Dynapac CC7200 Instruction Manual Download Page 5

Page: 5 / 101

2000h-

Maintenance

4812158801_E.pdf

2018-04-03

Operator’s seat - Adjusting....................................................................... 40

Interlock..................................................................................................... 40

Parking brake ............................................................................................ 41

Instruments and lamps - Checking............................................................ 41

Speed limiter ............................................................................................. 42

View .......................................................................................................... 42

Operator's station ...................................................................................... 43

Starting .................................................................................................................... 44

Starting the engine .................................................................................... 44

Driving ..................................................................................................................... 45

Operating the roller ................................................................................... 45

Interlock/Emergency stop/Parking brake - Check ..................................... 46

Vibration .................................................................................................................. 47

Manual/Automatic vibration....................................................................... 47

Manual vibration - Switching on ................................................................ 47

Amplitude - Changeover ........................................................................... 48

Braking .................................................................................................................... 48

Reserve brake........................................................................................... 48

Switching off.............................................................................................. 49

Parking .................................................................................................................... 49

Chocking the drums .................................................................................. 49

Master switch ............................................................................................ 50

Long-term parking.................................................................................................................. 51

Engine ....................................................................................................... 51

Battery....................................................................................................... 51

Air cleaner, exhaust pipe........................................................................... 51

Sprinkler system........................................................................................ 51

Fuel tank ................................................................................................... 51

Hydraulic reservoir .................................................................................... 52

Steering cylinder, hinges, etc. ................................................................... 52

Summary of Contents for CC7200

Page 1: ...r CC722 7200 CC722 7200 Engine Engine Cummins QSB 6 7 C IIIB T4i Cummins QSB 6 7 C IIIB T4i Serial number Serial number 10000326xxA007761 10000326xxA007761 10000361xxA014104 10000361xxA014104 Translat...

Page 2: ......

Page 3: ...itioning Optional 9 Special instructions 11 Standard lubricants and other recommended oils and fluids 11 Higher ambient temperatures above 40 C 104 F 11 Lower ambient temperature Freeze risk 11 Temper...

Page 4: ...Info decals 25 Instruments Controls 26 Locations Instruments and controls 26 Function descriptions 27 Display Regeneration of Diesel Particle Filter DPF filter 31 Locations Instruments and controls ca...

Page 5: ...ating the roller 45 Interlock Emergency stop Parking brake Check 46 Vibration 47 Manual Automatic vibration 47 Manual vibration Switching on 47 Amplitude Changeover 48 Braking 48 Reserve brake 48 Swit...

Page 6: ...mary 57 Preventive maintenance 59 Acceptance and delivery inspection 59 Warranty 59 Maintenance Lubricants and symbols 61 Maintenance symbols 62 Maintenance Maintenance schedule 63 Service and mainten...

Page 7: ...Air cleaner Cleaning 76 Rubber elements and fastening screws Check 77 Articulation and steering cylinder Lubrication 77 Hydraulic reservoir Check venting 78 Battery Checking the electrolyte level 78...

Page 8: ...E pdf 2018 04 03 Hydraulic fluid reservoir Draining 88 Maintenance 2000h 89 Hydraulic reservoir Replacing the fluid filters 89 Drum Changing the oil 90 Drum drive Changing the oil 91 Pump drive Changi...

Page 9: ...or hazardous procedure that can result in damage to the machine or property if the warning is ignored Safety information It is recommended to at least train operators in handling and daily maintenance...

Page 10: ...ximal performance The machine should be kept clean so that any leakages loose bolts and loose connections are discovered at as early a point in time as possible Inspect the machine every day before st...

Page 11: ...rsonnel CE marking and Declaration of conformity Applies to machines marketed in EU EEC This machine is CE marked This shows that on delivery it complies with the basic health and safety directives ap...

Page 12: ...Introduction 4812158801_E pdf 2018 04 03 4...

Page 13: ...de 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...

Page 14: ...ns to the roller that could affect safety Changes are only to be made after written approval has been given by Dynapac 18 Avoid using the roller before the hydraulic fluid has reached its normal worki...

Page 15: ...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 Pay attention to potential obstacles above the mach...

Page 16: ...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 gravity moves outwards when steering For example the center of g...

Page 17: ...circuit is only to be carried out by authorized companies The cooling system is pressurized Incorrect handling can result in serious personal injury Do not disconnect or undo the hose couplings The co...

Page 18: ...Safety Optional 4812158801_E pdf 2018 04 03 10...

Page 19: ...wever the following fluids must be used for other components Hydraulic system mineral oil Shell Tellus S2V100 or similar Other components that use transmission oil Shell Spirax AX 85W 140 or equivalen...

Page 20: ...cture ROPS or ROPS approved cab never carry out any welding or drilling in the structure or cab Never attempt to repair a damaged ROPS structure or cab These must be replaced with new ROPS structure o...

Page 21: ...ery Check that the battery used for jump starting has the same voltage as the dead battery Fig Jump starting 1 2 3 4 Turn the ignition and all power consuming equipment off Switch off the engine on th...

Page 22: ...Special instructions 4812158801_E pdf 2018 04 03 14...

Page 23: ...erational cycle described in EU directive 2000 14 EC on machines equipped for the EU market on soft polymer material with vibration switched on and the operator s seat in the transport position The no...

Page 24: ...60 D Drum diameter 1527 60 H1 Height with ROPS 3430 135 H1 Height with ROPS 3430 135 H2 Height with cab 3250 128 H2 Height with cab 3250 128 H3 Height w o ROPS cab 2630 104 H3 Height w o ROPS cab 2630...

Page 25: ...O1 Overhang left 112 4 5 O2 Overhang right 112 4 5 O2 Overhang right 112 4 5 R1 Turning radius external 8080 318 R1 Turning radius external 8080 318 R2 Turning radius inner 5950 234 R2 Turning radius...

Page 26: ...r tank front 670 177 front 670 177 rear 670 177 rear 670 177 Working capacity Compaction data Compaction data Static linear load front rear 38 7 40 0 kg cm 217 224 pli Static linear load front rear 38...

Page 27: ...ion fuses Fuses See the Electrical system section fuses Hydraulic system Opening pressure MPa Opening pressure MPa Drive system 35 Drive system 35 Supply system 2 0 Supply system 2 0 Vibration system...

Page 28: ...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 29: ...er on the frame 1 Fig PIN Front frame 1 Serial number The machine PIN Product Identification Number 1 is punched on the right edge of the front frame Explanation of 17PIN serial number 100 00123 V x A...

Page 30: ...ered outside of the EU the sign may lack CE marking and year of manufacture Please state the machine s PIN serial number when ordering parts Engine plates The engine s type plate 1 is located on top o...

Page 31: ...Master switch 4700904835 15 Warning Brake release 4700904895 4 Master switch 4700904835 15 Warning Brake release 4700904895 5 Warning Parking brake 47386084xx 16 Fixing point 4700382751 5 Warning Par...

Page 32: ...ith pivotal steering 4700903423 Warning Rotating engine components Keep your hands at a safe distance 4700903424 Warning Hot surfaces in the engine compartment Keep your hands at a safe distance 47009...

Page 33: ...g point Noise power level Diesel fuel Lifting point Hoisting plate Handbook compartment Master switch Hoisting plate Handbook compartment Master switch Battery voltage Water Hydraulic fluid level Batt...

Page 34: ...ine 28 Beeper 5 Electric heater Diesel engine 28 Beeper 6 Hourmeter 29 Speed limiter 6 Hourmeter 29 Speed limiter 7 Fuel level indicator 30 Forward reverse lever 7 Fuel level indicator 30 Forward reve...

Page 35: ...ngine stops Brace yourself for a sudden stop NOTE When starting the machine the emergency stop must be inactive 2 Emergency stop When pressed the emergency stop is activated The brakes are applied and...

Page 36: ...brake knob is activated and the brakes are applied 13 Warning lamp brakes Red If the lamp comes on the brake oil pressure is low or the parking brake knob is activated and the brakes are applied 14 W...

Page 37: ...se lever is in any other position The forward reverse lever controls both the roller s driving direction and speed When the lever is moved forward the roller moves forward etc The roller s speed is pr...

Page 38: ...erious fault Shows the error code along with lamp 40 If the lamp lights continuously stop the diesel engine immediately 41 Fault indicating lamp Red serious fault Shows the error code along with lamp...

Page 39: ...y be used if you are in an unsuitable location e g in a tunnel under a roof etc The auto mode is the normal mode The delayed mode should only be used if you are in an unsuitable location e g in a tunn...

Page 40: ...y to the automatic middle position 5 If manual regeneration is not performed after a warning to do so the engine heating lamp 5 comes on at the same time as DPF lamp continues to flash Continuing to w...

Page 41: ...orking lights rear 2 Working lights front 3 Windshield washer 4 Windshield wiper 5 Blower fan 1 2 3 4 5 7 6 Fig Cab roof right side 8 Fuse boxes 9 Right side window wiper 10 Right side window washer 1...

Page 42: ...5 Blower fan switch Press to operate the blower fan 6 Left side window washer switch Press to wash the left side window 6 Left side window washer switch Press to wash the left side window 7 Left side...

Page 43: ...switch 1 must be in the AC ON position to enable the fan switch 2 to work Ventilation Set the switch 1 in the middle position to run the fan at low speed without AC Ventilation Set the switch 1 in th...

Page 44: ...ater 10A 7 Horn 10A 3 Cab heater 10A 7 Horn 10A 4 Rotating beacon 10A 8 Starting 5A 4 Rotating beacon 10A 8 Starting 5A Fuse box lower F2 Fuse box lower F2 1 Sprinkler main circuit 15A 5 Indicator pan...

Page 45: ...d both are 80A fuses Fuses in cab Fig Fuse box in cab optional 1 Cab lighting washers 1 Cab lighting washers 2 Ventilation fan 2 Ventilation fan 3 Lights rear 3 Lights rear 4 Lights front 4 Lights fro...

Page 46: ...s ground to the battery The cable between the battery and the alternator must not be disconnected when the engine is running K16 Overspeed relay diesel engine 30A K16 Overspeed relay diesel engine 30A...

Page 47: ...d with power Water tanks Level Fig Water tank 1 Level gauge 1 When driving on asphalt check that the water tanks are filled See the relevant level gauges 1 Control table Setting Fig Control table 1 Lo...

Page 48: ...adjusted as illustrated Always make sure that the seat is secure before beginning operation Always make sure that the seat is secure before beginning operation Interlock The roller is equipped with In...

Page 49: ...ruments and lamps Checking 2 5 6 7 8 1 3 4 Fig Instrument panel 1 Starter switch 2 Fuel gauge 3 Emergency stop 4 Parking brake knob 5 Warning lamp charging 6 Hourmeter 7 Warning lamp engine oil pressu...

Page 50: ...ing Undo the locking knob 1 on the limiter Adjust the forward reverse lever to the desired speed and lock the knob in this position If the speed limiter knob 2 is pulled out the forward reverse lever...

Page 51: ...orn or has been subjected to a heavy load Check that rubber elements 2 on the platform are intact Worn elements will impair comfort Check that rubber elements 2 on the platform are intact Worn element...

Page 52: ...r manual automatic vibration in the mid position position 0 Turn the ignition key 3 to the right to the first position The preheating lamp 8 lights on the indicator panel When the lamp goes out turn t...

Page 53: ...ircumstances is the machine to be operated from the ground The operator must be seated inside the machine during all operation Set the speed control 2 in the desired working position right position du...

Page 54: ...tions Hold the steering wheel firmly and brace yourself for a sudden stop A buzzer goes on and after 4 seconds the engine switches off and the brakes are activated The interlock function is checked by...

Page 55: ...n vibration is controlled with a micro switch 6 which is influenced by two chambers on the shaft for the forward reverse lever The position for switching on and hence the speed can be adjusted Cams cl...

Page 56: ...t and wait until vibration stops before setting amplitude Braking Reserve brake 1 Fig Instrument panel 1 Parking brake switch Braking is normally activated using the forward reverse lever The hydrosta...

Page 57: ...hine when the is engine running unless the parking brake is activated Never disembark from the machine when the is engine running unless the parking brake is activated Make sure that the roller is par...

Page 58: ...witch 1 Key knob Before leaving the roller for the day switch the battery master switch 1 to the disconnected position and remove the key knob This will prevent battery discharging and will also make...

Page 59: ...to the manufacturer s instructions in the engine manual that is supplied with the roller Battery Remove the battery from the machine Clean the battery check that the electrolyte level is correct see u...

Page 60: ...hours of operation Grease the steering cylinder piston with conservation grease Grease the hinges on the doors to the engine compartment and the cab Grease both ends of the forward reverse control bri...

Page 61: ...the holes through the locking arm and locking lug and secure the dowel in position with the locking pin Lifting the roller Weight refer to the hoisting plate on the roller 1 2 Fig Roller prepared for...

Page 62: ...ne running 2 1 2 1 Fig Propulsion pump 1 Towing valve 2 Multifunction valve Activate the parking brake and temporarily shut off the engine Chock the drums to prevent the machine from rolling Activate...

Page 63: ...moving when the brakes are mechanically disengaged Set a steel bar in the pump lever 2 and pump by moving the bar up and down until the brakes release or until a certain amount of hydraulic resistance...

Page 64: ...e as shown in the figure Maximum gross pulling force 265 kN 59575 lbf Reverse the towing preparations Reverse the towing preparations Roller prepared for transport Fig Positioning 1 Chocks 2 Blocks 3...

Page 65: ...d reverse lever with care 10 Operate the roller Handle the forward reverse lever with care 11 Check the brakes Remember that the braking distance will be longer if the roller is cold 11 Check the brak...

Page 66: ...Operating instructions Summary 4812158801_E pdf 2018 04 03 58...

Page 67: ...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 b...

Page 68: ...Preventive maintenance 4812158801_E pdf 2018 04 03 60...

Page 69: ...Dynapac engine oil 200 P N 4812161855 5 liters P N 4812161856 20 liters HYDRAULIC FLUID Air temperature 15 C 50 C 5 F 122 F Dynapac hydraulic 300 P N 4812161868 20 liters P N 4812161869 209 liters HY...

Page 70: ...API GL 5 Air temperature 0 C 32 F above 40 C 104 F Shell Spirax S3 AX 85W 140 API GL 5 COOLANT Anti freeze protection down to about 37 C 34 6 F GlycoShell Carcoolant 774C mixed 50 50 with water COOLA...

Page 71: ...ve 2 Sprinkler system 9 Hydraulic pump operation 16 Drum drive 3 Fuel tank 10 Hydraulic fluid filter 17 Control table 3 Fuel tank 10 Hydraulic fluid filter 17 Control table 4 Engine mounting 11 Articu...

Page 72: ...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 Befo...

Page 73: ...lace as required Check that hoses and couplings are not leaking Check that hoses and couplings are not leaking 8 Check rubber elements and bolted joints 8 Check rubber elements and bolted joints 11 Lu...

Page 74: ...nt 14 Clean the outside of the hydraulic fluid cooler water cooler If necessary 14 Clean the outside of the hydraulic fluid cooler water cooler If necessary 15 Check belt tension for cooling fan and a...

Page 75: ...ne oil and oil filter Refer to the engine manual Check engine valve clearances Refer to the engine manual Check engine valve clearances Refer to the engine manual 15 Check the engine belt drive system...

Page 76: ...Maintenance Maintenance schedule 4812158801_E pdf 2018 04 03 68...

Page 77: ...ion 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 Diesel engine Che...

Page 78: ...uctions and in the engine manual Flush the system every other year and change the coolant Make sure also that the air flow through the cooler is unobstructed Flush the system every other year and chan...

Page 79: ...ctivate the parking brake switch 1 the brake warning lamp 3 on the instrument panel should come on and the roller should stop After testing the brakes set the forward reverse lever 2 in neutral Inacti...

Page 80: ...y necessary cleaning start the system and check that it works Wear protective goggles when working with compressed air Wear protective goggles when working with compressed air Scrapers Check adjustmen...

Page 81: ...lass Clean around the filler cap 5 before the cap is removed Check that the strainer in the filler pipe is intact Fill with fresh hydraulic fluid of the grade indicated in the Lubricant specification...

Page 82: ...iesel engine Short circuit press the filler gun against a non insulated part of the roller before refueling and against the filler pipe 2 while refueling Stop the diesel engine Short circuit press the...

Page 83: ...e poisoning Air cleaner Checking Change the main air filter Change the air cleaner main filter when the warning lamp on the control panel comes on when the engine is running at maximum speed Change th...

Page 84: ...Cleaning Wipe clean the inside of the cover 2 and the filter housing 5 See the previous illustration Wipe clean on both sides of the outlet pipe Outer edge of outlet pipe Inner edge of outlet pipe Wi...

Page 85: ...ion Fig Grease nipples 1 Bearing articulation 2 Bearing steering cylinder 2 1 Nobody must be allowed near the steering joint when the engine is running Risk of being crushed when the steering is opera...

Page 86: ...lame in the vicinity when checking the electrolyte level Explosive gas is formed when the alternator charges the battery Open the left door of the engine compartment Turn both quick fit screws on the...

Page 87: ...well tightened Clean corroded cable shoes and grease them with acid free Vaseline Always disconnect the negative cable first when disconnecting the battery When connecting the battery always connect t...

Page 88: ...Maintenance 50h 4812158801_E pdf 2018 04 03 80...

Page 89: ...on monoxide poisoning Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Pump drive Oil level Check Filling Fig Pump gear 1 Dipstick 1...

Page 90: ...2 Drain plug 3 Level plug 1 2 3 Place the roller on a level surface so that filler plug 1 is at the top Wipe around the plugs The oil level must reach the level plug 3 If necessary remove the filler...

Page 91: ...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 Drum Checking the oil level...

Page 92: ...1 Grease nipple 1 Lubricate the hinges for the hood side windows and any cab doors with grease Also lubricate the slide rails for the operator s seat and the control table s bearing with grease lubri...

Page 93: ...nd cannot be cleaned Remove the fluid filters 1 and and deliver to environmentally correct handling They are single use filters and cannot be cleaned Make sure that the old sealing rings are not left...

Page 94: ...risk of severe damage to the engine If a blocked filter is not replaced the exhaust fumes will be black and the engine will loose power There is also a risk of severe damage to the engine Backup filt...

Page 95: ...ationary for an extended period e g after being stationary overnight The fuel level should be as low as possible The roller should preferably have been standing with this side slightly lower so that w...

Page 96: ...plug or else all the hydraulic fluid will flow out Drainage must be performed when the roller has been stationary for an extended period e g after being stationary overnight Drain as follows Place a c...

Page 97: ...to leave the reservoir with the fluid Bear cleanliness in mind when working with hydraulic components Before replacing the fluid it is important that the roller has been warmed up for a sufficient len...

Page 98: ...ng Applies to both sides of the drum After warming up place the roller on a flat surface so that the plugs 2 are at the bottom Wipe around the plugs Remove the plug 2 on one side and drain the oil app...

Page 99: ...hinned prior to draining This makes it easier for any contaminants to leave the reservoir with the fluid Bear cleanliness in mind when working with hydraulic components Take great care when draining w...

Page 100: ...nnect the power Collect the oil in a container and dispose of for environmentally correct handling Collect the oil in a container and dispose of for environmentally correct handling Wipe around the pl...

Page 101: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden www dynapac com...

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