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Fayat Group DYNAPAC CA2500, Instruction Manual, Page: 3 / 176

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Fayat Group DYNAPAC CA2500 Instruction Manual Download Page 3

2000h-

Maintenance

4812162601_G.pdf

2021-04-14

Table of Contents

Introduction .............................................................................................................................. 1

The machine ............................................................................................... 1

Intended use ............................................................................................... 1

Training ....................................................................................................... 1

Signal symbols and meaning ...................................................................... 1

Safety information ....................................................................................... 1

General ....................................................................................................... 2

CE marking and Declaration of conformity.................................................. 3

Safety - General instructions.................................................................................................... 5

Safety - when operating ........................................................................................................... 7

Driving near edges ...................................................................................... 7

Work driving ................................................................................................ 8

Safety (Optional) ...................................................................................................................... 9

Air conditioning............................................................................................ 9

Special instructions ................................................................................................................ 11

Standard lubricants and other recommended oils and fluids .................... 11

Higher ambient temperatures, above +40°C (104°F)................................ 11

Temperatures............................................................................................ 11

High pressure cleaning ............................................................................. 11

Fire fighting ............................................................................................... 12

Roll Over Protective Structure (ROPS), ROPS approved cab .................. 12

Welding ..................................................................................................... 12

Battery handling ........................................................................................ 12

Jump starting (24V)................................................................................... 13

Technical specifications ......................................................................................................... 15

Vibrations - Operator station ..................................................................... 15

Noise level................................................................................................. 15

Electrical system ....................................................................................... 15

Slopes ....................................................................................................... 15

Dimensions, side view............................................................................... 16

Summary of Contents for DYNAPAC CA2500

Page 1: ...SF 3 8 IV T4F Cummins QSF 3 8 IV T4F Cummins F 3 8 V T4F Cummins F 3 8 V T4F Serial number Serial number 10000167xxA015825 10000167xxA015825 10000168xxA018468 10000168xxA018468 10000187xxA031260 10000...

Page 2: ......

Page 3: ...Work driving 8 Safety Optional 9 Air conditioning 9 Special instructions 11 Standard lubricants and other recommended oils and fluids 11 Higher ambient temperatures above 40 C 104 F 11 Temperatures 11...

Page 4: ...25 Machine description 27 Diesel engine 27 Electrical system 27 Propulsion system Transmission 27 Brake system 27 Steering system 27 Vibration system 28 Cab 28 FOPS and ROPS 28 Identification 29 Produ...

Page 5: ...st cleaning lamp disabled inhibit 50 Dynapac Sub System DSS 51 MAIN MENU 52 USER SETTINGS 52 MACHINE SETTINGS 53 SERVICE MENU 53 ABOUT 54 Operator help when starting 55 Operator help Workmode 55 Displ...

Page 6: ...anel adjustments 69 Parking brake 69 Display Control 70 Interlock 71 Operator position 71 View 72 Starting 73 Starting the engine 73 Driving 74 Operating the roller 74 Machine with gear change in sepa...

Page 7: ...83 Normal braking 83 Emergency braking 83 Switching off 84 Parking 84 Chocking the drums 84 Master switch 85 Long term parking 87 Engine 87 Battery 87 Air cleaner exhaust pipe 87 Fuel tank 87 Hydrauli...

Page 8: ...intenance schedule 103 Service and maintenance points 103 General 103 Periodic service service message Optional 104 Every 10 hours of operation Daily 105 After the FIRST 50 hours of operation 105 Ever...

Page 9: ...s 121 Pre fuel filter Draining 122 Maintenance measures 250 h 123 Drum cartridge Checking the oil level 123 Drum cartridge Cleaning the ventilation screw 124 Rear axle differential Check oil level 124...

Page 10: ...135 Seat bearing Lubrication 136 Maintenance 1000h 137 Hydraulic filter Replacement 137 Drum cartridge Checking the oil level 138 Drum cartridge Cleaning the ventilation screw 139 Drum cartridge Oil...

Page 11: ...2 Backup filter Change 153 Air cleaner Cleaning 154 Rear axle planetary gear Oil change 154 Rear axle differential Oil change 155 Drum gearbox Oil change 156 Radiator Check Cleaning 156 The engine fue...

Page 12: ...e 4812162601_G pdf 2021 04 14...

Page 13: ...Further information on operator training can be found in ISO 7130 Signal symbols and meaning WARNING Indicates potential hazardous situation procedure which if not avoided could result in death or ser...

Page 14: ...nance Read the entire manual before starting the machine and before carrying out any maintenance Replace immediately the instruction manuals if lost damaged or unreadable Replace immediately the instr...

Page 15: ...iodic maintenance where maintenance after every 10 and 50 hours of operation can be performed by the machine operator Other maintenance intervals must be carried out by accredited Dynapac service pers...

Page 16: ...Introduction 4812162601_G pdf 2021 04 14 4...

Page 17: ...have full bearing strength or the edge is close to a slope Avoid operating close to edges and ditches and the like as well as on poor ground conditions that jeopardizes the bearing strength and capaci...

Page 18: ...de after written approval has been given by Dynapac Avoid using the roller before the hydraulic fluid has reached its normal working temperature Braking distances can be longer than normal when the fl...

Page 19: ...nd operate the machine only when the person is fully visible or has given a clear indication of where he or she is Avoid driving across a slope Drive straight up and down sloping ground Avoid driving...

Page 20: ...ed cab and seat belt usage Avoid operating close to edges and ditches and the like as well as on poor ground conditions that jeopardizes the bearing strength and capacity to support the roller Pay att...

Page 21: ...n result in serious personal injury Do not disconnect or undo the hose couplings The cooling system is pressurized Incorrect handling can result in serious personal injury Do not disconnect or undo th...

Page 22: ...Safety Optional 4812162601_G pdf 2021 04 14 10...

Page 23: ...additional equipment such as noise suppression may need to be more carefully monitored in the higher temperature ranges High pressure cleaning Do not spray directly onto electrical components Do not u...

Page 24: ...g in the structure or 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 repa...

Page 25: ...tery A spark can ignite the oxy hydrogen gas formed around the battery Check that the battery used for jump starting has the same voltage as the dead battery Check that the battery used for jump start...

Page 26: ...Special instructions 4812162601_G pdf 2021 04 14 14...

Page 27: ...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...

Page 28: ...60 CA3500 CA4000 1520 60 D Diameter drum PD D Diameter drum PD CA2500 1490 58 5 CA2500 1490 58 5 CA3500 CA4000 1500 59 CA3500 CA4000 1500 59 S Thickness drum amplitude Nominal D S Thickness drum ampl...

Page 29: ...4 1 CA2500 105 4 1 CA3500 CA4000 87 3 4 CA3500 CA4000 87 3 4 O2 Overhang right frame side O2 Overhang right frame side CA2500 105 4 1 CA2500 105 4 1 CA3500 CA4000 87 3 4 CA3500 CA4000 87 3 4 R1 Turn r...

Page 30: ...13 300 CA4000D PD kg 13 100 13 300 lbs 28 890 29 330 lbs 28 890 29 330 Fluid volumes Fluid volumes Fuel tank 255 liters 67 3 gal Fuel tank 255 liters 67 3 gal Urea tank Urea tank CA2500 CA3500 20 lit...

Page 31: ...Hz 1 980 2 040 vpm 1 980 2 040 vpm CA3500D 31 30 34 30 Hz Std High CA3500D 31 30 34 30 Hz Std High 1 860 1 800 2 040 1 800 vpm 1 860 1 800 2 040 1 800 vpm CA2500PD CA3500PD 30 30 Hz CA2500PD CA3500PD...

Page 32: ...km h mph 11 5 7 12 5 8 TC NoSpin Rear axle TC NoSpin Rear axle 1st gear km h mph 4 5 3 4 2 5 1st gear km h mph 4 5 3 4 2 5 2nd gear km h mph 6 3 5 7 4 5 2nd gear km h mph 6 3 5 7 4 5 3rd gear km h mp...

Page 33: ...gear km h mph 12 7 5 12 5 8 TC NoSpin Rear axle TC NoSpin Rear axle 1st gear km h mph 4 2 5 4 2 5 1st gear km h mph 4 2 5 4 2 5 2nd gear km h mph 5 5 3 5 6 3 5 2nd gear km h mph 5 5 3 5 6 3 5 3rd gea...

Page 34: ...5 4 5 3rd gear km h mph 7 5 4 5 7 5 4 5 4th gear km h mph 12 7 5 12 5 8 4th gear km h mph 12 7 5 12 5 8 TC NoSpin Rear axle TC NoSpin Rear axle 1st gear km h mph 4 2 5 4 2 5 1st gear km h mph 4 2 5 4...

Page 35: ...pm parts per million or less Higher sulphur contents cause operating problems and put the useful life of components at risk which can lead to engine trouble Tier 4 F Stage IV V Cummins engines require...

Page 36: ...Electrical system section fuses Fuses See the Electrical system section fuses Hydraulic system Opening pressure MPa Opening pressure MPa Drive system 42 Drive system 42 Supply system 2 2 Supply system...

Page 37: ...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 38: ...Technical specifications 4812162601_G pdf 2021 04 14 26...

Page 39: ...he 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 s...

Page 40: ...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...

Page 41: ...d serial numbers 3 Cab ROPS plate Certification product and serial numbers 3 Cab ROPS plate Certification product and serial numbers 4 Component plate rear axle Product and serial numbers 4 Component...

Page 42: ...pe 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 ma...

Page 43: ...ngine The plates specify the type of engine serial number and the engine specification Please specify the engine serial number when ordering spares Refer also to the engine manual On certain machines...

Page 44: ...fluid Biological hydraulic fluid 4700272372 4700792772 6 Warning Ballasted tires 4700903985 17 Diesel fuel 4811000345 6 Warning Ballasted tires 4700903985 17 Diesel fuel 4811000345 7 Warning Locking...

Page 45: ...egible and remove dirt or order new decals if they have become illegible Use the part number specified on each decal If a part is replaced and this part have a decal make sure to also order the decal...

Page 46: ...aintenance instructions before operating the machine 4700903985 Warning Ballasted tire Read the instruction manual More information in section in Technical specifications 4700908229 Warning Risk of cr...

Page 47: ...Machine description 4812162601_G pdf 2021 04 14 4812129673 Warning CALIFORNIA Proposition 65 35...

Page 48: ...ook compartment Master switch Hoisting plate Handbook compartment Master switch Hydraulic fluid Biological hydraulic fluid Securing point Hydraulic fluid Biological hydraulic fluid Securing point Tire...

Page 49: ...e off blade Up 17 Reserve 29 1 Gear position switch Dip 6 Strike off blade Down 18 Increase in frequency 30 N A 6 Strike off blade Down 18 Increase in frequency 30 N A 7 Central warning indicator 19 R...

Page 50: ...First push will start vibrations second push will stop vibrations 4 Vibration on off First push will start vibrations second push will stop vibrations 5 Strike off blade up Optional Raises the strike...

Page 51: ...urn ON 21 Horn Press to sound the horn 21 Horn Press to sound the horn 22 Emergency stop Brakes the roller and switches off the engine The power supply goes off NB When starting the machine the emerge...

Page 52: ...n 3 Wheelspin and 4 Tortoise The current gear position is shown in the display by means of the following figures 29 Gear position switch Dip Activates the four different gear positions 1 Hare 2 Drum s...

Page 53: ...ode shown in the display Communication with the engine is interrupted Communication with the engine is interrupted The engine temperature is too high The engine temperature is too high Low oil pressur...

Page 54: ...tarted before any active screen choice is made the display will switch over to main screen This screen gives an overview and is kept during work The speed is shown in the middle of the display km h or...

Page 55: ...step at once Pressing the button approx 2 sec displays the main menu again Exit Return button returns 1 step at once Pressing the button approx 2 sec displays the main menu again Fig Temperature scre...

Page 56: ...ngine functions The message which consists of an SPN and FMI code can be interpreted via the engine supplier error code list The alarm message shown is acknowledged by pressing the OK button on the di...

Page 57: ...fluid temperature coldl If the symbol is displayed the hydraulic oil is cold and the speed cannot be increased until the oil has reached 0 C 32 F The maximum speed cannot be used between 0 C 32 F and...

Page 58: ...s restored once the Urea has been refilled 0 When the level drops close to zero the Urea level symbol flashes together with the icon for reduced power and the Yellow warning lights on the panel The op...

Page 59: ...he panel The operator should drain and refill the Urea tank with new Urea If the Urea tank is not refilled engine power is reduced and normal power is restored once the Urea has been refilled 4 In the...

Page 60: ...he exhaust system s after treatment gives a flashing Tampering symbol together with the icon for reduced power and the Yellow warning lights on the panel Engine power is reduced Immediately contact Se...

Page 61: ...system has not auto regenerated at the required time limit and requires an exhaust system cleaning See machine settings EAT Cleaning The Exhaust System Cleaning Regeneration Lamp notifies the operato...

Page 62: ...AT Cleaning 3 The Exhaust System Cleaning Regeneration Lamp notifies the operator that the aftertreatment system has not auto regenerated at the required time limit and requires an exhaust system clea...

Page 63: ...tion frequency meter Supervision only active if Adjustable frequency or ECO available Optional 8 Power group 1 see Fuse 3 8 Power group 1 see Fuse 3 9 Power group 2 see Fuse 4 9 Power group 2 see Fuse...

Page 64: ...e user and machine settings access the service menu for calibration purposes special service personnel only requires pin code and to see the version of installed software USER SETTINGS Users can chang...

Page 65: ...regeneration can be done and the parking button must be activated and that low speed is selected then the speed will increase to 1000 1200rpm for 20 45 minutes depending on the soot load Note that the...

Page 66: ...the display and requires special equipment and know how EDC CALIBRATION To calibrate move the joystick fully forward F and press in both black buttons on the top of the joystick See also manual W3025...

Page 67: ...be set before it is possible to start the machine Conditions that must be set Activated P brake Selector lever in neutral Speed selector for diesel engine in low Low idling not all models Operator he...

Page 68: ...splay of alarm see table for information High amplitude Low amplitude Strike off blade Vibration is enabled in the operating position Automatic vibration control If the function is activated via the r...

Page 69: ...achine description 4812162601_G pdf 2021 04 14 Instruments and controls cab Fig Right rear cab post 15 Hammer for emergency exit ACC Heater AC 10 14 Radio CD 8 9 15 1 2 3 4 5 6 7 Fig Cab roof front 57...

Page 70: ...ate the front screen wiper 5 Front wiper switch Press to operate the front screen wiper 6 Rear wiper switch Press to operate the rear screen wiper 6 Rear wiper switch Press to operate the rear screen...

Page 71: ...d if necessary turn down the heat and fan speed AC ACC NOTE When using AC ACC all the windows must be closed for the system to work efficiently To quickly reduce the temperature in the cab adjust the...

Page 72: ...2 Mode Displays the mode Automatic Heat Cool and Defrost 3 Temperature Set point Displays current inside set point temperature 4 Blower speed Displays current blower speed setting ACC Operation menus...

Page 73: ...s turned off while warming Heat is selected Heat Interior temperature warms up with the electronic heater valve A C compressor is turned off while warming Heat is selected Defrost When defrosting Defr...

Page 74: ...t will be turned off the blower will run at 15 the heater valve will be fully opened and the air circulation will switch to fresh air until the after coil temperature is above 20 C 78 F When the after...

Page 75: ...splay 5A 10 DEF Supply module 15A 3 ECU PWR1 Speed sensor 10A 11 12V outlet Radio 24 12V converter gateway Dyn lyzer 10A 3 ECU PWR1 Speed sensor 10A 11 12V outlet Radio 24 12V converter gateway Dyn ly...

Page 76: ...arter relay 4 and preheating relay 5 and fuses 6 7 are placed behind the battery disconnector plate 3 6 7 5 4 4 Starter relay 5 Preheating relay 6 Fuse engine ECU 30A F13 7 Fuse 10A F23 Fuse box at ma...

Page 77: ...b roof fuse box F7 1 Interior lighting 10A 1 Interior lighting 10A 2 Windscreen wiper washers 10A 2 Windscreen wiper washers 10A 3 Cab fan 15A 3 Cab fan 15A 4 Reserve 4 Reserve 5 Reserve 5 Reserve 6 R...

Page 78: ...Machine description 4812162601_G pdf 2021 04 14 66...

Page 79: ...connected if necessary The cover must be unlocked when operating so that the battery can be quickly disconnected if necessary 1 2 3 4 Fig Operator s seat 1 Lock pack Length adjustment 2 Weight adjustm...

Page 80: ...3 Wheel seat cushion inclination 4 Wheel backrest inclination 5 Wheel armrest inclination 6 Wheel lumbar support adjustment Adjust the operator s seat so that the position is comfortable and so that...

Page 81: ...new position To adjust the operator s seat see the section for basic comfort seat Adjust all settings when the machine is stationary Adjust all settings when the machine is stationary Always ensure t...

Page 82: ...ignition key 1 to position I the start screen will be shown in display 4 5 6 3 Fig Status image 3 Fuel level 4 Hourmeter 5 Voltmeter 6 Urea level Check that the voltmeter 5 reads at least 24 volts and...

Page 83: ...2 ROPS structure 3 Rubber element 4 Anti slip If a ROPS 2 Roll Over Protective Structure or a cab is fitted to the roller always wear the seat belt 1 provided and wear a protective helmet Replace the...

Page 84: ...4812162601_G pdf 2021 04 14 View Fig view Before starting make sure that the view forwards and backwards is unobstructed All cab windows should be clean and the rear view mirrors should be correctly a...

Page 85: ...0 seconds If the engine will not start wait a minute before trying 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...

Page 86: ...irements If the machine is only to be transported MID or ECO should be selected instead Check that the steering is working correctly by turning the steering wheel once to the right and once to the lef...

Page 87: ...mph Turtoise 1 5 5 km h 3 5 mph Turtoise 1 5 5 km h 3 5 mph Example is CA2500D TC Limited Slip Rear Axle for other alternatives see table in section for Technical data Carefully move the forward reve...

Page 88: ...uck select the gear position that is most suitable for the situation using the gear position switch Drum slipping select Drum spin mode gear position 2 Rear tires slipping select Wheelspin mode gear p...

Page 89: ...Anti Spin is activated or disengaged Carefully move the forward reverse lever 2 forwards or backwards depending on which direction of travel is required Speed increases as the lever is moved away fro...

Page 90: ...rake by activating the parking brake when the roller is moving very slowly forwards backwards Check in both directions Hold the steering wheel and brace yourself for a sudden stop when the brakes are...

Page 91: ...ing the switch 1 on the front of the forward reverse lever Always switch off vibration before the roller comes to a standstill Amplitude Changeover 1 Fig Control panel 1 High amplitude The amplitude s...

Page 92: ...nds on the soil type that is to be compacted and the chosen vibration amplitude If double jumps occur reduce the vibration frequency if possible as an initial measure If this does not help select a lo...

Page 93: ...y results in a high Evib value Evib1 is calculated on the downward movement of the drum loading phase Evib2 is calculated on the upward movement of the drum Unloading phase Which one of the two values...

Page 94: ...rmation is transmitted to the processor unit where it is analyzed The analyzed information is presented in the display as a digital value expressed as CMV Evib1 or Evib2 High or low measuring range is...

Page 95: ...e forward reverse lever is moved quickly forwards or backwards toward past neutral the system switches to a rapid braking Mode and the machine stops Activate normal driving Mode again by moving the fo...

Page 96: ...ollers without cab and lock it Parking Chocking the drums Fig Positioning 1 Chocks 1 Never disembark from the machine when the is engine running unless the parking brake is activated Never disembark f...

Page 97: ...1 to the disconnected position and remove the handle The DEF pump will still run for a while even if the master switch is turned off and is to prevent freezing in the DEF hoses This will prevent batte...

Page 98: ...Operation 4812162601_G pdf 2021 04 14 86...

Page 99: ...s with anti rust agent lubricate the machine thoroughly and apply grease to unpainted surfaces Engine Refer to the manufacturer s instructions in the engine manual that is supplied with the roller Bat...

Page 100: ...paulin and the ground If possible store the roller indoors and ideally in a building where the temperature is constant Urea tank DEF tank Draining of the urea tank DEF tank is recommended if left unus...

Page 101: ...then the machine so this is happening Weight refer to the hoisting plate on the roller 1 1 Fig Roller prepared for lifting 1 Lifting plate Lifting the roller The machine s gross weight is specified o...

Page 102: ...lifted load Make sure that the lifting device is secure in its position and on a level and stable suface You are recommended to lift the machine with a jack or similar positioned at the marking 3 and...

Page 103: ...knob Deactivate the brake with the parking brake knob 2 Move the forward reverse lever forwards or backwards just outside the neutral position If the control is in neutral the brakes are still activa...

Page 104: ...ton The release pump for the brakes is located on the valve block which is positioned in the rear of the engine compartment Press the break release button 3 Pump with the arm 2 until the brakes are re...

Page 105: ...f Reverse the towing preparations according to alternative 1 or 2 in the preceding section Reverse the towing preparations according to alternative 1 or 2 in the preceding section Transport Tie down a...

Page 106: ...itted distance interval in meters 1 3 Double lashings LC at least 1 7 tonnes 1700 daN STF 300 kg 300daN 1 3 Double lashings LC at least 1 7 tonnes 1700 daN STF 300 kg 300daN Double L1 Double L2 Double...

Page 107: ...ith a permitted load LC MSL of at least 1 7 tonnes 1 700 daN and a pre tension STF of at least 300 kg 300 daN The lashings are re tightened as required Each of lashings 1 3 is either a double or two s...

Page 108: ...Operating instructions Summary 4812162601_G pdf 2021 04 14 96...

Page 109: ...ing distance will be longer if the hydraulic fluid is cold 12 Test the brakes Remember that the braking distance will be longer if the hydraulic fluid is cold 13 Set the transportation working mode bu...

Page 110: ...Operating instructions Summary 4812162601_G pdf 2021 04 14 98...

Page 111: ...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 112: ...Preventive maintenance 4812162601_G pdf 2021 04 14 100...

Page 113: ...de Drum cartridge 2 2 liters side 2 3 qts side Hydraulic reservoir 41 liters 10 8 gal Hydraulic reservoir 41 liters 10 8 gal Oil in hydraulic system 80 liters 21 1 gal Oil in hydraulic system 80 liter...

Page 114: ...EL See engine manual TRANSMISSION OIL Air temperature 15 C 40 C 5 F 104 F Dynapac Gear 300 P N 4812161883 5 liters P N 4812161884 20 liters TRANSMISSION OIL Air temperature 15 C 40 C 5 F 104 F Dynapac...

Page 115: ...reservoir sight glass 19 Drive belts 32 Hydraulic fluid cooler 6 Hydraulic reservoir sight glass 19 Drive belts 32 Hydraulic fluid cooler 7 Bleeding filter 20 Wheel nuts 33 Fresh air filter 7 Bleedin...

Page 116: ...personnel Periodic service service message Optional A Service message Periodic Service is shown in the display 15 hours before First Service 50h For Periodic Service 250h 1000h a Service message is s...

Page 117: ...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 8 Change the hydraulic fluid filter 8 Change the hydraulic fluid...

Page 118: ...referred to Pos in fig Action Comment Pos in fig Action Comment 4 Inspect the filter element in the air cleaner Replace as required 4 Inspect the filter element in the air cleaner Replace as required...

Page 119: ...l in drum gearbox Only for machines with drum gearbox 13 Change the oil in drum gearbox Only for machines with drum gearbox 32 31 Clean the coolers 32 31 Clean the coolers 3 Replace the fuel filter Re...

Page 120: ...um gearbox 13 Change the oil in the drum gearbox Only for machines with drum gearbox 32 31 Clean the coolers 32 31 Clean the coolers 3 Replace the fuel filter Refer to the engine manual 3 Replace the...

Page 121: ...ce as required 4 Inspect the filter element in the air cleaner Replace as required 22 Check the oil level in the rear axle s differential 22 Check the oil level in the rear axle s differential 23 Chec...

Page 122: ...Maintenance Maintenance schedule 4812162601_G pdf 2021 04 14 110...

Page 123: ...ation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Scrapers Check adjustment It is important to consider movement of the drum when the machine turns i e the scrapers c...

Page 124: ...r tooth 2 to 25 mm 1 0 in between scraper tooth and drum Center each scraper tooth 2 between the pads Tighten the screws 1 Scrapers Heavy duty Pad drum Fig Scrapers 1 Screws 2 Scraper teeth 1 2 Undo t...

Page 125: ...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 t...

Page 126: ...every other year and change the coolant Also check that the air has unobstructed passage through the reservoir Flush the system every other year and change the coolant Also check that the air has uno...

Page 127: ...t a non insulated part of the roller before refuelling and against the filler pipe 1 while refuelling Never refuel while the engine is running Do not smoke and avoid spilling fuel Never refuel while t...

Page 128: ...s 2 Filler pipe 1 2 Place the roller on a level surface and check that the oil level in the sight glass 1 is between the max and min markings Top up with the type of hydraulic fluid specified in the l...

Page 129: ...ood ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Hydraulic filter Replacement Fig Hydraulic reservoir 2 Filler cover bleeder filter 3 Sight glass 2 3 Undo...

Page 130: ...on the new filter seal Screw tight the filter by hand 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...

Page 131: ...ed in the cartridges Repeat the procedure on the opposite side Tires Air pressure Wheel nuts Tightening Fig Wheels 1 Air valve 2 Wheel nut 1 2 Check the tire pressures using a pressure gauge If the ti...

Page 132: ...ug 2 Steering hitch Tightening Fig Steering hitch 1 Nut 1 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 e...

Page 133: ...r extraction 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 Air clea...

Page 134: ...Figure Pre fuel filter 1 Drain plug 2 Hand pump 1 2 Unscrew the drain plug 1 at the bottom of the fuel prefilter With the aid of the secondary hand operated pump make certain that all sediment comes o...

Page 135: ...air extraction if the engine is run indoors Risk of carbon monoxide poisoning Drum cartridge Checking the oil level Fig Left drum side 1 Groove 1 Position the roller on a flat surface with the groove...

Page 136: ...ller plug 1 2 1 Never work under the roller when the engine is running Park on a level surface Block the wheels securely Never work under the roller when the engine is running Park on a level surface...

Page 137: ...level if the level is low Use transmission oil See lubrication specification Clean and refit the plug Check the fluid level in the same way on the rear axle s other planetary gear Drum gearbox Checki...

Page 138: ...air Be careful when using a high pressure washer do not place the nozzle too close to the radiator Be careful when using a high pressure washer do not place the nozzle too close to the radiator Wear p...

Page 139: ...t the positive cable first When disconnecting the battery always disconnect the negative cable first When connecting the battery always connect the positive cable first The cable shoes should be clean...

Page 140: ...ubbles are visible through the sight glass this is a sign that the refrigerant level is too low If so stop the unit The unit may be damaged if it is run with insufficient refrigerant Fig Engine compar...

Page 141: ...extraction if the engine is run indoors Risk of carbon monoxide poisoning Drum cartridge Checking the oil level Fig Left drum side 1 Groove 1 Position the roller on a flat surface with the groove 1 o...

Page 142: ...e air cleaner s main filter when the warning lamp on the display lights when the diesel engine is operating at full speed 3 6 4 5 2 Fig Air cleaner 1 Clips 2 Cover 3 Main filter 4 Backup filter 5 Filt...

Page 143: ...leaner Cleaning Wipe clean on both sides of the outlet pipe Outer edge of outlet pipe Inner edge of outlet pipe Wipe clean the inside of the cover 2 and the filter housing 5 See the previous illustrat...

Page 144: ...und at the front or rear of the rear axle At a low level remove the filler plug 2 and top up with oil to the correct level Use transmission oil see lubricant specifications Clean and refit the plug Re...

Page 145: ...raulic fluid cooler 4 Condenser element AC Optional 5 Screws x 2 1 2 3 4 5 5 Check that air can pass unobstructed through the radiators 1 2 and 3 Clean a dirty radiator using compressed air or a high...

Page 146: ...e cleaned Han in to environment friendly station Refer to the engine manual for detailed instructions when replacing the fuel filter Refer to the engine manual for detailed instructions when replacing...

Page 147: ...ne manual 3 Fig Engine compartment 2 Oil filter 3 Dipstick 2 Take great care when draining warm fluid and oil Wear protective gloves and goggles Take great care when draining warm fluid and oil Wear p...

Page 148: ...nd operated grease gun Clean and grease the chain 3 between the seat and the steering column Also grease the seat slide rails 6 If the chain is slack on the sprocket 2 loosen the screws 4 and move the...

Page 149: ...ure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Hydraulic filter Replacement Fig Hydraulic reservoir 2 Filler cover bleeder filter 3 Si...

Page 150: ...ew filter seal Screw tight the filter by hand 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 har...

Page 151: ...1000 is used in the cartridges Do not overfill with oil risk for overheating Do not overfill with oil risk for overheating Now repeat the procedure on the opposite side of the drum Fig Drum 1 Ventila...

Page 152: ...e main filter 3 Do not remove the backup filter 4 Clean the air cleaner if necessary see section Air cleaner Cleaning When replacing the main filter 3 insert a new filter and refit the air cleaner in...

Page 153: ...previous illustration Wipe also both surfaces for the outlet pipe see adjacent figure Check that the hose clamps between the filter housing and the suction hose are tight and that the hoses are intact...

Page 154: ...er the drain oil to environmentally correct handling Refit the drainage plugs and top up with fresh oil until the correct level is reached Refit the level filler plugs Use transmission oil see Lubrica...

Page 155: ...cooler 3 Hydraulic fluid cooler 4 Condenser element AC Optional 5 Screws x 2 1 2 3 4 5 5 Check that air can pass unobstructed through the radiators 1 2 and 3 Clean a dirty radiator using compressed ai...

Page 156: ...eaned Han in to environment friendly station Refer to the engine manual for detailed instructions when replacing the fuel filter Refer to the engine manual for detailed instructions when replacing the...

Page 157: ...hat holds 19 liters 5 gal under the drain plug Replace the engine oil filter 2 at the same time Refer to the engine manual 3 Fig Engine compartment 2 Oil filter 3 Dipstick 2 Take great care when drain...

Page 158: ...olumn forward Tighten the screws and check chain tension No not tension the chain too tightly It should be possible to move the chain about 10 mm 0 4 in to the side with a forefinger thumb at the mark...

Page 159: ...t will gather near the drainage plug 1 Drain as follows Place a container under the plug 1 Loosen the drain plug 1 Then open the drain cock 2 and drain out water and sediment until only pure diesel fu...

Page 160: ...e the parking brake before lubricating 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...

Page 161: ...rain cock 2 Plug 1 2 Obtain a container for collecting the used fluid The container should be able to hold at least 60 liters 16 gal Observe care when draining hot hydraulic fluid Wear protective glov...

Page 162: ...ilter 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 Make sure that the old sealing...

Page 163: ...nd goggles 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 Save the oil and hand in to an...

Page 164: ...level glass Check on both drum cartridges Inspect the oil level glass in case of damage change to a new one At service 2000h it should be replaced if no change has been made before Air cleaner Checkin...

Page 165: ...rt 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 downwar...

Page 166: ...are intact Inspect the entire hose system all the way to the engine Check that the hose clamps between the filter housing and the suction hose are tight and that the hoses are intact Inspect the entir...

Page 167: ...engine is running Park on a level surface Block the wheels securely Never work under the roller when the engine is running Park on a level surface Block the wheels securely Wipe clean and remove the...

Page 168: ...cooler 3 Hydraulic fluid cooler 4 Condenser element AC Optional 5 Screws x 2 1 2 3 4 5 5 Check that air can pass unobstructed through the radiators 1 2 and 3 Clean a dirty radiator using compressed ai...

Page 169: ...eaned Han in to environment friendly station Refer to the engine manual for detailed instructions when replacing the fuel filter Refer to the engine manual for detailed instructions when replacing the...

Page 170: ...hat holds 19 liters 5 gal under the drain plug Replace the engine oil filter 2 at the same time Refer to the engine manual 3 Fig Engine compartment 2 Oil filter 3 Dipstick 2 Take great care when drain...

Page 171: ...olumn forward Tighten the screws and check chain tension No not tension the chain too tightly It should be possible to move the chain about 10 mm 0 4 in to the side with a forefinger thumb at the mark...

Page 172: ...t will gather near the drainage plug 1 Drain as follows Place a container under the plug 1 Loosen the drain plug 1 Then open the drain cock 2 and drain out water and sediment until only pure diesel fu...

Page 173: ...s a sign that the refrigerant level is too low If so stop the unit The unit may be damaged if it is run with insufficient refrigerant Check the moisture indicator 2 It should be blue If it is beige th...

Page 174: ...dentify if you have this type of steering hitch is that it 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 M14 174 Nm M14 174 Nm Re...

Page 175: ...nk The filter is located at the bottom of the unit To access the filter loosen the lid with a 27 mm sleeve and remove the filter using the tool supplied with the spare part filter Replace with new fil...

Page 176: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden www dynapac com...

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