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Fayat Group Dynapac CC900G, Instruction Manual

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Fayat Group Dynapac CC900G Instruction Manual Download Page 87

Maintenance - 1000h

4812163901_A.pdf

2019-09-23

Maintenance - 1000h

Performed after 1000 operating hours (each year)

Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.

Park the roller on a level surface.
The engine must be switched off and the
parking brake activated when checking or
adjusting the roller, unless otherwise specified.

Check that the engine cover is fully open before
carrying out work underneath it.

Check that the engine cover is fully open before
carrying out work underneath it.

Spark plug - Replace

Fig. Engine compartment left side
     1. Location of the spark plug on the
left and right sides of the engine.

1

Switch off the engine and push in the
reserve/parking brake knob.

Switch off the engine and push in the
reserve/parking brake knob.

Observe care with hot surfaces. Wear gloves.

Observe care with hot surfaces. Wear gloves.

Refer to the engine manual for detailed
instructions.

Refer to the engine manual for detailed
instructions.

Dispose of used spark plugs properly.

Dispose of used spark plugs properly.

79

Summary of Contents for Dynapac CC900G

Page 1: ...Vibratory roller Vibratory roller CC900G CC900G Engine Engine Honda GX630RH QYD Honda GX630RH QYD Serial number Serial number 10000303xxA023833 10000303xxA023833 Translation of original instruction Translation of original instruction Reservation for changes Reservation for changes Printed in Sweden Printed in Sweden ...

Page 2: ......

Page 3: ...ns 9 Standard lubricants and other recommended oils and fluids 9 Higher ambient temperatures above 40 C 104 F 9 Lower ambient temperature Freeze risk 9 Temperatures 9 High pressure cleaning 9 Fire fighting 10 Roll Over Protective Structure ROPS 10 Battery handling 10 Jump starting 11 Technical specifications 13 Vibrations Operator station 13 Noise level 13 Slopes 13 Dimensions side view 14 Dimensi...

Page 4: ...2 Product and component plates 22 Machine plate 22 Product identification number on the frame 23 Engine plates 24 Decals 25 Location decals 25 Location decals CALIFORNIA 26 Safety decals 26 Info decals 29 Instruments Controls 29 Locations Instruments and controls 29 Function description 30 Electrical system 31 Relays and fuses on the machine 31 Operation 33 Before starting 33 Operator s seat Adjus...

Page 5: ...rake 38 Reserve brake 38 Switching off 39 Parking 39 Chocking the drums 39 Miscellaneous 41 Locking the articulation 41 Lifting the roller 41 Unlocking the articulation 41 Securing CC900G for loading 42 Retractable ROPS Optional 43 Towing 44 Releasing the brake 45 Towing the roller 46 Operating instructions Summary 47 Preventive maintenance 49 Acceptance and delivery inspection 49 Warranty 49 Main...

Page 6: ... operation 58 Every 1000 hours of operation 59 Every 2000 hours of operation 60 Maintenance 10h 61 Engine Checking the oil level 61 Hydraulic reservoir Level check Filling 61 Refueling 62 Water tank Filling 62 Sprinkler system Check cleaning 62 Air circulation Check 63 Scrapers Check adjustment 63 Warning lamps Check 64 Air cleaner check 64 Maintenance 20h 65 Engine oil and oil filter Change 65 Ma...

Page 7: ... 79 Spark plug Replace 79 Engine s fuel filter Check 80 Hydraulic fluid cooler Cleaning Option 80 Forward Reverse controls and joints Check and lubrication 81 Front drum Checking the oil level 82 Hydraulic reservoir Check venting 82 Steering joint Check 83 Air cleaner replace insert 83 Hydraulic fluid filter Change 84 Engine oil and oil filter Change 84 Engine s fuel filter Check 85 Maintenance 20...

Page 8: ... 09 23 Air cleaner replace insert 90 Hydraulic fluid filter Change 91 Engine oil and oil filter Change 91 Engine s fuel filter Check 92 Hydraulic reservoir fluid change 93 Front drum Changing the oil 94 Water tank Cleaning 94 ...

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

Page 10: ...neral This manual contains instructions for machine operation and maintenance The machine must be correctly maintained for maximal 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 Do not spray with high pressure cleaner directly onto gaskets and bearing spacings in steering hitch and drum and ...

Page 11: ...l contains instructions for periodic 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 personnel Additional instructions for the engine can be found in the manufactuer s engine manual Additional instructions for the engine can be found in the manufactuer s eng...

Page 12: ...Introduction 4812163901_A pdf 2019 09 23 4 ...

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

Page 14: ...the fluid is cold See instructions in the STOP section 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 For your own protection always wear helmet working boots with steel toecaps ear protectors reflecting clothing high visibility jacket working gloves...

Page 15: ...d down sloping ground Work driving 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 attention to potential obstacles above the machine such as overhead cables and the branches of trees etc Pay particular attention to the stability of the substrate when compacting close to edges ...

Page 16: ...right when you steer to the left Seated position Figure Seat position 1 ROPS 2 Seat belt 2 1 Remain seated at all times when operating the roller Always use the seat belt where fitted Where the seat belt is not used there is a great risk that the operator will be thrown off and land under the machine if the machine topples over Always use the seat belt where fitted Where the seat belt is not used ...

Page 17: ...Shell Tellus T100 or equivalent Lower ambient temperature Freeze risk Make sure that the watering system is empty drained of water sprinkler hoses tank s or that anti freeze has been added to prevent the system freezing Temperatures The temperature limits apply to standard versions of rollers High pressure cleaning Do not spray water directly onto electrical components or the instrument panels Pla...

Page 18: ... a damaged ROPS structure it must be replaced with a new one Battery handling When removing batteries always disconnect the negative cable first When removing batteries always disconnect the negative cable first When fitting batteries always connect the positive cable first When fitting batteries always connect the positive cable first Dispose of old batteries in an environmentally friendly way Ba...

Page 19: ...tery 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 the machine which is providing jump start power First connect the jump start battery s positive terminal 1 to the flat battery s positive terminal 2 Then connect the jump start battery s negative termi...

Page 20: ...Special instructions 4812163901_A pdf 2019 09 23 12 ...

Page 21: ...evel The noise level is measured in accordance with the operational 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 noise level is measured in accordance with the operational cycle described in EU directive 2000 14 EC on machines equipped for the EU market on ...

Page 22: ...base 1350 53 1 D Drum diameter 584 23 0 D Drum diameter 584 23 0 H1 Height with ROPS 2300 90 5 H1 Height with ROPS 2300 90 5 H2 Height w o ROPS 1585 62 4 H2 Height w o ROPS 1585 62 4 K Ground clearance 261 10 3 K Ground clearance 261 10 3 L Length 2107 83 0 L Length 2107 83 0 S Drum shell thickness 9 0 35 S Drum shell thickness 9 0 35 14 ...

Page 23: ... 38 2 B Width 970 38 2 O Overhang 35 1 38 O Overhang 35 1 38 R1 Turning radius outside 2700 106 3 R1 Turning radius outside 2700 106 3 R2 Turning radius inside 2660 104 7 R2 Turning radius inside 2660 104 7 W Drum shell thickness 900 35 4 W Drum shell thickness 900 35 4 α Steering angle 34 34 α Steering angle 34 34 15 ...

Page 24: ... Vibration frequency 70 Hz 4200 rpm Vibration frequency 70 Hz 4200 rpm Centrifugal force 16 7 kN 3752 lb Centrifugal force 16 7 kN 3752 lb Note The frequency is measured at high revs The amplitude is measured as the real value and not the nominal Propulsion Propulsion Speed range 0 8 kph 0 5 mph Speed range 0 8 kph 0 5 mph Climbing capacity theoretical 35 Climbing capacity theoretical 35 General E...

Page 25: ...e MPa Psi Opening pressure MPa Psi Drive system 27 0 3915 Drive system 27 0 3915 Supply system 2 0 290 Supply system 2 0 290 Vibration system 22 0 3190 Vibration system 22 0 3190 Control systems 7 0 1015 Control systems 7 0 1015 Brake disengagement 2 0 290 Brake disengagement 2 0 290 17 ...

Page 26: ...70 470 520 560 620 M22 446 497 626 699 752 839 M22 446 497 626 699 752 839 M24 570 640 800 900 960 1080 M24 570 640 800 900 960 1080 M30 1130 1260 1580 1770 1900 2100 M30 1130 1260 1580 1770 1900 2100 STRENGTH CLASS Metric coarse screw thread bright galvanized fzb Metric coarse thread zinc treated Dacromet GEOMET STRENGTH CLASS M thread 10 9 Oiled 10 9 Dry 12 9 Oiled 12 9 Dry M thread 10 9 Oiled 1...

Page 27: ...olt dimensions M12 PN 4700508063 Bolt dimensions M12 PN 4700508063 Strength class 8 8 Strength class 8 8 Tightening torque 70 Nm Tightening torque 70 Nm ROPS bolts which are to be torque tightened must be dry ROPS bolts which are to be torque tightened must be dry 19 ...

Page 28: ...Technical specifications 4812163901_A pdf 2019 09 23 20 ...

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

Page 30: ...ers 2 Engine plate Type description product and serial numbers 3 ROPS plate Certification product and serial numbers 3 ROPS plate Certification product and serial numbers 4 Component plate drum Product and serial numbers 4 Component plate drum Product and serial numbers Machine plate 1 Fig Operator s platform left side 1 Machine plate The machine plate 1 is attached to the front left side of the r...

Page 31: ...A pdf 2019 09 23 Please state the machine s PIN when ordering spares Product identification number on the frame 1 Fig PIN Front frame The machine PIN Product Identification Number 1 is punched on the right edge of the front frame 23 ...

Page 32: ...9 23 Engine plates The engine serial number 1 is punched below the starter Figure Engine 1 Serial number 2 EPA plate USA 1 2 Please specify the engine serial number when ordering spares Refer also to the engine manual The engine s EPA plate 2 24 ...

Page 33: ...72373 2 Warning Rotating engine components 4700903423 9 Hydraulic fluid level 4700272373 3 Warning Hot surfaces 4700903424 10 Hoisting plate 4700904870 3 Warning Hot surfaces 4700903424 10 Hoisting plate 4700904870 4 Warning Instruction manual 4700903459 11 Fixing point 4700382751 4 Warning Instruction manual 4700903459 11 Fixing point 4700382751 5 Warning Locking 4700908229 5 Warning Locking 4700...

Page 34: ...e completely legible and remove dirt or order new decals if they have become illegible Use the part number specified on each decal 4700903422 Warning Crush zone articulation drum Maintain a safe distance from the crush zone Two crush zones on machines fitted with pivotal steering 4700903423 Warning Rotating engine components Keep your hands at a safe distance 4700903424 Warning Hot surfaces in the...

Page 35: ...700903459 Warning Instruction manual The operator must read the safety operation and maintenance instructions before operating the machine 4700908229 Warning Risk of crushing The articulation must be locked when lifting Read the instruction manual 27 ...

Page 36: ...Machine description 4812163901_A pdf 2019 09 23 4812130471 Warning CALIFORNIA Proposition 65 28 ...

Page 37: ...ition key 7 Fuse box 2 Control engine speed 8 Sprinkler 2 Control engine speed 8 Sprinkler 3 Parking brake 9 Horn 3 Parking brake 9 Horn 4 Vibration on off switch 10 Emergency stop 4 Vibration on off switch 10 Emergency stop 5 Fuel level Hour meter 11 Choke 5 Fuel level Hour meter 11 Choke 6 Forward Reverse lever 12 Parking brake warning lamp Hydraulic oil temperature not in use 6 Forward Reverse ...

Page 38: ...ver is moved forward the roller moves forward etc The roller s speed is proportional to the distance the lever is from the neutral position The further the lever is from the neutral position the higher the speed 6 Forward Reverse lever The lever must be in neutral to start the gasoline engine The engine cannot be started if the forward reverse lever is in any other position The forward reverse lev...

Page 39: ...V 30A 1 K1 Starting 12V 30A 2 K2 Start vibration brake 12V 15A 2 K2 Start vibration brake 12V 15A 3 K22 Cooling fan hydraulic system Option 12V 30A 3 K22 Cooling fan hydraulic system Option 12V 30A 4 K20 Drive restriction relay 12V 10A 4 K20 Drive restriction relay 12V 10A Fuses Fuses 5 7 5A Start stop valve Fuel pump Restriction relay VBS relay Vibration 5 7 5A Start stop valve Fuel pump Restrict...

Page 40: ...Machine description 4812163901_A pdf 2019 09 23 32 ...

Page 41: ... comfortable and so that the controls are within easy reach The seat can be adjusted lengthways 1 Sprinkler Check 1 3 8 Figure Instrument panel 1 Ignition key 3 Pparking brake 8 Switch sprinkler Make sure that the parking brake 3 is activated Make sure that the parking brake 3 is activated Set the knob 8 for the sprinkler in the open position and check that the drums are watered 33 ...

Page 42: ...g Operator s station 1 Seat belt 2 ROPS Optional 3 Anti slip If a ROPS Roll Over Protective Structure 2 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 Replace the seat belt 1 if it shows signs of wear or has been subjected to high levels of force Ensure that th...

Page 43: ...oo long If the engine does not start immediately wait a minute or so before trying again Warm up the engine at idling speed for a few minutes although longer if ambient temperature is below 10 C 50 F Push in the choke as soon as possible Fig Instrument panel 12 Parking brake warning lamp 12 When the engine is warm check that the parking brake warning lamp 12 is still lit When starting and driving ...

Page 44: ...stationary When compacting asphalt remember to turn on the sprinkler system 8 Make sure that the area in front of and behind the roller is clear Make sure that the area in front of and behind the roller is clear Carefully move the forward reverse lever 6 forwards or backwards depending on which direction of travel is required Speed increases as the lever is moved away from the neutral position The...

Page 45: ...irmly and brace yourself for a sudden stop The engine switches off and the brakes are activated Check the function of the emergency stop by pressing the emergency stop when the roller is moving slowly forwards backwards Check in both directions Hold the steering wheel firmly and brace yourself for a sudden stop The engine switches off and the brakes are activated Check the function of the parking ...

Page 46: ...ut activating the parking brake 3 Never leave the operator platform without activating the parking brake 3 Reserve brake 3 Fig Controls 3 Parking brake 10 Emergency stop 10 Braking is normally activated using the forward reverse lever The hydrostatic transmission retards and slows the roller when the lever is moved towards the neutral position A disc brake in each drum motor acts as reserve brake ...

Page 47: ...m without activating the parking brake Never leave the operator platform without activating the parking brake Make sure that the roller is parked in a safe place with respect to other road users Chock the drums if the roller is parked on sloping ground Make sure that the roller is parked in a safe place with respect to other road users Chock the drums if the roller is parked on sloping ground Keep...

Page 48: ...Operation 4812163901_A pdf 2019 09 23 40 ...

Page 49: ...fications Lifting gear such as chains steel wires straps and lifting hooks must be dimensioned and used in accordance with the applicable safety regulations for lifting devices Lifting gear such as chains steel wires straps and lifting hooks must be dimensioned and used in accordance with the applicable safety regulations for lifting devices Stand well clear of the hoisted machine Make sure that t...

Page 50: ... meters 1 4 Double lashings LC at least 1 7 tonnes 1700 daN STF 300 kg 300daN 1 4 Double lashings LC at least 1 7 tonnes 1700 daN STF 300 kg 300daN Double L1 L2 Double L3 L4 Double L1 L2 Double L3 L4 0 6 3 0 0 1 3 0 0 6 3 0 0 1 3 0 The distance L1 above is between points D and E D is the projected point directly at right angles laterally in relation to the edge of the platform from the lashing mou...

Page 51: ... double lashing runs in a sling through a lashing point or around a machine part and down into two different mounts on the platform Each of lashings 1 3 is either a double or two single lashings A double lashing runs in a sling through a lashing point or around a machine part and down into two different mounts on the platform Lashings in the same direction are placed in different lashing mounts on...

Page 52: ...ition before operation Always make sure the ROPS is locked in raised position before operation Grease the tensioning screw 1 and stud 3 periodically Towing The roller can be moved up to 300 meters 1 000 ft using the instructions below 1 Fig Drum 1 Propulsion motor located left front and right rear Switch off the gasoline engine and push in the emergency stop knob Chock the drum to prevent the roll...

Page 53: ...ches the brake 107 inner thread 3 Tighten the two screws 192 alternately a little at a time so that the brake piston 107 loose screw approximately 2 turns Tightening the screws 192 too hard can damage the inner mechanism Tightening the screws 192 too hard can damage the inner mechanism The machine should be started with reactivated brake The machine should be started with reactivated brake 45 ...

Page 54: ... roller has no brakes and can only be slowed and stopped by the vehicle towing the roller The roller must be towed slowly max 3 km h 2 mph and for short distances only max 300 m 1000 ft The roller must be towed slowly max 3 km h 2 mph and for short distances only max 300 m 1000 ft When towing recovering a machine the towing device must be connected to both lifting holes Pulling forces shall act lo...

Page 55: ...r that the braking distance will be longer if the roller is cold 9 Test the brakes Remember that the braking distance will be longer if the roller is cold 10 Use vibration only when the roller is in motion 10 Use vibration only when the roller is in motion 11 Check that the drums are thoroughly watered when watering is required 11 Check that the drums are thoroughly watered when watering is requir...

Page 56: ...Operating instructions Summary 4812163901_A pdf 2019 09 23 48 ...

Page 57: ... to the customer delivery inspection must be conducted as per the check list in the warranty document Any transport damage must be reported immediately to the transport company as this is not covered by the product warranty Warranty The warranty is only valid if the stiplulated delivery inspection and the separate service inspection have been completed as per the warranty document and when the mac...

Page 58: ...Preventive maintenance 4812163901_A pdf 2019 09 23 CALIFORNIA Decal and location of decal shown in section Machine description Proposition 65 50 ...

Page 59: ... high or extremely low ambient temperatures See the Special instructions chapter or consult Dynapac Other fuel and lubricants are required when operating in areas with extremely high or extremely low ambient temperatures See the Special instructions chapter or consult Dynapac Fluid volumes Fluid volumes Drum 3 5 liters 3 7 qts Drum 3 5 liters 3 7 qts Hydraulic reservoir 12 liters 3 2 gal Hydraulic...

Page 60: ... panolin com BIOLOGICAL HYDRAULIC FLUID When it leaves the factory the machine may be filled with biologically degradable fluid The same type of fluid must be used when changing or topping up BP Biohyd SE S46 BIOLOGICAL HYDRAULIC FLUID When it leaves the factory the machine may be filled with biologically degradable fluid The same type of fluid must be used when changing or topping up BP Biohyd SE...

Page 61: ...vel Air filter Engine oil filter Battery Engine oil filter Battery Hydraulic reservoir level Sprinkler Hydraulic reservoir level Sprinkler Hydraulic fluid filter Sprinkler water Hydraulic fluid filter Sprinkler water Drum oil level Recycling Drum oil level Recycling Lubricating oil Fuel filter Lubricating oil Fuel filter 53 ...

Page 62: ...Maintenance Lubricants and symbols 4812163901_A pdf 2019 09 23 54 ...

Page 63: ...ard Reverse lever 8 Battery maintenance free 14 Fuel tank filling 2 Forward Reverse lever 8 Battery maintenance free 14 Fuel tank filling 3 Reserve parking brake 9 Sprinkler 15 Steering joint 3 Reserve parking brake 9 Sprinkler 15 Steering joint 4 Hydraulic fluid cooler option 10 Scrapers 16 Front drum filling with oil 4 Hydraulic fluid cooler option 10 Scrapers 16 Front drum filling with oil 6 En...

Page 64: ...ed out at the point in time that occurs first Where both operational hours and time intervals are specified maintenance should be carried out at the point in time that occurs first Every 10 hours of operation Daily Refer to the contents to find the page number of the sections referred to Pos in fig Action Comment Pos in fig Action Comment Before starting up for the first time on that day Before st...

Page 65: ...on Comment Action Comment 12 Change the hydraulic fluid filter 12 Change the hydraulic fluid filter Every 50 hours of operation Refer to the contents to find the page number of the sections referred to Pos in fig Action Comment Pos in fig Action Comment 3 Test the brakes 3 Test the brakes 7 Clean the air cleaner Refer to the engine manual 7 Clean the air cleaner Refer to the engine manual 11 Check...

Page 66: ...gine manual 6 Change the oil filter Refer to the engine manual 6 Change the oil filter Refer to the engine manual Check lubrication of controls and pivots Lubricate as necessary Check lubrication of controls and pivots Lubricate as necessary Replace valve cover gasket Refer to the engine manual Replace valve cover gasket Refer to the engine manual Every 500 hours of operation Refer to the contents...

Page 67: ...ecessary Check lubrication of controls and pivots Lubricate as necessary Replace valve cover gasket Refer to the engine manual Replace valve cover gasket Refer to the engine manual 6 Clean the combustion chamber Refer to the engine manual 6 Clean the combustion chamber Refer to the engine manual 16 Check the oil level in the front drum 16 Check the oil level in the front drum 13 Check the hydrauli...

Page 68: ... engine manual 6 Clean the combustion chamber Refer to the engine manual 6 Clean the combustion chamber Refer to the engine manual 13 Check the hydraulic reservoir cover breather 13 Check the hydraulic reservoir cover breather 15 Check the condition of the articulation 15 Check the condition of the articulation 7 Replace the air cleaner insert Refer to the engine manual 7 Replace the air cleaner i...

Page 69: ...e engine cover is fully open when work is carried out under the cover Open the engine cover lock and lower the engine cover forwards Check the oil level using the dipstick 1 The level should be between the marks If the level is near the lower mark top off with fresh engine oil via the filler cap 2 See under the heading lubricants for the correct oil grade Never overfill with oil as this can damage...

Page 70: ...ng Stop the engine Short circuit press the filler gun against the filler pipe 1 while refuelling The tank holds 23 liters 31 7 gal of fuel Water tank Filling Fig Water tank 1 Tank cap 1 Unscrew the tank cap 1 and fill with clean water Unscrew the tank cap 1 and fill with clean water Fill the water tank it holds 175 liters Only additive A small amount of environmentally friendly antifreeze Only add...

Page 71: ...nut 2 Frame side 1 2 Scrapers Check adjustment Make sure that the scrapers are undamaged Adjust the scrapers if necessary in the following way For firmer application of the scraper undo the locking nut 2 and turn it to the right until the desired application is achieved Lock this setting by tightening the locking nut against the frame side 2 Adjust the pressure on both scraper brackets To set a lo...

Page 72: ...trol panel is functional 12 Fig Control panel 3 Parking brake 12 Parking brake warning lamp 3 12 Air cleaner check Fig Engine 1 Air filter 1 Check that hoses and couplings are not leaking and that the air cleaner cover is on properly Clean the air cleaner when operated in extremely dusty environments 64 ...

Page 73: ...efore draining the oil Switch off the engine and push in the reserve parking brake knob Switch off the engine and push in the reserve parking brake knob Take great care when draining fluids and oils Wear protective gloves and goggles Take great care when draining fluids and oils Wear protective gloves and goggles Place a receptacle that holds at least 4 liters 1 gal under the drain plug 2 4 Fig En...

Page 74: ...t the drain plug 2 to the end of the hose Fill with fresh engine oil see under Lubricants heading for the correct oil grade refit the filler cap 4 and check the level on the dipstick Start the engine and check the tightness around the oil filter 66 ...

Page 75: ...k that the engine cover is fully open before carrying out work underneath it Check that the engine cover is fully open before carrying out work underneath it Brakes Check 3 12 Figure Instrument panel 3 Parking brake 12 Brake warning lamp Check the brakes by carrying out the following Check the brakes by carrying out the following Drive the roller slowly forwards Activate the parking brake 3 The br...

Page 76: ...ter container and its cover with a damp rag Make sure that dirt does not enter the suction pipe Clean the air cleaner when operated in extremely dusty environments Refit the filter element and the cover and secure the cover with put the latch 1 to locked position Rubber elements and fastening screws Check Figure Drum suspension 1 Rubber element 2 Fastening screws 1 2 Check all the rubber elements ...

Page 77: ...ver is fully open before carrying out work underneath it Check that the engine cover is fully open before carrying out work underneath it Spark plug Check and adjustment Fig Engine compartment left side 1 Spark plug 1 Switch off the engine and push in the reserve parking brake knob Switch off the engine and push in the reserve parking brake knob Observe care with hot surfaces Wear gloves Observe c...

Page 78: ...Maintenance 100h 4812163901_A pdf 2019 09 23 70 ...

Page 79: ...ly open before carrying out work underneath it Check that the engine cover is fully open before carrying out work underneath it Spark plug Replace Fig Engine compartment left side 1 Location of the spark plug on the left and right sides of the engine 1 Switch off the engine and push in the reserve parking brake knob Switch off the engine and push in the reserve parking brake knob Observe care with...

Page 80: ...Replace the fuel filter 1 Refer to the engine manual for detailed instructions Refer to the engine manual for detailed instructions Dispose of the old filter carefully Dispose of the old filter carefully Hydraulic fluid cooler Cleaning Option Clean the hydraulic fluid cooler s cooling flanges ideally with compressed air Blow the cooler clean by blowing air from the inside outwards Wear gloves and ...

Page 81: ...nder the drain plug 2 4 Fig Engine compartment right side 4 Filler cap Undo the oil filler cap 4 and remove the plug 2 from the end of the drain hose 1 allow all the engine oil to run out Deliver the drained oil to special waste handling Deliver the drained oil to special waste handling Refer to the engine manual for detailed instructions when changing oil and filters Refer to the engine manual fo...

Page 82: ...pressure to keep the forward reverse lever in the set position during operation If the lever gets stiff after prolonged use lubricate the lever at the bearing bushings and at the cable with a few drops of oil at each place 3 2 Fig Engine compartment 1 F R lever cable 2 Heat cover 3 Air filter 1 If the forward reverse lever still is stiff after the above adjustments lubricate the other end of the c...

Page 83: ... open before carrying out work underneath it Front drum Checking the oil level Figure Front drum drive side 1 Oil plug 1 Park the roller on a level surface and drive the roller slowly until the oil plug 1 is in the middle of the semicircle shaped notch in the drum suspension Switch off the engine disconnect the power and push in the reserve parking brake knob Switch off the engine disconnect the p...

Page 84: ...locked in either direction clean with a little diesel oil and blow with compressed air until unblocked or replace the cap with a new one Wear eye protectors and gloves when working with compressed air Wear eye protectors and gloves when working with compressed air Steering joint Check Fig Steering joint Inspect the steering joint to detect any damage or cracks Check and tighten any loose bolts Che...

Page 85: ...ll the air cleaner cover latch 1 to the unlocked position and remove the cover 2 Remove the wing nut 3 from the filter element 4 Lift out the foam filter element 8 and the filter element 4 Dry the inside of the filter container and its cover with a damp rag Make sure that dirt does not enter the suction pipe Reinstall with new filter element and secure the cover with put the latch 1 to locked posi...

Page 86: ...Maintenance 500h 4812163901_A pdf 2019 09 23 78 ...

Page 87: ...cover is fully open before carrying out work underneath it Check that the engine cover is fully open before carrying out work underneath it Spark plug Replace Fig Engine compartment left side 1 Location of the spark plug on the left and right sides of the engine 1 Switch off the engine and push in the reserve parking brake knob Switch off the engine and push in the reserve parking brake knob Obser...

Page 88: ...e the fuel filter 1 Refer to the engine manual for detailed instructions Refer to the engine manual for detailed instructions Dispose of the old filter carefully Dispose of the old filter carefully Hydraulic fluid cooler Cleaning Option Clean the hydraulic fluid cooler s cooling flanges ideally with compressed air Blow the cooler clean by blowing air from the inside outwards Wear gloves and eye pr...

Page 89: ...re to keep the forward reverse lever in the set position during operation If the lever gets stiff after prolonged use lubricate the lever at the bearing bushings and at the cable with a few drops of oil at each place 3 2 Fig Engine compartment 1 F R lever cable 2 Heat cover 3 Air filter 1 If the forward reverse lever still is stiff after the above adjustments lubricate the other end of the control...

Page 90: ...he hole s lower edge If necessary top off with fresh transmission fluid See under the heading lubricants for correct fluid grade Clean the magnetic oil plug 1 from any metallic residue and refit the plug Hydraulic reservoir Check venting Figure Engine compartment right side 1 Hydraulic fluid tank cap 1 Unscrew and make sure that the reservoir cap is not blocked Air must have unobstructed passage t...

Page 91: ...ch 2 Cover 3 Wing nut 4 Filter element 5 Case 6 Seal 7 Air chamber 8 Foam filter element 1 2 3 4 5 6 7 8 Pull the air cleaner cover latch 1 to the unlocked position and remove the cover 2 Remove the wing nut 3 from the filter element 4 Lift out the foam filter element 8 and the filter element 4 Dry the inside of the filter container and its cover with a damp rag Make sure that dirt does not enter ...

Page 92: ...et makes contact with the filter base Then rotate a further turn Do not over tighten The seal can be damaged Do not over tighten The seal can be damaged Start the engine and check that the filter does not leak Engine oil and oil filter Change Fig Engine compartment left side 1 Drain hose 2 Plug 3 Oil filter 1 2 3 2 Run the engine until it is warm before draining the oil Switch off the engine and p...

Page 93: ...rain plug 2 to the end of the hose Fill with fresh engine oil see under Lubricants heading for the correct oil grade refit the filler cap 4 and check the level on the dipstick Start the engine and check the tightness around the oil filter Engine s fuel filter Check Fig Engine compartment left side 1 Fuel filter 1 Switch off the engine and push in the reserve parking brake knob Switch off the engin...

Page 94: ...Maintenance 1000h 4812163901_A pdf 2019 09 23 86 ...

Page 95: ...ne cover is fully open before carrying out work underneath it Check that the engine cover is fully open before carrying out work underneath it Spark plug Replace Fig Engine compartment left side 1 Location of the spark plug on the left and right sides of the engine 1 Switch off the engine and push in the reserve parking brake knob Switch off the engine and push in the reserve parking brake knob Ob...

Page 96: ...e the fuel filter 1 Refer to the engine manual for detailed instructions Refer to the engine manual for detailed instructions Dispose of the old filter carefully Dispose of the old filter carefully Hydraulic fluid cooler Cleaning Option Clean the hydraulic fluid cooler s cooling flanges ideally with compressed air Blow the cooler clean by blowing air from the inside outwards Wear gloves and eye pr...

Page 97: ...lever cable 2 Heat cover 3 Air filter 1 If the forward reverse lever still is stiff after the above adjustments lubricate the other end of the control cable with a few drops of oil The cable is located on the top of the propulsion pump Hydraulic reservoir Check venting Figure Engine compartment right side 1 Hydraulic fluid tank cap 1 Unscrew and make sure that the reservoir cap is not blocked Air ...

Page 98: ...ch 2 Cover 3 Wing nut 4 Filter element 5 Case 6 Seal 7 Air chamber 8 Foam filter element 1 2 3 4 5 6 7 8 Pull the air cleaner cover latch 1 to the unlocked position and remove the cover 2 Remove the wing nut 3 from the filter element 4 Lift out the foam filter element 8 and the filter element 4 Dry the inside of the filter container and its cover with a damp rag Make sure that dirt does not enter ...

Page 99: ...et makes contact with the filter base Then rotate a further turn Do not over tighten The seal can be damaged Do not over tighten The seal can be damaged Start the engine and check that the filter does not leak Engine oil and oil filter Change Fig Engine compartment left side 1 Drain hose 2 Plug 3 Oil filter 1 2 3 2 Run the engine until it is warm before draining the oil Switch off the engine and p...

Page 100: ...rain plug 2 to the end of the hose Fill with fresh engine oil see under Lubricants heading for the correct oil grade refit the filler cap 4 and check the level on the dipstick Start the engine and check the tightness around the oil filter Engine s fuel filter Check Fig Engine compartment left side 1 Fuel filter 1 Switch off the engine and push in the reserve parking brake knob Switch off the engin...

Page 101: ...n order to remove as much of the oil as possible Drain the hydraulic oil into a drainage container Use a receptacle that holds at least 15 liters 4 gal Use a receptacle that holds at least 15 liters 4 gal Collect the oil and deliver to special waste handling Collect the oil and deliver to special waste handling Change the hydraulic fluid filter see under heading Every 900 hours of operation Fill w...

Page 102: ...hat will hold at least 4 liters 1 gal under the plug Remove the plug 1 and let the oil run out Deliver the drained oil to special waste handling Deliver the drained oil to special waste handling See under the section Every 500 hours of operation for filling oil Water tank Cleaning 1 Fig Water tank 1 Cap Keep in mind that there is a risk of freezing in winter Drain the tank pump and lines Keep in m...

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Page 104: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden www dynapac com ...

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