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Fayat Group Dynapac CA25, Instruction Manual

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Fayat Group Dynapac CA25 Instruction Manual Download Page 64

 

Maintenance 

– Maintenance schedule 

 

02-17-2021 

4812325897EN  

 64 

Maintenance, every 500 hours of operation 

 

Refer  the  figure  "Revision  and  Inspection  Points

”  to find 

the page number of the sections referred to!  
 
 

22 

Replace the Diesel engine oil and oil filter 

Refer to the engine manual 

2 

Replace the fuel filter and fuel pre-filter 

Refer to the engine manual 

4 

Replace the primary air filter  

 

34 

Check the air conditioning filter 

 

20,11,14 

Check the oil level in rear axle and drum  

 

27 

Check the battery 

 

- 

Check the bolted joints 

 

- 

Check the rubber elements 

 

- 

Cleaning the cartridge ventilation  

 

28 

Check and clean the radiator 

 

 
 

Maintenance, every 1000 hours of operation 

 

Refer  the  figure  "Revision  and  Inspection  Points

”  to find 

the page number of the sections referred to!  
 

7 

Replace the hydraulic fluid filter 

 

34 

Check the air conditioning filter 

 

22 

Replace the Diesel engine oil and oil filter 

Refer to the engine manual 

2 

Replace the fuel filter and fuel pre-filter 

Refer to the engine manual 

4 

Replace the primary and secondary air filter 

 

20 

Replace oil in rear axle differential 

 

21 

Replace oil in the rear axle planetary gears  

 

11 

Check the drum cartridge oil 

 

27 

Check the battery 

 

- 

Check the bolted joints 

 

- 

Check the rubber elements 

 

- 

Cleaning the cartridge ventilation 

 

8,23 

Drain the condensate from hydraulic oil reservoir and 
fuel tank 

 

- 

Check the engine belt tension  

Refer to the engine manual 

30 

Lubricate the forward/reverse lever setting 

 

28 

Check and clean the radiator 

 

16 

Steering hitch - Tightening 

 

Summary of Contents for Dynapac CA25

Page 1: ... manual 4812325897EN Operating Maintenance Vibratory Roller CA25 30 35 Engine Cummins QSF 3 8 From the serial number 10000179xxB006062 10000181xxB005992 10000183xxB006276 Reservation for changes Printed in Brasil ...

Page 2: ......

Page 3: ... 24 Machine description Instruments Controls 27 A C System operation 37 Operation Starting 41 Operation Driving 45 Operation Vibration 46 Operation Braking 49 Miscellaneous 53 Operating instructions Summary 57 Preventive maintenance 58 Maintenance Lubricants and symbols 59 Maintenance Maintenance schedule 61 Scheduled maintenance and lubrication 62 Every 10 hours of operation Daily 62 Maintenance ...

Page 4: ... or serious injury if the warning is ignored CAUTION Marks a danger or hazardous procedure that can result in damage to the machine or property if the warning is ignored Safety information The safety manual supplied with the machine must be read by all roller operators Always follow the safety instructions Do not remove the manual from the machine We recommend that the operator reads the safety in...

Page 5: ... filters drain oil and fuel remnants to environmentally correct disposal This manual contains instructions for periodic maintenance can be performed by the machine operator Additional instructions for the engine can be found in the manufacture s engine manual CE marking and Declaration of conformity Applies to machines marketed in EU EEC This machine is CE marked This shows that on delivery it com...

Page 6: ...e terrain stability conditions are irregular or dangerous use the Roll Over Protection Structure ROPS Always use the seat belt with ROPS 7 Drive slowly in sharp bends 8 Avoid driving across slopes Drive straight up or straight down the slope Operate the machine in first gear and always check the operation of the brakes 9 When operating the machine near the beginning of slopes or holes make sure th...

Page 7: ...used on 17 Do not make any changes or modifications 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 working temperature Braking distances can be longer than normal when the fluid is cold See instructions in the STOP section 19 For your own protection alway...

Page 8: ...rations off and all reservoirs full When driving the machine on a stable floor the application of vibration the speed of the machine on the ground and the lifting of the center of gravity can cause the machine to overturn even on a lower slope indicated in this manual To exit the cab in an emergency release the hammer on the rear right post and break the rear window When operating on slopes or uns...

Page 9: ...eratures however maximum 50 C 122 F the following recommendations apply The Diesel engine can be run at this temperature using normal oil the following oils must be used Hydraulic system mineral oil Shell Tellus 15W40 or equivalent Lower ambient temperatures Risk of freezing Make sure that the cooling system is emptied drained sprayer hoses tanks or that anti freeze has been added to prevent the s...

Page 10: ... pressure jets Fire fighting If the machine catches fire use an BCD class powder fire extinguisher A BC class carbon dioxide fire extinguisher can also be used Roll Over Protective Structure ROPS ROPS approved cab If the machine is fitted with a Roll Over Protective Structure ROPS or ROPS approved cab never carry out any welding or drilling in the structure or cab Never attempt to repair a damaged...

Page 11: ...gnite the oxy hydrogen gas formed around the battery Check that the battery used for jump starting has the same voltage as the dead battery Turn the ignition 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 ba...

Page 12: ...e 2002 44 EC Limit is 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 Electrical system The machine was tested for electromagnetic compatibility EMC in accordance with EN 13309 2000 Construction machinery Noise level The noise level is measured in accordance with the maximum limit described in Resolução Nº 433 do Cons...

Page 13: ...18 9 H1 Height with ROPS cab D 2890 113 8 H1 Height with ROPS cab PD 2890 113 8 H2 Height without ROPS D 2400 94 5 H2 Height without ROPS PD 2400 94 5 D Diameter drum D CA25 CA30 1500 59 CA35 1510 59 4 D Diameter drum PD 1694 66 7 S Thickness drum amplitude Nominal D CA 25 CA30 25 0 98 CA35 30 1 2 S Thickness drum amplitude Nominal PD 20 0 79 K1 Clearance tractor frame 460 18 1 K2 Clearance drum f...

Page 14: ...5D 2276 89 6 B2 Width rear 2130 83 9 O1 Overhang left frame side CA25 PD D CA30 PD D and CA35 PD 63 2 48 CA35 D 73 2 87 O2 Overhang right frame side CA25 CA30 and CA35 PD 63 2 48 CA35 D 73 2 87 R1 Turn radius external CA25 CA30 5650 222 4 CA35 5660 222 8 R2 Turning radius inner CA25 PD D CA30 PD D and CA35 PD 3255 128 1 CA35 D 3245 127 8 W Width drum 2130 83 9 ...

Page 15: ...0 11 400 11 500 lb 24912 25132 25353 CA35D kg 12 100 12 200 12 300 lb 26676 26896 27117 CA35PD kg 12 500 12 600 12 700 lb 27558 27778 27999 Fluid volumes D PD Rear axle Differential 10 liters 10 6 qts Planetary gear standard axle 1 9 liters each 2 qts each Drum gearbox 3 liters 3 2 qts Cartridge 2 2 liters 2 3 qts each Hydraulic oil reservoir 55 liters 14 4 gal Oil in the hydraulic system 80 liter...

Page 16: ...mm 0 07 pol Amplitude High PD 2 0 mm 0 079 pol Amplitude Low D CA25 CA30 0 9 mm 0 035 pol CA35 0 8 mm 0 031 pol Amplitude Low PD 1 1 mm 0 043 pol Vibration frequency amplitude high low D 33 Hz 1 980 vpm Vibration frequency amplitude high low PD 30 Hz 1 800 vpm Centrifugal force amplitude high D 250 kN 56 202 lb Centrifugal force amplitude high PD 270 kN 60 698 lb Centrifugal force amplitude low D ...

Page 17: ...h Traction Control 0 6 8 mph Electrical system Battery 12V 170A Alternator 12V 135A Fuses See the Electrical system section fuses Tire Tire dimensions Tire dimensions Std type 18 4 x 26 0 10 ply 180 kPa 1 8 kg cm2 16psi Diamond type 23 1 x 26 0 12 ply 110 kPa 1 1 kp cm2 16psi Tractor type 23 1 x 26 0 8 ply 110 kPa 1 1 kp cm2 16psi Liquid filled tires extra weight up to 500 kg tire 1100 lbs tire Wh...

Page 18: ...ightening torque 800 Nm With Dacromet treatment The ROPS bolts that will be tightened should be dry Air Conditioning Automatic Climate Control ACC Optional The system described in this manual is an AC ACC type Automatic Climate Control ACC is a system that maintains the set temperature in the cab provided windows and doors are kept closed Coolant weight when full 1 2 kg ...

Page 19: ... 38 M10 40 45 56 62 68 76 M12 70 78 98 110 117 131 M14 110 123 156 174 187 208 M16 169 190 240 270 290 320 M20 330 370 470 520 560 620 M22 446 497 626 699 752 839 M24 570 640 800 900 960 1080 M30 1130 1260 1580 1770 1900 2100 Metric coarse thread zinc treated Dacromet GEOMET STRENGTH CLASS M Thread 10 9 Oiled 10 9 Dry 12 9 Oiled 12 9 Dry M6 12 15 14 6 18 3 M8 28 36 34 43 M10 56 70 68 86 M12 98 124...

Page 20: ...tic system with a hydraulic pump supplying two motors connected in parallel one for the rear axle and one for the drum The speed of the machine is proportional to the angle of the control lever the deflection of the forward reverse lever regulates the speed A speed selector and anti spin system are available as options Brake system The brake system comprises a service brake secondary brake and par...

Page 21: ...ir conditioning is available as an accessory Emergency exit The cab has two emergency exits the door and the rear cab window which can be broken with the emergency hammer located in the cab FOPS and ROPS FOPS is the abbreviation for Falling Object Protective Structure roof protection and ROPS is the abbreviation for Roll Over Protective Structure The cab is approved as a protective cab in accordan...

Page 22: ...ufacturer s name and address the type of machine the PIN product identification number serial number service weight engine power and year of manufacture If the machine is delivered outside the EU there are no CE markings and on some machines the year of manufacture may not be specified Please state the machine s PIN when ordering spares Explanation of 17PIN serial number A Manufacturer B Family Mo...

Page 23: ... plate The engine plate 1 are affixed to the top of the engine The plate specifies the type of engine serial number and the engine specifications Please specify the engine serial number when ordering spares Refer also to the engine manual Fig Engine 1 Engine plate ...

Page 24: ... 8 Hydraulic fluid 15 Coolant 2 Warning Rotating engine parts 9 Lifting point 16 Hydraulic oil level 3 Warning Hot surfaces 10 Fixing point 17 Articulation lock 4 Warning Ballasted tires 11 Master switch 5 Warning Starting gas 12 Manual compartment 6 Emergency exit cab 13 Tires pression 7 Diesel fuel 14 Hoisting plate ...

Page 25: ...faces in the engine compartment Keep your hands at a safe distance 4700903985 Warning Ballasted tire Read the instruction manual 4700903459 Warning Instruction manual The operator must read the safety operation and maintenance instructions before operating the machine 4700791642 Warning Gas shall not be used to start the machine 4700908229 Warning Risk of crushing The articulation must be locked w...

Page 26: ...iption Decals 02 17 2021 4812325897EN 26 Info decals Coolant Diesel fuel Lifting point Hoisting plate Manual compartment Master switch Hydraulic oil Tire pressure Securing point Hydraulic oil level Fire extinguisher ...

Page 27: ...ls Fig Instruments and control panel 1 Ignition switch 2 Emergency stop 3 Vibration on off 4 Manual compartment 5 Forward Reverse lever 6 Seat switch 7 Control protection 8 Membrane panel 9 Traffic lights switch 10 Warning lights switch 11 Direction indicators switch 12 Parking brake switch 13 Control panel 29 13 1 8 10 9 11 2 12 6 2 3 5 7 4 ...

Page 28: ...ne the lever must be in neutral The engine cannot be started if the forward reverse 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 when the lever is move backward the roller moves backward The roller s speed is proportional to the distance the lever is from the neutral position...

Page 29: ...indicators switch optional When pressed to one side the respective indication lights up In the central position the function is turned off 12 Parking brake switch Press the button to activate the parking brake the machine stops the engine running Always use the parking brake when the machine is on a sloping surface 13 Control panel Detailed information on how it operates is given below ...

Page 30: ... TURN OFF LED Transport Mode LEFT LED Work Mode vibration Red Amplitude Selector LEFT LED Amplitude low Red RIGHT LED Amplitude high Work Lights Enables ROPS Cabin work lights TURN OFF LED LEFT LED Turn on the lights on the left side Red RIGHT LED Turn on the lights on the left and right side simultaneously Amplitude high low Work mode Rotating beacon Work lights Gear Selector reduce Gear Selector...

Page 31: ...F LED LEFT LED Turn on Yellow Gear Selector reduce TURN OFF LED Work mode LEFT LED Turtle mode for speed reduction Red Gear Selector increase Enables the machine change function TURN OFF LED LED ESQUERDO Hare mode for speed increase Red Horn Press the button to sound the horn Engine speed selector LEFT LED low speed Red CENTRE LED Eco mode Green RIGHT LED high speed Red ...

Page 32: ...ons F N R and is located in the upper left corner of the Display 2 N neutral Indicates that the lever is in the Neutral position F Forward An arrow facing left in front of the F appears on the display R Reverse An arrow facing right in front of the R appears on the display Hour meter The hourglass icon appears on the left side of the screen indicating the hour meter The number of hours appears to ...

Page 33: ...Compaction mode Compacting status active on the roller 8 Automatic Vibration Control AVC Press one of the buttons 9 on the end of the panel An arrow will appear to the right 10 Press the upper button 9 to display the submenu Pressing the lower button 9 activates the AVC 11 to which after activated its icon will appear in the lower right corner of the display To activate the vibration click on butt...

Page 34: ...ow Selecting this button brings up a list of error codes When the last error code appears scroll the list back up to the first error code 5 The Active Start mode appears when you change the direction of the travel 6 If the submenu remains inactive for more than 20 seconds the screen will return to the Active Start menu 7 When an OK appears in the box to the right below the screen will go blank 8 W...

Page 35: ...sage on the screen 2 Warning lamp Yellow Less serious fault Correct as soon as possible It turns on along with a message on the screen 3 Heating Yellow The symbol must be erased before moving the ignition key to position 2 and activating the starter motor 4 Park brake indicator Red The lamp turns on when the parking brake is activated 5 Fuel level Yellow The symbol is turn on there is less than 10...

Page 36: ...ttom to activate the rear washers 3 Fuse box Contains fuses from the electric system in the cab 4 Air conditioning AC Analogic ventilation control A Analogic temperature control D 5 Compressor switch Actuates the air conditioning compressor B 6 Cab air recirculation switch Activates recirculation function blocking external air entry C 5 Defroster nozzle Turn the defroster nozzle to direct the air ...

Page 37: ...e control panel located on the right roof of the cabin Through this control panel it is possible Control fan speed selector A Actuate the air conditioning compressor switch B Activate recirculation function by blocking the external air entry selector C Control the temperature by opening or closing the heating valve selector D Operation Ventilation To use the ventilation Set the selector A at the d...

Page 38: ...ows Open the windows for a few moments to allow the warm air present inside to be expelled quickly and after a few minutes of air conditioning close the windows and slow down the fan so that a pleasant climate can be achieved inside the cabin To clear the windows on cold or rainy days proceed as follows Keep the windows closed Open all defroster nozzles directing them to the windows Set the select...

Page 39: ...Main fuses There are three main fuses They are located on the battery switch The fuse is a flat pin type Main power 2 40A Orange High Engine ECM 3 30A Green Cab power 4 30A Green The relays are located on the back of the battery switch they are the start relay 3 and the pre heating relay 4 Fig Engine compartment 2 Main fuse 3 Engine fuse 4 Cab fuse Fig Steering compartment 1 Control unit ECU 1 2 4...

Page 40: ...itch alternator vibration switch joystick F5 3A Compaction Meter Speed Sensor F6 10A Stereo System Left Work Lights F7 10A Right Work Lights F8 Spare F9 Spare F10 5A Ignition switch F11 10A Power socket outlet Platform and Rear Dyn link F12 1A ECU memory F13 10A Direction Indicators F14 15A Headlights Position Lights K2 Main Relay K6 1 Right Work Lights K6 2 Left Work Lights K8 Headlights Position...

Page 41: ... the engine canopy must remain unlocked during operation Operator s seat standard Adjustment Adjust the operator s seat so that the position is comfortable and so that the controls are within easy reach There is a scale 50 130 Kg that can be changed according to the weight of the operator The seat can be adjusted longitudinally 1 only from top to bottom to return to the initial position just move ...

Page 42: ...a cab is fitted to the roller always wear the seat belt 1 provided and wear a protective helmet Replace the seat belt 1 if it shows signs of wear or has been subjected to high levels of force Check that rubber elements 3 on the platform are intact Worn elements will impair comfort Ensure that the anti slip 4 on the platform is in good condition Replace where anti slip friction is poor If the machi...

Page 43: ...he rear view mirrors should be correctly adjusted Interlock The roller is equipped with Interlock The Diesel engine with switch off after 4 7 seconds if the operator gets off the seat when going forwards backwards If the parking brake is activated the diesel engine will not stop if the forward reverse lever is moved out of neutral Sit down for all operations Fig View ...

Page 44: ...ong If it does not work wait 60 seconds to try again At the start of the Diesel engine when the ambient temperature is below 10 C 50 F it must be warmed up at idle low speed until the hydraulic oil temperature exceeds 10 C 50 F With a temperature below 0 C 32 F the Diesel engine and hydraulic system must be heated for at least 15 minutes When starting and driving a machine that is cold remember th...

Page 45: ... roller is clear Carefully move the forward reverse lever 5 forwards or backwards depending on which direction of travel is required Speed increases as the lever is moved away from the neutral position The speed should always be controlled by the front rear lever never changing the engine speed Test the emergency stop by pressing the relevant button 2 with the machine at low speed Prepare for a su...

Page 46: ...he forward reverse lever Vibration Switching on Never activate vibration when the roller is stationary This can damage both the surface and the machine Engage and disengage vibration using the switch 3 on the bottom of the forward reverse lever Vibration should only be activated at high or low speed Always switch off vibration before the roller comes to a standstill Fig Control panel 8 Amplitude s...

Page 47: ...lot on PD the readings may not give any sure conclusions However ABC is still active The ABC is only possible to disable via the service tool Setting CMV limit The compaction meter value view in display will give the operator all information needed during compaction engine rpm gear position speed frequency and inclinations are in display together with actual CMV and the limit set in brackets Use t...

Page 48: ... frequency Some CMV references for compacted materials Material CMV Rocking 40 200 Gravel 25 100 Sand 20 60 Silte 5 30 Clay 0 80 The water content in the compacted soil not relevant for rock fill has a large influence on stiffness wet soil will result in low values and dry soil will result in higher values When double jump occurs the value CMV will be reduced these lower values should not be used ...

Page 49: ...and pull the button 1 If the machine is equipped with the Interlock function it will be necessary to occupy the operator s seat for the engine to start again Normal braking Press the switch 3 to switch off the vibration Move the forward reverse lever 4 to the neutral position to stop the roller Set the speed control regulator to the idle low position Set the parking brake switch to active position...

Page 50: ...h 1 to the disconnected position and remove the key This will prevent battery discharging and will also make it difficult for unauthorized persons to start and operate the machine Also lock the hood to the engine compartment Chocking the drums Never disembark from the machine when the is engine running unless the parking brake is activated Make sure that the roller is parked in a safe place with r...

Page 51: ...ngine Refer to the manufacturer s instructions in the engine manual that is supplied with the roller Battery Dismantle the battery from the machine Clean the battery check that the electrolyte level is correct and give it a maintenance charge once a month Air cleaner exhaust pipe Cover the air cleaner or its opening with plastic or tape Also cover the exhaust pipe opening This is to avoid moisture...

Page 52: ...ompartment and cab doors Lubricate both ends of the forward reverse lever chrome parts 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 in a building where the temperature is constant Tires All weather Check that tire pressure is 110 ...

Page 53: ...ert the safety pin 1 into the holes in the arm 2 and secure the lock pin with the safety pin 3 Lifting the roller The machine s gross weight is specified on the hoisting plate 1 Refer also to the Technical specifications Lifting equipment such as chains steel wires straps and lifting hooks must be dimensioned in accordance with the relevant safety regulations for the lifting equipment Stand well c...

Page 54: ...instructions below Alternative 1 Short distance towing with the engine running Activate the parking emergency brake and temporarily stop the engine Chock the wheels to prevent the roller from moving Loosen both towing valves 1 middle hex nut three turns to the left holding the multi function valve 2 lower hex nut stationary The valves are on the forward drive pump Start the engine and allow it to ...

Page 55: ...covering the roller must be braked by the towing vehicle A towing bar must be used as the roller has no brakes The roller must be towed slowly max 3 km h 2 mph and only towed short distances max 300 m 330 yards When towing retrieving a machine the towing device must be connected to both lifting holes The pulling force must act longitudinally on the machine as shown in the figure Maximum gross pull...

Page 56: ...rs 1 and then attach them to the transport vehicle Place supports under the cylinder frame 2 to avoid overloading the roller suspension when it is held by tensioning cables Secure the machine with stretch handle 3 on all four corners The adhesives indicate the fixing points Remember to unlock the articulation before starting the roller Fig Transport 1 Chocks 2 Support 3 Stretch handle ...

Page 57: ...um starting position 10 Drive the roller Operate the F R lever with care 11 Test the brakes Remember that the braking distance will be longer if the hydraulic fluid is cold 12 Use vibration only when the roller is in motion 13 In an emergency Press the parking emergency brake button Hold the steering wheel firmly Brace yourself for a sudden stop 14 When parking Press the reserve parking brake butt...

Page 58: ...y 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 stipulated delivery inspection and the separate service inspection have been completed as per the warranty document and when the mac...

Page 59: ...2161867 5L P N 4812161868 20L TRANSMISSION OIL Air temperature 15 C 40 C 5 F 104 F Air temperature 0 C 32 F above 40 C 104 F Dynapac Gear oil 300 Shell Spirax S2 ALS 85W 140 P N 4812161883 5L P N 4812161884 20L CARTRIDGE OIL Air temperature 15 C 40 C 5 F 104 F Dynapac Drum Oil 1000 P N 4812161887 5L P N 4812161888 20L GREASE Dynagrease P N 4812030096 0 4 Kg FUEL See engine manual COOLANT Anti free...

Page 60: ... 4812325897EN 60 Maintenance symbols Engine oil level Tire pressure Engine oil filter Air filter Hydraulic reservoir level Battery Hydraulic fluid filter Recycling Transmission oil level Fuel filter Drum oil level Coolant level Oil for lubrication ...

Page 61: ...sel fuel filling 3 Oil level Diesel engine 15 Rubber elements and fastening screws 27 Battery 4 Air filter 16 Steering hitch 28 Water radiator 5 Hydraulic reservoir sight glass 17 Steering cylinders x2 29 Drive belts 6 Bleeding filter 18 Wheel nuts 30 Forward Reverse lever 7 Hydraulic oil filter 19 Tires pressure 31 Engine cover 8 Drainage hydraulic oil reservoir 20 Rear axle differential 32 Diese...

Page 62: ...tified personnel Park the compactor on a flat surface Always check and adjust the machine shut off the engine and confirm that the Forward Reverse lever is in the Neutral position When the engine is running indoors make sure that there is sufficient air inlet to avoid carbon monoxide poisoning Maintenance 10 hours Every 10 hours of operation Daily Refer the figure Revision and Inspection Points to...

Page 63: ... Check clean the air filter elements Replace as required 16 Lubricate the central joint 17 Lubricate the steering cylinders 30 Check the forward reverse lever adjust 18 Check the tires pressure 19 Check the tightness of the wheel nuts Maintenance every 250 750 hours of operation Refer the figure Revision and Inspection Points to find the page number of the sections referred to 22 Replace the Diese...

Page 64: ... operation Refer the figure Revision and Inspection Points to find the page number of the sections referred to 7 Replace the hydraulic fluid filter 34 Check the air conditioning filter 22 Replace the Diesel engine oil and oil filter Refer to the engine manual 2 Replace the fuel filter and fuel pre filter Refer to the engine manual 4 Replace the primary and secondary air filter 20 Replace oil in re...

Page 65: ...e engine manual 4 Replace the primary and secondary air filter 20 Replace oil in rear axle differential 21 Replace oil in the rear axle planetary gears 9 Replace the hydraulic oil 11 Replace the drum cartridge oil 12 Replace the oil in the drum gearbox 28 Replace engine coolant 27 Check the battery Check the bolted joints Check the rubber elements Cleaning the cartridge ventilation 8 23 Drain the ...

Page 66: ...Maintenance Maintenance schedule 02 17 2021 4812325897EN 66 Maintenance Schedule Check the machine s hour meter for the type of maintenance required ...

Page 67: ... the screws 1 then adjust each scraper tooth 2 to 25 mm 1 in between scraper tooth and drum Center each scraper tooth 2 between the pads Tighten the screws 1 Air circulation Check Ensure that the engine has free circulation of cooling air through the protective grille in the hood To open the engine hood turn the lock handle 1 upward Raise the hood to its fully open position checking that the red s...

Page 68: ...tions and in the engine manual Diesel engine Check oil level Take care not to touch any hot parts of the engine or the radiator when removing the dipstick Risk for burns Pull up the dipstick 1 and check that the oil level is between the upper and lower marks For further details refer to the engine s instruction manual Hydraulic reservoir Check oil level The sight glass is located on the right side...

Page 69: ...ard slowly Hold in the steering wheel and prepare for a sudden stop Press the parking brake button 1 The machine should stop abruptly while the engine is running After checking the brakes place the forward reverse lever in neutral Reactivate the parking brake switch 1 The machine is ready to operate Emergency stop Move the machine forward slowly Hold in the steering wheel and prepare for a sudden ...

Page 70: ...nment friendly waste disposal station This is a single use filter and cannot be cleaned Make sure that the old sealing ring is not left on the filter holder otherwise this could cause leakage between the new seal and the old one Clean carefully around the filter holder s sealing surfaces Apply a thin coat of fresh hydraulic fluid on the new filter seal First tighten the filter until its seal is in...

Page 71: ...ith new lubricant oil See lubricant specifications for more information about quality Drum gearbox Oil change Place the machine on a flat surface so that the plugs 1 and 2 are in the position shown in the figure Clean and remove the plugs 1 2 3 and drain the oil into a container with a capacity of approximately 3 0 liters Replace the plug 1 and fill up with oil up to the level plug 3 in accordance...

Page 72: ...sk of being crushed when the steering is operated Switch off the engine and activate the parking brake before lubrificating The easiest way to identify if you have this type of steering hitch is that has a new type of nut 1 at the top as shown Actual torque Nm should be when the machine s position is straight ahead M16 174 Nm 1 Fig Sterring hitch 1 Nut ...

Page 73: ...ve the backup filter 4 Clean the air filter if necessary see section Air Filter Clean When replacing the main filter 3 insert a new filter and refit the air cleaner in the reverse order Check the condition of the dust valve 6 replace if necessary When refitting the cover make sure that the dust valve is positioned downwards Air filter Clean Clean the inside of the cover 2 and the filter housing 5 ...

Page 74: ...tion point Check that the grease penetrates the bearings If the grease does not penetrate the bearings it may be necessary to relieve the central articulation with a hydraulic jack and simultaneously repeat the operation Forward Reverse lever Adjusting Make sure the forward reverse lever is firmly in your place If you want to adjust the firmness of the lever make pressure adjustment 19mm or wrench...

Page 75: ...chnical Specifications When changing the tires it is important that both of them have the same rolling radius This is necessary to ensure proper functioning of the anti slip in the rear axle Check the tightening torque of the wheel nuts 2 at 630 Nm 465 lbf ft Check both wheels and all nuts This only applies to a new machine or newly fitted wheels Check the safety manual that accompanies the roller...

Page 76: ...r at the same time Refer to the engine manual Value of plug tightening torque 24 N m Hand in the drained oil and filter to an environment friendly waste disposal station Diesel engine Fuel filter and pre filter Replace Remove the threaded fuel filter using the filter wrench Lubricate the O ring with clean engine oil Do not pre fill the engine fuel filter Install the filter in the filter head Tight...

Page 77: ...in a dusty environment Rear axle differential Check oil level Never work under the roller when the engine is running Park on a level surface Block the wheels securely Wipe clean and remove the level plugs 1 and check that the oil level reaches the lower edge of the plug holes If the level is low remove the filler plug 2 and top up with oil to the correct level Use transmission oil refer lubricant ...

Page 78: ...Drum cartridge Checking the oil level Position the roller on a flat surface with the plug 1 and drum number plate 2 are visible on the right side The oil level should now reach the sight glass 3 If necessary remove the plug 1 and fill to the middle of the sight glass Clean the magnetic filler plug 1 of any metallic residue before refitting the plug Refer to the correct oil grade in the lubricant s...

Page 79: ...nozzle too close to the radiator When disconnecting the battery always disconnect the negative cable first When connecting the battery always connect the positive cable first Dispose of batteries properly The battery contains environmentally harmful lead When performing welding work on the machine disconnect the battery cable and then all the cables connected to the alternator Bolted joints Check ...

Page 80: ... to eliminate excess pressure inside the drum Radiator Check Cleaning Check that air can pass unobstructed through the radiators 1 2 and 3 Clean a dirty radiator using compressed air or a high pressure water jet Blow air or direct water through the cooler in the opposite direction to that of the cooling air Be careful when using a high pressure washer do not place the nozzle too close to the radia...

Page 81: ...at the same time Refer to the engine manual Value of plug tightening torque 24 N m Hand in the drained oil and filter to an environment friendly waste disposal station Diesel engine Fuel filter and pre filter Replace Remove the threaded fuel filter using the filter wrench Lubricate the O ring with clean engine oil Do not pre fill the engine fuel filter Install the filter in the filter head Tighten...

Page 82: ...ere is a fresh air filter 1 located at the front of the cab Remove the three screws 2 and remove the protective cover Clean or replace them with new filters It may be necessary to change the filters more often if the machine is working in a dusty environment Rear axle differential Check oil level Never work under the roller when the engine is running Park on a level surface Block the wheels secure...

Page 83: ...Drum cartridge Checking the oil level Position the roller on a flat surface with the plug 1 and drum number plate 2 are visible on the right side The oil level should now reach the sight glass 3 If necessary remove the plug 1 and fill to the middle of the sight glass Clean the magnetic filler plug 1 of any metallic residue before refitting the plug Refer to the correct oil grade in the lubricant s...

Page 84: ...nozzle too close to the radiator When disconnecting the battery always disconnect the negative cable first When connecting the battery always connect the positive cable first Dispose of batteries properly The battery contains environmentally harmful lead When performing welding work on the machine disconnect the battery cable and then all the cables connected to the alternator Bolted joints Check ...

Page 85: ... to eliminate excess pressure inside the drum Radiator Check Cleaning Check that air can pass unobstructed through the radiators 1 2 and 3 Clean a dirty radiator using compressed air or a high pressure water jet Blow air or direct water through the cooler in the opposite direction to that of the cooling air Be careful when using a high pressure washer do not place the nozzle too close to the radia...

Page 86: ... a thin coat of fresh hydraulic fluid on the new filter seal First tighten the filter until its seal is in contact with the filter attachment Then turn an additional half revolution Do not tighten the filter too hard as this could damage the gasket Start the engine and check that there is no leakage of hydraulic fluid from the filter Check level of fluid in the sight glass 3 and top up as required...

Page 87: ...ne manual Value of plug tightening torque 24 N m Hand in the drained oil and filter to an environment friendly waste disposal station Diesel engine Fuel filter and pre filter Replace Remove the threaded fuel filter using the filter wrench Lubricate the O ring with clean engine oil Do not pre fill the engine fuel filter Install the filter in the filter head Tighten the filter until the gasket touch...

Page 88: ...ards Rear axle differential Oil change Never work under the roller when the engine is running Park on a level surface Block the wheels securely Clean and remove the three level filler plugs 1 and 3 and all three drain plugs 2 The level filler plugs are located on the front and rear of the axle and the drain plugs are located on the underside and rear Drain the oil into a container The volume is ap...

Page 89: ...vironmentally correct handling Rear axle planetary gear Oil change Oil filler Position the roller so that the plug 1 in the planetary gear is at 9 o clock Clean and remove the plug Fill with oil to lower edge of level hole Use transmission oil See the lubrication specification Clean and refit the plug 1 Check the fluid level in the same way on the rear axle s other planetary gear 2 Fig Oil drain P...

Page 90: ...de in the lubricant specification Do not overfill with oil risk for overheating Bolted joints Check Steering pump to Diesel engine 1 55 N m lightly lubricated Rear axle suspension 2 330 N m 243 ft lbf oiled Engine suspension 3 Check if all M12 bolts 20 pieces are tightened with 70 N m and lightly greased Wheel nuts 4 Check if all nuts are tight 630 N mm and oiled The above information is valid onl...

Page 91: ...with high pressure water and do not place the jet nozzle too close to the radiator When disconnecting the battery always disconnect the negative cable first When connecting the battery always connect the positive cable first Dispose of batteries properly The battery contains environmentally harmful lead When performing welding work on the machine disconnect the battery cable and then all the cable...

Page 92: ... roller after it has been stationary for a long time e g after standing overnight The fuel level should be as low as possible The roller should preferably have been standing with this side somewhat lower so that water and sediment will gather near the drainage plug 1 Drain as follows Place a container under the cock Loosen the drain plug 1 Then open the drain plug and drain out water and sediment ...

Page 93: ...iendly waste disposal station Take great care when draining warm fluid and oil Wear protective gloves and goggles Diesel engine Check the belt tension Check the position of the belt in the tension pulley it should be centered if the belt has too much wear replace it Refer the engine manual for more information Controls Lubrication Lubricate the mechanical throttle forward reverse system Remove the...

Page 94: ...otective goggles when working with compressed air or high pressure water jets Steering hitch Tightening Nobody must be allowed near the steering joint when the engine is running Risk of being crushed when the steering is operated Switch off the engine and activate the parking brake before lubrificating The easiest way to identify if you have this type of steering hitch is that has a new type of nu...

Page 95: ...in coat of fresh hydraulic fluid on the new filter seal First tighten the filter until its seal is in contact with the filter attachment Then turn an additional half revolution Do not tighten the filter too hard as this could damage the gasket Start the engine and check that there is no leakage of hydraulic fluid from the filter Check level of fluid in the sight glass 3 and top up as required Air ...

Page 96: ...ne manual Value of plug tightening torque 24 N m Hand in the drained oil and filter to an environment friendly waste disposal station Diesel engine Fuel filter and pre filter Replace Remove the threaded fuel filter using the filter wrench Lubricate the O ring with clean engine oil Do not pre fill the engine fuel filter Install the filter in the filter head Tighten the filter until the gasket touch...

Page 97: ...ards Rear axle differential Oil change Never work under the roller when the engine is running Park on a level surface Block the wheels securely Clean and remove the three level filler plugs 1 and 3 and all three drain plugs 2 The level filler plugs are located on the front and rear of the axle and the drain plugs are located on the underside and rear Drain the oil into a container The volume is ap...

Page 98: ...vironmentally correct handling Rear axle planetary gear Oil change Oil filler Position the roller so that the plug 1 in the planetary gear is at 9 o clock Clean and remove the plug Fill with oil to lower edge of level hole Use transmission oil See the lubrication specification Clean and refit the plug 1 Check the fluid level in the same way on the rear axle s other planetary gear 2 Fig Oil drain P...

Page 99: ...lug 1 is perpendicular Place a receptacle for about 5 liters 1 32 gal under the drain plug 2 Observe care when draining drum oil hot drum oil Wear protective gloves and goggles Save the oil and hand in to an environment friendly waste disposal station Clean and unscrew the filler plug 1 and the drain plug 2 Allow all the oil to run out Fit the drain plug and fill with new lubricant oil See the lub...

Page 100: ...w freezing point the engine should be running for some time after adding the distilled water Otherwise there is a risk of the electrolyte freezing Check that the ventilation holes in the element caps are clogged and then place the cap The cable shoes should be clean and tightened Corroded cable shoes should be cleaned and greased with acid proof vaseline Be careful when washing with high pressure ...

Page 101: ...ts and fastening screws Check Check all rubber elements 1 replace all of the elements if more than 25 of them on one side of the drum are cracked deeper than 10 15 mm 0 4 0 6 in Check using a knife blade or pointed object Check also that the screw fasteners 2 are tightened Drum cartridge Cleaning the ventilation Clean the drum s ventilation hole and ventilation screw 1 The hole is required to elim...

Page 102: ...drain plug and drain out water and sediment until only pure diesel fuel emerges at the plug Screw the drainage plug again Store the waste and the oil and take them to a waste disposal station with environmental rules Hydraulic reservoir Draining The condensate from the hydraulic reservoir is drained through the drain cock 1 Drain the roller after it has been stationary for a long time e g after st...

Page 103: ...lements Refit the cover Radiator Check Cleaning Check that air can pass unobstructed through the radiators 1 2 and 3 Clean a dirty radiator using compressed air or a high pressure water jet Blow air or direct water through the cooler in the opposite direction to that of the cooling air Be careful when using a high pressure washer do not place the nozzle too close to the radiator Wear protective go...

Page 104: ... crushed when the steering is operated Switch off the engine and activate the parking brake before lubrificating The easiest way to identify if you have this type of steering hitch is that has a new type of nut 1 at the top as shown Actual torque Nm should be when the machine s position is straight ahead M16 174 Nm 1 Fig Sterring hitch 1 Nut ...

Page 105: ...story 02 17 2021 4812325897EN 105 Revision DATE VERSION MODIFICATION 08 07 2020 0 General 10 07 2020 1 Dynapac oils part number added in symbols and lubrificants 02 17 2021 2 Steering hitch torque adjustment added ...

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Page 107: ...Dynapac do Brasil Industria e Comercio de Maquinas Ltda Rua Georg Schaeffler 430 Sorocaba SP Brasil Tel 55 15 3412 7500 Fax 55 15 3412 7522 www dynapac com ...

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