 4 kg cm 45 4 47 pli 45 4 47 pli Amplitude A...

Page 25: ... amplitude is measured as the real value and not the nominal General Engine Engine Manufacturer Model Kubota D1105 E4B Manufacturer Model Kubota D1105 E4B Power Power kW 18 1 kW 18 1 HP 24 6 HP 24 6 Engine speed 2800 rpm Engine speed 2800 rpm Electrical system Electrical system Battery 12V 60Ah Battery 12V 60Ah Alternator 12V 40A Alternator 12V 40A Fuses See the Electrical system section fuses Fus...

Page 26: ...70 470 520 560 620 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 STRENGTH CLASS Metric coarse screw thread bright galvanized fzb Metric coarse thread zinc treated Dacromet GEOMET STRENGTH CLASS M thread 10 9 Oiled 10 9 Dry 12 9 Oiled 12 9 Dry M thread 10 9 Oiled 1...

Page 27: ...076 Supply system 2 0 290 Supply system 2 0 290 Vibration system 22 0 3190 Vibration system 22 0 3190 Control systems 7 0 1015 Control systems 7 0 1015 Brake disengagement 2 0 290 Brake disengagement 2 0 290 Slopes Max 20 or 36 Max 20 or 36 This angle has been measured on a hard flat surface with the machine stationary The steering angle was zero the vibration was switched OFF and all tanks were f...

Page 28: ...Technical specifications 4812160801_D pdf 2018 12 17 20 ...

Page 29: ...rake is hydrostatisc and is activated by moving the control lever to neutral Secondary Parking brake The secondary and parking brake system consists of sprung multiple disc brakes in the motors The brakes are released with hydraulic pressure and are operated with a switch on the instrument panel Steering system The steering system is a hydrostatic system The control value on the steering column di...

Page 30: ...ion could result in the approval according to the ROPS standards becoming invalid Identification Product identification number on the frame 1 Fig PIN right side The machine PIN Product Identification Number 1 is punched on the right edge of the front frame 1 Fig PIN front right 22 ...

Page 31: ...ame and address the type of machine the PIN Product Identification Number serial number operating weight engine power and year of manufacture CE markings and the year of manufacture may be omitted on machines supplied to markets outside the EU Please state the machine s PIN when ordering spares Explanation of 17PIN serial number 100 00123 V x A 123456 100 00123 V x A 123456 A B C F A B C F A Manuf...

Page 32: ...ine s type plate 1 is located on top of the cylinder head cover The plate specifies the type of engine its serial number and the engine specification 1 Fig Engine 1 Type plate Please specify the engine serial number when ordering spares Refer also to the engine manual 24 ...

Page 33: ...n manual 4700903459 11 Battery disconnector Option 4700904835 5 Warning Locking 4700908229 12 Hydraulic fluid level 4700272373 5 Warning Locking 4700908229 12 Hydraulic fluid level 4700272373 6 Acoustic power level 4700791293 13 Bio hydraulic fluid PANOLIN Option 4700792772 6 Acoustic power level 4700791293 13 Bio hydraulic fluid PANOLIN Option 4700792772 7 Diesel fuel 4700991658 14 Fixing point 4...

Page 34: ...0904835 5 Warning Locking 4700908229 12 Hydraulic fluid level 4700272373 5 Warning Locking 4700908229 12 Hydraulic fluid level 4700272373 6 Acoustic power level 4700791293 13 Bio hydraulic fluid PANOLIN Option 4700792772 6 Acoustic power level 4700791293 13 Bio hydraulic fluid PANOLIN Option 4700792772 7 Diesel fuel 4700991658 14 Fixing point 4700382751 7 Diesel fuel 4700991658 14 Fixing point 470...

Page 35: ...ing 4700903423 Warning Rotating engine components Keep your hands at a safe distance 4700903424 Warning Hot surfaces in the engine compartment Keep your hands at a safe distance 4700903459 Warning Instruction manual The operator must read the safety operation and maintenance instructions before operating the machine 4700908229 Warning Risk of crushing The articulation must be locked when lifting R...

Page 36: ...ad the instruction manual Info decals Noise power level Diesel fuel Lifting point Noise power level Diesel fuel Lifting point Hoisting plate Handbook compartment Battery isolation switch Hoisting plate Handbook compartment Battery isolation switch Hydraulic oil level Biological hydraulic fluid PANOLIN Securing point Hydraulic oil level Biological hydraulic fluid PANOLIN Securing point Starting ins...

Page 37: ...tion indicators 13 Sprinkler timer 18 Direction indicators 14 Road lights 19 Horn 14 Road lights 19 Horn 15 Working lights 20 Vibration manual automatic 15 Working lights 20 Vibration manual automatic 16 Hazard warning lights 21 Vibration selector Front rear drum 16 Hazard warning lights 21 Vibration selector Front rear drum 22 Control panel 22 Control panel Option 31 Parking brake On Off Option 3...

Page 38: ...tion On Off 26 Fuel level 4 Vibration On Off 26 Fuel level 5 Handbook compartment 27 Water temperature engine 5 Handbook compartment 27 Water temperature engine 6 Forward reverse lever 28 Battery charging 6 Forward reverse lever 28 Battery charging 7 Seat switch 29 Glow plug 7 Seat switch 29 Glow plug 8 Fuse box 30 Hourmeter 8 Fuse box 30 Hourmeter 9 Instrument cover 31 Parking brake 9 Instrument ...

Page 39: ... the roller is proportional to the distance of the lever from the neutral position The further the lever is from the neutral position the higher the speed 6 Forward Reverse lever The engine can only be started when the lever is in neutral The engine will not start if the forward reverse lever is not in the neutral position Direction of travel and speed of the roller is regulated with the forward r...

Page 40: ...on indicators are on etc In the middle position the function is shut off 19 Horn switch Press to sound the horn 19 Horn switch Press to sound the horn 20 Vibration MAN AUTO switch In the upper position the vibration is switched on off with the switch on the forward reverse lever The function is activated with the switch In the middle position the vibration system is switched off In the lower posit...

Page 41: ...ine has run 31 Parking brake On Off switch To activate the brakes press the top of the switch to change the position of the lever To disengage the brakes press down the red part at the same time as the switch and change the position of the lever NOTE When starting the machine the parking brake must be activated Always use the parking brake when the machine is stationary on a sloping surface 31 Par...

Page 42: ...nction of the fuses are shown below All fuses are flat pin fuses Fuses in engine compartment Fuses in engine compartment F10 Main fuse Type E High 30A F10 Main fuse Type E High 30A F20 Heater plugs 50A F20 Heater plugs 50A Relays Fig Relays 1 2 3 4 1 K1 Starting 1 K1 Starting 2 K5 Glow plug 2 K5 Glow plug 3 K9 Direction indicators 3 K9 Direction indicators 4 K10 Brake lights 4 K10 Brake lights 34 ...

Page 43: ...e key 1 to the On position CC version Fix the red cable lug 3 on the plus terminal on the battery The roller is now supplied with power The engine cover must be unlocked when operating so that the battery can be quickly disconnected if necessary The engine cover must be unlocked when operating so that the battery can be quickly disconnected if necessary Driver seat CC version Adjustment 1 Fig Oper...

Page 44: ...t forget to use the seat belt 4 Do not forget to use the seat belt 4 Instruments and lamps Checking 1 3 22 12 1 Figure Instrument panel 1 Starter switch 3 Emergency stop 12 Switch watering 22 Warning panel Make sure that the emegency stop is pulled out and the parking brake is activated When the forward reverse lever is in neutral the automatic brake function is engaged Make sure that the emegency...

Page 45: ...reverse lever is moved out of neutral when the operator is not sitting down and the parking brake button has not been activated Roller equipped with HY TTC 71 ECU If the operator is leaving the seat with the diesel engine running travel lever in neutral position and parking brake disengaged the buzzer will set and the diesel engine will shut down after four seconds During these four seconds the di...

Page 46: ...elements will reduce comfort Ensure that the anti slip 5 on the platform is in good condition Replace where anti slip friction is poor Ensure that the anti slip 5 on the platform is in good condition Replace where anti slip friction is poor Machines with folding ROPS must always be operated with the ROPS raised and locked in position Machines with folding ROPS must always be operated with the ROPS...

Page 47: ...ot run the starter motor for too long If the engine does not start wait a minute or so before trying again Do not run the starter motor for too long If the engine does not start wait a minute or so before trying again At high ambient temperatures set the speed control 2 to the position just over idling Set the speed control to full speed when starting a cold engine Preheating Turn key to position ...

Page 48: ...l the machine reaches the working temperature When starting and driving a machine that is cold remember that the hydraulic fluid is also cold and that braking distances can be longer than normal until the machine reaches the working temperature Fig Control panel 24 Oil pressure lamp 25 Brake lamp 28 Charging lamp 29 Glow lamp 28 29 24 25 Ensure that there is good ventilation air extraction if the ...

Page 49: ... goes off Turn the engine speed control upwards 2 and lock it in the working position Check that the steering is working correctly by turning the steering wheel once to the right and once to the left while the roller is stationary When compacting asphalt remember to turn on the sprinkler system 12 12 25 31 Figure Instrument panel 12 Switch for sprinkler 25 Parking brake lamp 31 Parking brake Caref...

Page 50: ...steering wheel firmly and brace yourself for a sudden stop The engine switches off and the brakes are activated Check the function of the emergency stop by pressing the emergency stop when the roller is moving slowly forwards backwards Check in both directions Hold the steering wheel firmly and brace yourself for a sudden stop The engine switches off and the brakes are activated Check the function...

Page 51: ... lever is moved towards the neutral position Press the switch 4 to switch off the vibration 4 31 2 3 6 Figure Control panel 2 Engine speed control 3 Emergency stop 4 Vibration On off 6 Forward reverse lever 31 Parking brake Move the forward reverse lever 6 to the neutral position to stop the roller When starting and driving a machine that is cold remember that the hydraulic fluid is also cold and ...

Page 52: ...ngine stops After braking return the forward reverse lever to the neutral position and pull out the emergency stop Restart the engine Switching off 1 2 31 22 9 Figure Instrument panel 1 Starter switch 2 Engine speed control 9 Instrument cover 22 Panel for warning lamps 31 Parking brake Turn the engine speed control 2 back to idling Allow the engine to idle for a few minutes to cool Activate the pa...

Page 53: ...eep in mind that there is a risk of freezing during the winter Drain the water tanks and water lines Keep in mind that there is a risk of freezing during the winter Drain the water tanks and water lines Master switch Optional 1 2 Fig Battery compartment 1 Battery disconnector only PLUS version 2 Power socket 12V 3 Cable lug 3 The power to the roller should be disconnected at the end of the working...

Page 54: ...Operation 4812160801_D pdf 2018 12 17 46 ...

Page 55: ...s Engine Refer to the manufacturer s instructions in the engine manual that is supplied with the roller Battery Remove the battery from the machine clean grease the cable connectors terminals and trickle charge the battery once a month The battery is otherwise maintenance free Air cleaner exhaust pipe Cover the air cleaner see under the heading Every 50 hours of operation or Every 500 hours of ope...

Page 56: ...rvation grease Grease the hinges on the doors to the engine compartment Grease both ends of the forward reverse control bright parts see under the heading Every 500 hours of operation Hoods tarpaulin Lower the instrument cover over the instrument panel Cover the entire roller with a tarpaulin A gap must be left between the tarpaulin and the ground If possible store the roller indoors and ideally i...

Page 57: ...ing the locking pin 1 Lifting the roller Weight refer to the hoisting plate on the roller 1 Fig Roller prepared for lifting 1 Hoisting plate The machine s gross weight is specified on the hoisting plate 1 Refer also to the Technical specifications The machine s gross weight is specified on the hoisting plate 1 Refer also to the Technical specifications Lifting gear such as chains steel wires strap...

Page 58: ...the Cargo Securing Certificate for the specific machine if this is avaliable and applicable If not tie down and secure the machine according to the cargo securing rules that are valid for the country where the transport takes place Never lash over the machine s articulated joint nor over the machine s operator platform Never lash over the machine s articulated joint nor over the machine s operator...

Page 59: ...erval in meters 1 4 Double lashings LC at least 1 7 tonnes 1700 daN STF 300 kg 300daN 1 4 Double lashings LC at least 1 7 tonnes 1700 daN STF 300 kg 300daN Double L1 L2 Double L3 L4 Double L1 L2 Double L3 L4 0 6 3 0 0 1 3 0 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 las...

Page 60: ...e platform Each of lashings 1 3 is either a double or two single lashings A double lashing runs in a sling through a lashing point or around a machine part and down into two different mounts on the platform Lashings in the same direction are placed in different lashing mounts on the trailer Lashings that are pulled in opposite directions may be placed in the same lashing mount however Lashings in ...

Page 61: ...ches the brake 107 inner thread 3 Tighten the two screws 192 alternately a little at a time so that the brake piston 107 loose screw approximately 2 turns Tightening the screws 192 too hard can damage the inner mechanism Tightening the screws 192 too hard can damage the inner mechanism The machine should be started with reactivated brake The machine should be started with reactivated brake 53 ...

Page 62: ... 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 be towed slowly max 3 km h 2 mph and for short distances only max 300 m 1000 ft When towing recovering a machine the towing device must be connected to both lifting holes Pulling forces shall act lo...

Page 63: ...ever with care 11 Check the brakes drive slowly Remember that the braking distance will be longer if the roller is cold 11 Check the brakes drive slowly Remember that the braking distance will be longer if the roller is cold 12 Use vibration only when the roller is in motion 12 Use vibration only when the roller is in motion 13 Check that the drums are thoroughly watered when watering is required ...

Page 64: ...Operating instructions Summary 4812160801_D pdf 2018 12 17 56 ...

Page 65: ... to the customer delivery inspection must be conducted as per the check list in the warranty document Any transport damage must be reported immediately to the transport company as this is not covered by the product warranty Warranty The warranty is only valid if the stiplulated delivery inspection and the separate service inspection have been completed as per the warranty document and when the mac...

Page 66: ...Preventive maintenance 4812160801_D pdf 2018 12 17 58 ...

Page 67: ...lways use high quality lubricants and the amounts recommended Too much grease or oil can cause overheating resulting in rapid wear Always use high quality lubricants and the amounts recommended Too much grease or oil can cause overheating resulting in rapid wear Other fuel and lubricants are required when operating in areas with extremely high or extremely low ambient temperatures See the Special ...

Page 68: ...leaves the factory the machine may be filled with biologically degradable fluid The same type of fluid must be used when changing or topping up BP Biohyd SE S46 BIOLOGICAL HYDRAULIC FLUID When it leaves the factory the machine may be filled with biologically degradable fluid The same type of fluid must be used when changing or topping up BP Biohyd SE S46 DRUM OIL Air temp 15 C 40 C 5 F 104 F Dynap...

Page 69: ... Engine oil filter Battery Engine oil filter Battery Hydraulic reservoir level Sprinkler Hydraulic reservoir level Sprinkler Hydraulic fluid filter Sprinkler water Hydraulic fluid filter Sprinkler water Drum oil level Recycling Drum oil level Recycling Lubricating oil Fuel filter Lubricating oil Fuel filter Coolant level Coolant level 61 ...

Page 70: ...Maintenance Lubricants and symbols 4812160801_D pdf 2018 12 17 62 ...

Page 71: ...ever 8 Battery maintenance free 14 Fuel tank refilling 2 Forward Reverse lever 8 Battery maintenance free 14 Fuel tank refilling 3 Emergency brake 9 Sprinkler left side 3 Emergency brake 9 Sprinkler left side 4 Hydraulic fluid cooler radiator 10 Scrapers 15 Steering joint 4 Hydraulic fluid cooler radiator 10 Scrapers 15 Steering joint 5 Alternator belt 11 Rubber element 16 Drums filling with oil 5...

Page 72: ...point in time that occurs first Where both operational hours and time intervals are specified maintenance should be carried out at the point in time that occurs first Every 10 hours of operation Daily Refer to the contents to find the page number of the sections referred to Pos in fig Action Comment Pos in fig Action Comment Before starting up for the first time on that day Before starting up for ...

Page 73: ...eck rubber elements and bolted joints 11 Check rubber elements and bolted joints Every 250 750 1250 1750 hours of operation Refer to the contents to find the page number of the sections referred to Pos in fig Action Comment Pos in fig Action Comment 7 Clean the air cleaner filter element check that hoses and connectors are tight 7 Clean the air cleaner filter element check that hoses and connector...

Page 74: ...r filter element check that hoses and connectors are tight 7 Replace the air cleaner filter element check that hoses and connectors are tight 6 Change the fuel filter Refer to the engine manual 6 Change the fuel filter Refer to the engine manual 6 Change the engine oil and oil filter Refer to the engine manual 6 Change the engine oil and oil filter Refer to the engine manual 4 Check coolant freezi...

Page 75: ...t check that hoses and connectors are tight 6 Change the fuel filter Refer to the engine manual 6 Change the fuel filter Refer to the engine manual 6 Change the engine oil and oil filter Refer to the engine manual 6 Change the engine oil and oil filter Refer to the engine manual 4 Check coolant freezing point Change the coolant every other year 4 Check coolant freezing point Change the coolant eve...

Page 76: ...l 4 Check coolant freezing point Change the coolant every other year 4 Check coolant freezing point Change the coolant every other year 16 Check the oil level in the drums 16 Check the oil level in the drums 13 Check the hydraulic reservoir cover breather 13 Check the hydraulic reservoir cover breather 12 Change hydraulic fluid filter 12 Change hydraulic fluid filter 6 Check the engine valve clear...

Page 77: ...Maintenance Maintenance schedule 4812160801_D pdf 2018 12 17 Service Checklist 69 ...

Page 78: ...Maintenance Maintenance schedule 4812160801_D pdf 2018 12 17 70 ...

Page 79: ... that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that the engine cover is fully open when work is carried out under the cover Ensure that the engine cover is fully open when work is carried out under the cover Diesel engine Check oil level Fig Engine 1 Dipstick 2 Filler cap 1 2 Open the engine cover lock and lower the engine cover...

Page 80: ...uid grade Check Coolant system Figure Cooling water container 1 Filler cap 2 Level marking 1 2 Check that all hoses hose connectors are intact and tight Fill with coolant as specified in the lubricants specification Take great care when opening the radiator cap while the engine is hot Wear protective gloves and goggles Take great care when opening the radiator cap while the engine is hot Wear prot...

Page 81: ...zzle during refueling by pressing it against the filler pipe 1 Stop the engine Short circuit the fueling nozzle during refueling by pressing it against the filler pipe 1 The tank holds 23 liters 6 1 gal of fuel Water tank Filling Fig Water tank 1 Tank cap 1 Unscrew the tank cap 1 and fill with clean water Unscrew the tank cap 1 and fill with clean water Fill the water tank The CC version tank hold...

Page 82: ...t 2 0 bar gal min at 40 psi Standard yellow 0 63 0 20 Standard yellow 0 63 0 20 Option blue 0 98 0 30 Option blue 0 98 0 30 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 Wear protective goggles when working with compressed air Wear protective goggles when work...

Page 83: ... the circulation of air to the engine through the grille in the engine cover is unobstructed Fig Front scrapers in transport position 2 Locking nut 3 Mounting plate 2 3 Scrapers Check adjustment Make sure that the scrapers are undamaged Adjust the scrapers if necessary in the following way For firmer application of the scraper undo the locking nut 2 and adjust it until the desired application is a...

Page 84: ...or Fig Air cleaner 1 Indicator 1 If the indicator 1 on the air cleaner turns red empty the dust pouch 2 on the air cleaner The dust pouch is emptied by pressing the rubber bellows with your fingers Check also that the air hoses are in good condition Clean the air cleaner when operated in extremely dusty environments 2 Fig Air cleaner right side 2 Dust pouch 76 ...

Page 85: ... the roller very slowly forward Hold the steering wheel firmly and brace yourself for a sudden stop Press in the emergency stop button 3 The roller will stop abruptly and the engine will switch off After testing the brakes set the forward reverse lever in neutral Pull out the emergency stop button 3 Start the engine The roller is now ready for operation Refer also to the section in the manual on o...

Page 86: ...Maintenance 10h 4812160801_D pdf 2018 12 17 78 ...

Page 87: ...oning Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that the engine cover is fully open when work is being carried out under it Ensure that the engine cover is fully open when work is being carried out under it After the first 50 hours of operation the oil filters should be changed After the first 50 hours of operation th...

Page 88: ...er elements on both sides of the roller The screws on the rubber elements are sealed with Loctite Check the rubber elements on both sides of the roller Belt tension on the hydraulic pump drive belt Check Fig Engine compartment 1 Screw 2 Screw 1 2 If the hydraulic pump drive belt can be pressed in 5 6 mm between the pulleys with a force of 50 Nm then the belt is correctly tensioned Do as follows to...

Page 89: ... extraction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that the engine cover is fully open when work is being carried out under it Ensure that the engine cover is fully open when work is being carried out under it Air cleaner Cleaning Change Fig Air cleaner 1 Catches 2 Cover 3 Main filter 4 Backup filter 5 Filter housing 1 2 3 4 5 Clean the air cleaner Remove the main fi...

Page 90: ... Check the friction of the forward reverse controls The friction screws should be set so that the forward reverse lever remains in the position in which it is set whilst the machine is operated The control s 0 position is determined by a screw which engages with the groove on the shaft between the controls If the control begins to be stiff after a longer period of use lubricate the controls by the...

Page 91: ...traction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that the engine cover is fully open when work is being carried out under it Ensure that the engine cover is fully open when work is being carried out under it Hydraulic fluid cooler Cleaning Fig Engine com...

Page 92: ...achine is operated The control s 0 position is determined by a screw which engages with the groove on the shaft between the controls If the control begins to be stiff after a longer period of use lubricate the controls by the bearings and the control cable with a few drops of oil Fig Engine compartment 1 F R control cable 2 Propulsion pump 1 2 If the forward reverse lever still is stiff after the ...

Page 93: ...3 by undoing the catches 1 and then the cover 2 Check that the filter element is undamaged Clean the element by banging it against your hand or other soft object Then blow clean with compressed air max 5 bars from the inside of the filter Also clean the filter housing 5 and the cover 2 Replace the filter cartridge after 5 cleanings or more frequently Replace the filter cartridge after 5 cleanings ...

Page 94: ... plug 2 in the end of the drain hose 1 Let all the engine oil flow out Deliver the drained oil to special waste handling Deliver the drained oil to special waste handling Refer to the engine manual for detailed instructions when changing oil and filters Refer to the engine manual for detailed instructions when changing oil and filters Remove the oil filter 4 and fit a new filter Collect any spilla...

Page 95: ...every other year Also check the freezing point Change the coolant every other year Drum Checking the oil level Fig Drum drive side 1 Oil plug 1 Park the roller on a level surface and drive the roller slowly until the oil plug 1 is in the middle of the semicircle shaped notch in the drum suspension Switch off the engine disconnect the power and push in the emergency stop button Switch off the engin...

Page 96: ...rotectors and gloves when working with compressed air Wear eye protectors and gloves when working with compressed air Belt tension on the hydraulic pump drive belt Check Fig Engine compartment 1 Screw 2 Screw 1 2 If the hydraulic pump drive belt can be pressed in 5 6 mm between the pulleys with a force of 50 Nm then the belt is correctly tensioned Do as follows to tension the belt Undo the screws ...

Page 97: ... the engine is run indoors Risk of carbon monoxide poisoning Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that the engine cover is fully open when work is being carried out under it Ensure that the engine cover is fully open when work is being carried out under it Hydraulic fluid cooler Cleaning Fig Engine compartment 1 ...

Page 98: ...e is operated The control s 0 position is determined by a screw which engages with the groove on the shaft between the controls If the control begins to be stiff after a longer period of use lubricate the controls by the bearings and the control cable with a few drops of oil Fig Engine compartment 1 F R control cable 2 Propulsion pump 1 2 If the forward reverse lever still is stiff after the above...

Page 99: ...undoing the catches 1 and then the cover 2 Check that the filter element is undamaged Clean the element by banging it against your hand or other soft object Then blow clean with compressed air max 5 bars from the inside of the filter Also clean the filter housing 5 and the cover 2 Replace the filter cartridge after 5 cleanings or more frequently Replace the filter cartridge after 5 cleanings or mo...

Page 100: ... 2 in the end of the drain hose 1 Let all the engine oil flow out Deliver the drained oil to special waste handling Deliver the drained oil to special waste handling Refer to the engine manual for detailed instructions when changing oil and filters Refer to the engine manual for detailed instructions when changing oil and filters Remove the oil filter 4 and fit a new filter Collect any spillage Fi...

Page 101: ... other year Also check the freezing point Change the coolant every other year Drum Checking the oil level Fig Drum drive side 1 Oil plug 1 Park the roller on a level surface and drive the roller slowly until the oil plug 1 is in the middle of the semicircle shaped notch in the drum suspension Switch off the engine disconnect the power and push in the emergency stop button Switch off the engine dis...

Page 102: ...th directions If blocked in either direction clean with a little diesel oil and blow with compressed air until unblocked or replace the cap with a new one Wear eye protectors and gloves when working with compressed air Wear eye protectors and gloves when working with compressed air Fig Engine compartment right side 1 Sight glass 1 Check the hydraulic oil level in the sight glass 1 and top off wher...

Page 103: ...e damaged Do not over tighten The seal can be damaged Start the engine and check that the filter does not leak Alternator belt Checking tension Change Fig Alternator viewed from the front 1 Mounting screw 2 Mounting screw 3 Alternator belt 1 2 3 Switch off the engine disconnect the power and switch on the emergency brake button Switch off the engine disconnect the power and switch on the emergency...

Page 104: ...ressed in 5 6 mm between the pulleys with a force of 50 Nm then the belt is correctly tensioned Do as follows to tension the belt Undo the screws 1 and 2 Press over the hydraulic pump so that the belt tensions to the specified extent Tighten screw 1 and then screw 2 Check that the belt still has the correct tension after tightening Replace the belt when necessary or after 2000 h 96 ...

Page 105: ... if the engine is run indoors Risk of carbon monoxide poisoning Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Ensure that the engine cover is fully open when work is being carried out under it Ensure that the engine cover is fully open when work is being carried out under it Hydraulic fluid cooler Cleaning Fig Engine compartment...

Page 106: ...e is operated The control s 0 position is determined by a screw which engages with the groove on the shaft between the controls If the control begins to be stiff after a longer period of use lubricate the controls by the bearings and the control cable with a few drops of oil Fig Engine compartment 1 F R control cable 2 Propulsion pump 1 2 If the forward reverse lever still is stiff after the above...

Page 107: ...undoing the catches 1 and then the cover 2 Check that the filter element is undamaged Clean the element by banging it against your hand or other soft object Then blow clean with compressed air max 5 bars from the inside of the filter Also clean the filter housing 5 and the cover 2 Replace the filter cartridge after 5 cleanings or more frequently Replace the filter cartridge after 5 cleanings or mo...

Page 108: ... 2 in the end of the drain hose 1 Let all the engine oil flow out Deliver the drained oil to special waste handling Deliver the drained oil to special waste handling Refer to the engine manual for detailed instructions when changing oil and filters Refer to the engine manual for detailed instructions when changing oil and filters Remove the oil filter 4 and fit a new filter Collect any spillage Fi...

Page 109: ... other year Also check the freezing point Change the coolant every other year Drum Checking the oil level Fig Drum drive side 1 Oil plug 1 Park the roller on a level surface and drive the roller slowly until the oil plug 1 is in the middle of the semicircle shaped notch in the drum suspension Switch off the engine disconnect the power and push in the emergency stop button Switch off the engine dis...

Page 110: ...h directions If blocked in either direction clean with a little diesel oil and blow with compressed air until unblocked or replace the cap with a new one Wear eye protectors and gloves when working with compressed air Wear eye protectors and gloves when working with compressed air Fig Engine compartment right side 1 Sight glass 1 Check the hydraulic oil level in the sight glass 1 and top off where...

Page 111: ...o special waste handling This is a single use filter and cannot be cleaned 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 makes contact with the filter base Then rotate a further turn Do not over tighten The seal can be damaged Do not over tighten The se...

Page 112: ...hat holds at least 15 liters 4 gal Use a receptacle that holds at least 15 liters 4 gal Start the pumpen so that it sucks out the fluid from the tank Check that the hose to the pump reaches the bottom of the hydraulic reservoir to ensure that as much of the fluid as possible is drained Collect the oil and deliver to special waste handling Collect the oil and deliver to special waste handling Fill ...

Page 113: ... around 10 mm halfway between the pulleys it is correctly tensioned Tighten first screw 1 and then screw 2 Check that the belt still has the correct tension after tightening Water tank Cleaning Fig Bay under the floor 1 Drainage tap 2 Water filter 3 Water pump 1 2 3 Keep in mind that there is a risk of freezing in winter Drain the tank pump and lines Keep in mind that there is a risk of freezing i...

Page 114: ... the drained oil to special waste handling Refit the plug Top up with new oil in position 2 See Every 500 hours of operation for filling oil Fuel tank Cleaning Fig Fuel tank 1 Hose from external pump 1 It is easiest to clean the tank when it is almost empty Pump out any bottom sediment using an external pump To remove any additional bottom sediment fill the tank with two liters of diesel and then ...

Page 115: ...pump drive belt Check Fig Engine compartment 1 Screw 2 Screw 1 2 If the hydraulic pump drive belt can be pressed in 5 6 mm between the pulleys with a force of 50 Nm then the belt is correctly tensioned Do as follows to tension the belt Undo the screws 1 and 2 Press over the hydraulic pump so that the belt tensions to the specified extent Tighten screw 1 and then screw 2 Check that the belt still h...

Page 116: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden www dynapac com ...

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Dynapac CC1000, Instruction Manual

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