Fayat DYNAPAC CT3000 Instruction Manual Download Page 1

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Instructions Manual

Operation & Maintenance

4812325559EN

Tamping Roller

CT3000

Engine

Cummins QSB 6.7 ℓ, Tier III and Tier IV

From serial number

10000505xxB005408

10000513xxB005408

Reserves the right to introduce modifications

Printed in Brazil

Summary of Contents for DYNAPAC CT3000

Page 1: ...Operation Maintenance 4812325559EN Tamping Roller CT3000 Engine Cummins QSB 6 7 ℓ Tier III and Tier IV From serial number 10000505xxB005408 10000513xxB005408 Reserves the right to introduce modifications Printed in Brazil ...

Page 2: ...2 4812325559EN 2018 02 20 ...

Page 3: ... 34 Braking 38 Stopping 40 Parking 41 Lifting 42 Towing 43 Transportation 44 General instructions of operation Summary 48 Introduction 49 Symbols and Lubricants 50 Specifications 52 Lubrication and maintenance points 55 Lubrication and maintenance procedures 56 Daily Every 10 hours of operation 60 Weekly Every 50 hours of operation 70 Biweekly Every 100 hours of operation 75 Monthly Every 250 hour...

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Page 5: ...move the manual from the machine Main This manual has information about the operation and usage of the machine For instructions and information about lubrication and maintenance please refer to the respective Maintenance Section When releasing the emergency parking brake check that the warning lamp has turned off after 10 seconds if not check the cause of the abnormality before operating the equip...

Page 6: ...stacles above your head Always look up and down 10 Take special attention when operating on rough terrain Never exceed the speed of 12 4 mph 20 km h 11 Obey all the safety rules and use the proper protection equipment according to the work that will be done 12 Maintain the machine always clean Clean immediately dirt grease or oil present on the operator s platform Keep all the signals lanterns hea...

Page 7: ...teering wheel As an example move to the right when the steering wheel is shifted to the left It is recommended to use the Roll Over Protective Structure ROPS while operating on slopes or irregular ground Always avoid when possible to operate transversally on slopes When on slopes preferably operate up and down Always use the first speed when operating on slopes Always operate the machine with door...

Page 8: ... personal injuries Do not release or loose hoses or fittings with the system loaded Working Lights Xenon CAUTION High voltage The working lights are Xenon type which have a secondary high voltage power source Any maintenance procedure in the lighting system must only be performed by qualified personnel and the main power source must be shut off CAUTION Dangerous residue for human being and environ...

Page 9: ...Safety decals Location and description 2018 02 20 4812325559EN 5 Safety decals Location and description 1 1 3 2 3 2 5 5 6 7 4 6 8 9 9 7 10 10 10 10 11 12 13 14 15 16 ...

Page 10: ... 8 Fuel 13 Hydraulic oil level 3 WARNING Extremely hot surface danger Do not touch these surfaces 8 Fuel Tier IV engine 14 Engine coolant 4 WARNING Before operating the machinery it is recommended to the operator to read the Safety and Engine Manuals as well as the instructions of operation and maintenance 9 Lifting position 15 Hydraulic oil 5 WARNING Danger for hands and arms rotating belts Keep ...

Page 11: ...ations also were below the action level of 2 5 m s specified in the same directive Limit is 5 m s Noise level Sound levels have been measured according to the operational cycle described in the EU directive 2000 14 EC on machines equipped for the EU market with operator seat in transport position Guaranteed sound power level LwA 103 dB A Sound pressure level at the operator s ear platform LpA 85 3...

Page 12: ...mber and other important information about the product When ordering replacement parts always inform the serial number and the machine model NOTE When ordering replacement parts always inform the serial number and the machine model Product Identification Number PIN on the chassis The product identification number PIN 2 is engraved on the front chassis on the right side right below the fuel tank 1 ...

Page 13: ...5 E Unit code B Sorocaba Brasil F Sequential serial number from 000001 to 999999 Engine identification plate The engine identification plate 1 is located in the middle of the engine valve cover This plate has information such as serial number model and other information about the engine NOTE When ordering replacement parts always inform the serial number and machine model 100 00505 V E B 123456 A ...

Page 14: ...ction display side control panel and operator s control keyboard 1 Multifunction display 2 Operator s Control Keyboard 3 Warning lights switch 4 Parking brake switch 5 Starter key switch 6 Beacon warning light switch Optional 7 Emergency stop button 8 Go Home switch 9 Blade control joystick 3 4 5 6 7 8 2 1 9 ...

Page 15: ...ptional 19 Front working lights Optional 20 Enable the regeneration Tier IV Engine 21 Empty 22 Engine radiators assembly cleaning 23 Disable the regeneration Tier IV Engine 24 Brake test 25 Horn Speed lever The equipment has four speeds forward and four speeds backwards completely automatic Powershift Position the lever forward or backward according to the desired direction On middle position the ...

Page 16: ...Operator s instruments and controls 12 4812325559EN 2018 02 20 Cab instruments Fig Rear right column ...

Page 17: ...sition NOTE The parking brake must be activated before turning on the machine 5 Engine starter key switch Turn the switch to the left to turn off the electric system In the middle position the switch turn on all the electric system Turn the switch to the right to activate the starter motor 6 Beacon warning light switch Optional Press the switch to activate the beacon warning light if equipped 7 Em...

Page 18: ... turn ON OFF all rear working lights 16 Front working lights button Press to turn ON OFF all front working lights 17 Night working lights button Optional Press to turn ON OFF all night working lights if equipped 18 Rear night working lights button Optional Press to turn ON OFF all rear night working lights if equipped 19 Front night working lights button Optional Press to turn ON OFF all front nig...

Page 19: ...dshield washers switch Press the top to activate the front washers Press the bottom to activate the rear washers 31 Asymmetric front wiper switch Press to operate the front side windshield wiper 32 Asymmetric rear wiper switch Press to operate the rear side windshield wiper 33 Asymmetric side windshield washers switch Press the top to activate the front side washers Press the bottom to activate th...

Page 20: ... The set point temperature will flash on the display press until reaches desired temperature Display The display shows set point value bar graph evaporator speed active function and other information It also serves to allow the operator to view the coil and return temperature as well as the parameters It also serves to alert when there is some system flaws Operation Mode To change the operation mo...

Page 21: ...al ventilation The manual ventilation has three speeds When some function cooling heating or automatic mode is active the ventilation function is always on To change the fan speed press the key Ventilation mode and after set the desired speed with the keys or After press the key to confirm or wait a few seconds and the speed will be saved ...

Page 22: ...creen is shown until the diesel engine starts operating or if one of the function buttons below the screen is pressed Is the engine starts running before the selection of the current screen the screen will change to the main screen This screen shows an overview and stays throughout the operation The speed is shown in the middle of the screen The status of the machine gears N 1 2 3 e 4 is shows wit...

Page 23: ...ton to show engine and machine alarms Definition menu selection button which opens the main menu The definitions can be changed in the main menu Exit back button goes 1 step back at a time If the button is pressed for approximately 2 seconds the main menu is shown again Press the selection button 1 to show the temperature and pressure screen which shows the engine oil temperature on the upper left...

Page 24: ... transmission controls which monitor their functions The message which shows SPN and FMI codes can be understood as a relation of failure codes from the engine and transmission suppliers Press the OK button on the screen to delete the message When a machine alarm is activated it is shown on the screen along with an alarm text detailing it Press the OK button on the screen to delete the message Fig...

Page 25: ...This symbol is shown when the engine is too hot Stop the engine immediately and find the failure Also refer to the engine manual Warning symbol hydraulic oil temperature This symbol is shown when the hydraulic oil is too hot Do not move the roller run the engine in neutral wait for the oil to be cooled and find the failure Warning symbol low fuel level This symbol is shown when the fuel level is a...

Page 26: ...g settings choose between the metric or imperial system and define whether there will be sound alarms NOTA In every screen pressing the button returns to the Initial screen Press the and buttons to adjust the brightness and contrast values as you wish Press to return to the main screen Fig User settings screen Fig Brightness and contrast screen ...

Page 27: ...to Go Home Switch on the page 10 When this failure happens park the machine on a safe place and contact DYNAPAC Press the OK button 1 on the screen to delete the message To activate the transmission emergency mode carry out the following procedure 1 Open the right engine door and connect the XGT connector Turn off the engine and keep the start engine switch in O position 2 Open the right cover nex...

Page 28: ...isconnect the XA9 R1 connector NOTE The procedure above neutralizes the transmissions normal operation and enables the emergency mode 5 In the cab activate the button in the panel NOTE The emergency mode reduces functionalities of the transmission it only allows that the machine to work on the 1º gear forward or backward 5 Fig 4 Connector XA9 R1 Fig 5 Forward Backward button Fig 3 Cable º312 3 ...

Page 29: ... parking brake If the engine or the hydraulic system becomes inoperative the emergency parking brake can be released so the machine can be towed safely to be repaired To release the emergency parking brake execute the following procedure 1 Release all three screws from the caliper cover of the emergency parking brake 1 Be careful with spring pressure when performing this procedure 2 Release the nu...

Page 30: ... very low level Operator should refill the DEF tank with DEF DEF Lamp With Check Engine Lamp Illuminates when the DEF level is critically low If the tank is not refilled immediately power will be reduced Operator should refill the DEF tank with DEF Normal engine power will be restored after the DEF tank is refilled Flashing DEF Lamp With Check Engine Lamp Illuminates when the DEF level is near zer...

Page 31: ...med in a timely manner after the Exhaust System Cleaning Lamp is illuminated the Check Engine Lamp will illuminate and engine power will be significantly reduced Park the equipment when safe to do so and press the Exhaust System Cleaning Start Switch Once the cleaning is complete full engine power will be restored Exhaust System Cleaning Lamp Flashes when a stationary Exhaust System Cleaning event...

Page 32: ...eded when the Exhaust System Cleaning Lamp illuminates When the Start Switch is pressed cleaning begins and this is confirmed by the Exhaust System Cleaning Lamp flashing The HEST lamp may illuminate during the manual parked Exhaust System Cleaning to indicate higher than normal exhaust temperatures and safety considerations apply The switch returns to the standard Mid Position after pressing the ...

Page 33: ...d mainly protects the electrical devices Operator s controls The operator s control and the machine operation have two adjust options 180º shifting and steering column inclination The 180º shifting is possible by pulling the lever 1 upwards Make sure that the controls are in their home positions before operating the machine The steering column inclination is adjusted by releasing the fixing lever ...

Page 34: ...nclination adjustment the adjustment is performed through the button 5 that can be found under the armrest turning it to the right or left 6 Lumbar rest adjustment to adjust it rotate the button 6 clockwise or anti clockwise Sub abdominal seat belt If the machine is enabled with cab the operator should use the seat belt To adjust the seat belt pull the retraction mechanism in a uniform way taking ...

Page 35: ...n Make sure all warning lights are working properly This machine is adjusted at the factory with the main preset functions i e four of them with functions in the local language This machine is programmed to shut down the engine if the operator fails to operate it within the maximum time limit of 20 minutes Visibility Before starting the engine make sure that the visibility around the machine is no...

Page 36: ...mpressor with a capacity of 50 psi is enough for the job The application of compressed air in the valves is only performed when it is noticed the misalignment in the four scales located besides every cushion and also in the cab 1 Park the machine on a completely flat surface shut off the engine and the main switch 2 Check if the arrow in the scales is aligned with the number ZERO in the 4 cushions...

Page 37: ...g key switch 3 to the right to the first position I and then to the starting position Release the switch as soon as the engine starts running Do not hold the starter motor for much longer the maximum allowed is 30 seconds If the engine does not work wait approximately one minute before trying again Heat the engine for some minutes in idling or for longer if the room temperature is below 50 F 10 C ...

Page 38: ...the accelerator position The speed obtained will be always within the range chosen by the operator For example if the operator selects the 2nd gear the machine speed will be restricted between the 1st and 2nd gears at most 2 Put the Forward Reverse lever to the desired travel direction Never exceeds 12 5 mph 20 km h during the tamping and travel operations at the job s site This operation may caus...

Page 39: ... direction when the machine is traveling The transmission electronic module does not allow sudden reversing while traveling because this action can damage the transmission box 4 During the operation check if all the indicators indicate that all readings re normal and all warning lamps are off The display will show if any function is above its specific limit and an alert will sound If a warning ale...

Page 40: ...ling blade operation Optional The leveling blade control lever joystick 1 has four stages LIFT move the lever backwards RETAIN release the lever in any stage LOWER move the lever forward FLUCTUATE move the lever completely forward If the lever is released on the stage Lift or Lower it will always return to the stage Retain If the lever is released in the Fluctuate stage it will not return to the R...

Page 41: ... release the lever in any stage LOWER move the lever forward FLUCTUATE move the lever completely forward LEFT ANGULATIONS move the lever laterally to the left RIGHT ANGULATIONS move the lever laterally to the right LEFT INCLINATION press the button and move the lever laterally to the left to incline the blade to the left release the button to stop the movement RIGHT INCLINATION press the button an...

Page 42: ... has a mechanical activation through a spring that is hydraulically released and operated by button 2 located on the side control panel When pressed the parking brake is activated To release the parking brake slide the red button side backwards towards the operator and change the switch s position NOTE The parking brake must be activated before turning on the machine Make sure that the machine is ...

Page 43: ...rol panel In case of an emergency the parking brake can be applied as an additional to mobilize the machine If the machine is traveling forward as an emergency asset you can lower the blade to stop the machine Use this resource only after exhaust all the others resources During emergency brakeage the operator should hold firmly to the steering wheel until the machine is fully stopped 3 Fig Side pa...

Page 44: ...eep the engine working in low idle Allow the engine to keep working about 3 to 5 minutes 3 Turn off the engine turning the switch 3 to the O position 4 Push the blade control lever 4 smoothly forward until it lowers all the way to the ground if it is not locked In case of long inactivity periods the main switch should be turned off 2 1 Fig Steering pedals and controls 3 4 Fig Side panel ...

Page 45: ...cks on the tamping when parking on slopes Shut off the engine too To avoid accidents on slopes or hills park transversally to the direction of the inclination Never leave the machine while the engine is operational Before exiting apply the emergency parking brake Make sure that the machine is parked on a safe place and that is not blocking the traffic ...

Page 46: ...ipment through the specific rings for this purpose Always use steel cables and chains according to the safety regulations Equipment weight With ROPS cab With enclosed cab Operational weight 44 841 lbs 20 340 kg 45 304 lbs 20 550 kg With leveling blade 47 487 lbs 21 540 kg 47 928 lbs 21 740 kg With tilting blade 49 251 lbs 22 340 kg 49 714 lbs 22 550 kg Make sure that the lifting hooks are safely c...

Page 47: ...necessary 2 Install the drawbar avoid the use of cables and chains With the engine on lift the leveling blade or the tilting blade if equipped refer to Operation chapter and release the longitudinal transmission universal joint of the front and rear axle If the machine s breakage system is disabled avoid towing the machine on slopes when the machine is at high speed Always use the drawbar Fig Towi...

Page 48: ...ion 2 Shim the tamping cylinders 3 Tie the machine on the four fixing spots marked with safety decals Use proper chains or steel cables 4 Lock the chassis joint Before turning off the machine lock the chassis joint Extend the bar 1 and lock it with the pin and its lock 2 to the rear segment of the chassis Remember to remove the joint lock before using the machine Fig Joint lock 1 2 ...

Page 49: ... s position on the equipment is marked on both cylinders Front 9 4 240 mm Rear 5 129 mm Positioning the cylinder on the machine Make sure that the pads meet the standard of the following figure during the installation of the cylinders Installation of the tamping cylinders Check the minimum distance between the tire and the support easels so that the cylinders will not touch them thus preventing th...

Page 50: ...based lubricant oil grease or Vaseline 5 After the assembly install the tire locks and apply a torque of 140 lb ft 190 N m on the screws NOTE Apply a chemical lock Loctite in all fixating screws of the guide ring 6 After installing the locks put the tires in a central position inside the cylinders sharing equally the gap between the tire and the lock 7 Inflate all the tires with 3 10 4 13 bar 45 6...

Page 51: ...sary adjust the positioning of the scraping bars at a 1 25 mm gap NOTE Use a bar with a 1 diameter approx 25 mm to assist on adjustment For the transportation of the machine for long distances it is recommended to disassembly all the accessories referred to in this chapter so they can be assembled and adjusted later M20 BOLTS 383 5 lb ft 520 N m dry 346 6 lb ft 470 N m greased Fig Installing the s...

Page 52: ...n the position O Turn on the engine and keep it running until it is warmed up Always check the brakes Before starting the work shift carry out an operational system test When operating the machine use the forward backward lever carefully When parking the machine turn off the engine apply the parking brake and shim the tamping rollers When towing the machine refer to the towing instructions in this...

Page 53: ...ication and maintenance please refer to the respective Operation Section The machine requires special care in order to ensure its adequate operation Keep the machine clean so leakage loose bolts and connections as well as other faults may be easily detected Read carefully all the instructions before performing any service When operating the engine in enclosed rooms check if there is proper ventila...

Page 54: ... 40 C Room temperature over 104 F 40 C Shell Tellus V 68 or equivalent Shell Tellus T100 or equivalent TRANSMISSION OIL Spirax S4 CX 10W or equivalent DIFFERENTIAL OIL All temperatures Shell Spirax S2 A 90 or equivalent GREASE Shell Gadus S2 V220 or equivalent FUEL TIER III Diesel comum TIER IV Diesel com baixíssimo teor de enxofre COOLANT 50 potable water 50 coolant additive GlycoShell Carcoolant...

Page 55: ...e Symbols and lubricants 2018 02 20 4812325559EN 51 Engine oil level Engine oil filter Hydraulic fluid level Air filter Brake fluid Hydraulic fluid filter Transmission oil level Fuel filter Battery Coolant level ...

Page 56: ...Distance between axles 10 6 ft 3 250 mm External turning ratio 20 6 ft 6 300 mm Steering angle 40º Vertical swing 12º FUELING VOLUME Front and rear axle each 13 2 gal 50 L Hydraulic system reservoir 60 7 gal 230 L Tier III engine lubricant oil with filter 5 gal 19 L Tier III engine lubricant oil without the filter 4 7 gal 18 L Tier IV engine lubricant oil with filter 5 gal 19 L Tier IV engine lubr...

Page 57: ...ith a torque wrench METRIC THREAD RESISTANCE CATEGORY 8 8 10 9 M4 1 8 lb ft 2 5 N m 2 5 lb ft 3 4 N m M5 3 6 lb ft 4 9 N m 5 2 lb ft 7 0 N m M6 6 2 lb ft 8 4 N m 8 9 lb ft 12 N m M8 15 5 lb ft 21 N m 20 7 lb ft 28 N m M10 29 5 lb ft 40 N m 41 3 lb ft 56 N m M12 51 6 lb ft 70 N m 72 3 lb ft 98 N m M16 124 7 lb ft 169 N m 177 lb ft 240 N m M20 243 4 lb ft 330 N m 346 7 lb ft 470 N m M24 420 4 lb ft ...

Page 58: ... the windows and doors are kept closed Coolant designation HFC R134 A Coolant weight when full 1 000 g 2 2 lb Engine ENGINE Make and model Cummins QSB 6 7ℓ Tier III IV Type Turbo Diesel water coolant and air cooling Number of cylinders 6 in line 4 periods Power SAE J1995 194 kW 260 HP 2 200 RPM Tier III 194 kW 260 HP 2 200 RPM Tier IV Rotation of idle speed 750 RPM Blades BLADES Type Leveling and ...

Page 59: ... filter 22 Cab 2 Alternator belt 9 Tires 16 Front and rear axle 24 Fuse and relay box 3 Pre filter 10 Hydraulic cylinder of the blade 17 Wheel bolts 25 Electronic modules 4 Air filter 11 Fuel tank 18 Service brake 26 Transmission box 5 Hydraulic oil reservoir 12 Scrapers 19 Transmission box oil filter 27 Longitudinal transmission shift 6 Hydraulic oil filters 13 Main fuel filter 20 Transmission bo...

Page 60: ...engine 18 21 Check the brakes 58 12 Check the scrapers adjustment 59 9 Check the tire pressure 60 17 Check the tightening of the wheel bolts 60 5 Check the hydraulic oil reservoir oil level 61 22 Check the alignment of the cab cushions 61 1 Check the engine s coolant level 62 14 Check the engine s lubricant oil level 62 2 Check the tension on the alternator s belt 63 3 Check the pre filter s water...

Page 61: ...0 6 Replace the hydraulic oil filters ONLY ON THE FIRST 50 HOURS 71 After the first 50 hours of operation replace the engine oil the hydraulic system filter elements the fuel filters the engine lubricant oil Do NOT replace the hydraulic oil now In more severe temperature environments and dust reduce the frequency of cleaning the radiator BIWEEKLY Every 100 hours of operation ITEM ON PAG 52 PROCEDU...

Page 62: ...Y Every 500 hours of operation ITEM ON PAG 52 PROCEDURE PAGE 4 Replace the air filter main element 79 19 Replace the transmission box oil filters 79 BY ANNUALLY Every 1 000 hours of operation ITEM ON PAG 52 PROCEDURE PAGE Check the condition of the hydraulic hoses and connections 80 6 Replace the hydraulic oil filters 81 5 Drain the condensed water from the hydraulic oil reservoir 82 18 Check the ...

Page 63: ...Every 2 000 hours of operation ITEM ON PAG 52 PROCEDURE PAGE 5 6 Clean the reservoir replace the hydraulic oil and the brake and fan drive circuit filters 88 1 Replace the engine coolant 89 11 Clean and refuel the fuel tank 90 Check the vibration shock absorber of the engine crankshaft 90 ...

Page 64: ...engine switches off and the brakes are activated 3 Check the function of the emergency stop by pressing the emergency stop button when the machine 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 4 Check the function of the parking brake start the machine engine For ...

Page 65: ...king brake 1 The warning lamp should turn off otherwise check the cause of the problem Only release the parking brake if none of the warning lamps is on 3 Move slowly the machine forward and backward increasing and controlling the engine acceleration 4 Press the service brake pedal The machine should stop immediately either forward or backward 5 When finishing all testing stop and turn off the mac...

Page 66: ... 1 Release the fixing bolts 1 from the scrapers bar not completely 2 Adjust the scraper so that its distance relevant to the cylinders stays among 1 approx 25 mm NOTE Use a bar with a 1 diameter approx 25 mm to assist on adjustment 3 Tighten the fixing bolts again 1 with the following torque values M20 383 lb ft 520 N m dry 346 lb ft 470 N m greased M16 199 lb ft 270 N m dry 177 lb ft 240 N m grea...

Page 67: ... pressure 6 9 bar 100 psi When used as dozer When replacing the tires it is important to know that they have the same diameter and original width otherwise they can slide into the cylinder or unable its installation Check the tightening of the wheel bolts The wheel bolts should be tightened crossed alternately and opposite to each other Bolts dry torque 545 lb ft 740 N m Fig Wheel tire and compact...

Page 68: ... 1 Park the machine on a completely flat surface shut off the engine and the main switch 2 Check if the arrow in the scales is aligned with the number ZERO in the four cushions NOTE The adjustment is at real time or in others words when a cushion is inflated of deflated the other cushions are affected as well 3 Apply compressed air in the valves or deflate the cushions crossed according to the sca...

Page 69: ... 10 minutes Initially turn the cap only once it does allow the depressurization of the system Wait a moment and then remove the cap completely Check the engine s lubricant oil level To check the oil level shut down the engine and wait a few minutes until all the oil returns to the crankcase 1 Pull off the dipstick 2 and clean it with a clean with a cloth without threads 2 Put the dipstick back all...

Page 70: ...ers If the tension of a used belt is under the minimum value adjust it again to the maximum value for used belts Check the pre filter s water divider Check and drain the remaining water in the pre filter divider 1 Clean the filter body with a cloth including the drainage plug 2 At the lower part of the filter loosen manually the water drainage plug 1 3 Allow the water that is stored in the divider...

Page 71: ... idle and the transmission warmed up at 176 F 80 C and through the display located on the left side of the machine 3 Oil should be at the designated level of the display If it s below this mark fill with the recommended oil Check the Multi function display and the operator s control keyboard 1 Turn the key starter switch 1 to the position I The screen of the multi function display and the keys lig...

Page 72: ...e reservoir with fuel During this process keep the tip of the pump in contact with the filler nozzle Always fill with fuel recommended by DYNAPAC The usage of mixed contaminated dirty or low quality fuel damages the injection and engine components The repairs resulting from these conditions are NOT covered by the warranty Check the cabin s cushion height The cab s height is verified through scales...

Page 73: ...ight the clamps if necessary For further information refer to the Operation and Engine Maintenance Manual Check if there is damage and dirt in the exhaust gases post treatment connecting line system Clean it if necessary Clean the dust ejector valve Tier IV Engine Clean the dust ejector valve from the air filter daily after the working shift pressing the valve and releasing the dust when it is ope...

Page 74: ...mpactation Maximum pressure 6 9 bar 100 psi When used as dozer When replacing the tires it s important to know that they have the same diameter and original width otherwise they can slide into the cylinder or unable its installation Check the tightening of the wheel bolts The wheel bolts should be tightening crossed alternately and opposite to each other Bolts dry torque 545 lb ft 740 N m Fig Whee...

Page 75: ...thers don t have restrictions if necessary clean them 5 The battery terminals should be kept clean and the contact cables should be always tight In case they are rusted clean them with a water and sodium bicarbonate solution and apply a layer of Vaseline to prevent a new corrosion process When removing the battery initially disconnect the negative terminal Nevertheless when installing the battery ...

Page 76: ...d from the grease fittings Use only grease recommended by DYNAPAC 4 If the grease hasn t penetrated it will be necessary to relief the bearing with a hydraulic jack and to repeat the steps above Lubricate the steering system joints 1 Clean all the grease fitting nozzles before performing the lubrication 2 Lubricate each grease fitting front and rear on each side with approximately 2 manual cycles ...

Page 77: ...and universal joints and that a small excess came out of them and from the grease fitting nozzle It is recommended to keep a little bit of grease in the grease fitting because it helps preventing the deposit of dirt on it heck the condition of the hydraulic hoses and connections Verify if the hydraulic system hoses and connections are loose cracked or damaged and if so replace them Also check the ...

Page 78: ... with new oil recommended by DYNAPAC and lubricate the seal ring with the same oil Use only hydraulic oil recommended by DYNAPAC 7 Install the element screwing it manually until it reaches the base of the filter then adjust it with another turn Don t adjust it excessively because the seal ring may be damaged and it may cause leaks 8 Run the machine engine and check the oil level at the display and...

Page 79: ... container 4 Install the drainage plug and tighten it with a 69 lb ft 93 N m torque 5 Refill with the recommended oil until the edge of the refueling plug Replace the transmission box oil filters ONLY ON THE FIRST 100 HOURS 1 Clean the area around the base of the filters 2 Remove the filter elements individually with a belt wrench and discard them 3 Clean inside the base of the filters and the hou...

Page 80: ...ission box oil level in this section 7 Inspect visually the transmission box for leakages Verify the torque in the screws of Chassis joint 1 Make sure that the machine is on a leveled ground and the parking brake is applied 2 With a torque wrench verify if the top screw is with 200 Nm If necessary make the torque in screw 3 With a torque wrench verify if the lower screw is with 556 Nm If necessary...

Page 81: ...aps A C etc If the machine operates under severe conditions replace the cushions if their rubber or spacer is damaged Check the transmission box oil level 4 Turn the steering wheel completely to the right to allow better access to the level display Keep personnel away from the chassis joint while executing this operation risk of accidents 5 Check the oil level with the engine working in low idle a...

Page 82: ...t level can be found when the oil flows out from the plug hole 4 Fill it with the recommended oil if necessary through the refueling plug until it reaches the correct level 5 Install the drainage plug and tighten it with a 69 lb ft 93 N m torque Check the parking brake disc and pads 1 Check the parking brake pads for wear Replace the pads if their thickness is less than 6 mm 2 Check if the thickne...

Page 83: ...he washing of the hives Replace the lubricant oil and the engine oil filter Never perform maintenance under the machine when the engine is running Always park the machine on a leveled ground and shim the cylinders 1 Make sure that the roller is on a leveled ground and the parking brake is applied then open both the engine side covers 2 Open the cap of the oil filler nozzle 1 3 Clean the area aroun...

Page 84: ... not adjust it excessively because the seal ring may be damaged and it may cause leaks 6 Fill the engine again with the new engine oil recommended by DYNAPAC with the proper amount through the filler nozzle 1 7 Wait a few minutes until the oil is entirely inside the crankcase 8 Pull the dipstick 2 out clean it with a clean cloth without threads 9 Put the dipstick back all the way to the end and pu...

Page 85: ...d The replacement should be done when the fuel level reaches the black strip 3 Clean inside the bases of the filters and the housing of the ring seals 4 Fill the new filter elements with fuel recommended by DYNAPAC and lubricate the seal rings with the same fuel Use only filters recommended by DYNAPAC 5 Install the elements tighten them manually until they reach the base of the filter then adjust ...

Page 86: ...the filters element individually with a belt wrench and discard them 3 Clean inside the base of the filters and the housing of the seal rings 4 Complete the new filters elements with new oil recommended by DYNAPAC and lubricate the seal ring with the same oil Use only hydraulic oil recommended by DYNAPAC 5 Install the elements individually screwing them manually until they reach the base of the fi...

Page 87: ...ly Every 1 000 hours of operation Check the condition of the hydraulic hoses and connections Verify if the hydraulic system hoses and connections are loose cracked or damaged and if so replace them Also check the seal rings and clamps If they are damaged replace them Fig Hydraulic connections ...

Page 88: ...ed by DYNAPAC and lubricate the seal ring with the same oil Use only hydraulic oil recommended by DYNAPAC 7 Install the elements 2 tightening them manually until they reach the bases of the filter then adjust it with another turn Do not adjust it excessively because the seal ring may be damaged and it may cause leaks 8 Run the machine engine and check the oil level at the display and fill it if ne...

Page 89: ...he machine when the engine is running Always park the machine on a leveled ground and shim the cylinders 1 Make sure that the machine is on a leveled ground and the parking brake is applied 2 Clean the area around the inspection plug of the service brake friction discs 3 Release and remove the inspection plug of the service brake friction discs 1 and check the thickness of the friction discs Frict...

Page 90: ... F 80 C 194 F 90 C TAKE CARE OF THE ENVIRONMENT All used oil shall be collected and stored properly for recycling Do not discard oil on the soil sewerage system or any other location that can harm the environment 4 Clean the area around the base of the filters 5 Remove the filters element individually with a belt wrench and discard them 6 Clean inside the base of the filters and the housing of the...

Page 91: ...and feeds the torque converter approximately 8 minutes 12 Check the level with the engine at low idle and add recommended oil until the lower mark of the display 13 When the oil temperature is between 356 F 180 C 392 F 200 C perform the final verification of the level 14 The oil should be at the maximum level as indicated on the display If it is below this mark fill with the recommended oil Fig Tr...

Page 92: ... new safety element on the air filter casing pressing it against the casing s base Replace the safety element every time you detect any trace of dirt The element cannot be cleaned or reused 7 Install the main element on the air filter casing pressing it against the casing base Clean it if necessary 8 Clean the air collector installed on the cap of the air filter and inside the cap as well 9 Mount ...

Page 93: ...e side plug NOTE The sediment water draining process on the fuel tank should also be made when the equipment is not being used for a long period of time Check the alternator belt tensions Tier IV Engine Checking the belt tension should be done with a belt tension meter of tension type or Burroughs type A new belt should have a tension of 200 lb 890 N A used belt should have a tension of 80 160 lb ...

Page 94: ...e engine is running Always park the machine on a leveled ground and shim the cylinders 1 Make sure that the machine is on a leveled ground and the parking brake is applied 2 Clean the area around the drainage plug 1 and remove the refueling plug 2 3 Release and remove the drainage plug and drain the oil in a proper container 4 Install the drainage plug and tighten it with a 69 lb ft 93 N m torque ...

Page 95: ...for recycling Do not discard oil on the soil sewerage system or any other location that can harm the environment 5 Perform an internal cleaning of the reservoir using hot water under pressure with a proper detergent Clean the reservoir until the dirt is totally eliminated than dry it with pressurized air 6 Close the drainage plug and reinstall the inspection cap tightening the fixing bolts NOTE Re...

Page 96: ...system or any other location that can harm the environment 3 Fill the system through the expansion reservoir with the proper mixture of coolant according to the item Symbols and Lubricants 4 The level of the engine coolant can be visualized through the reservoir translucent walls which are located in the engine compartment near the radiators The level should be between the marks MIN and MAX when t...

Page 97: ...el the fuel tank The usage of mixed contaminated dirty or low quality fuel damages the injection and engine components The repairs resulting from these conditions are NOT covered by the warranty Check the vibration shock absorber of the engine crankshaft 1 Inspect the rubber element of the shock absorber and check if it is worn If there are missing pieces of rubber or if the rubber element is more...

Page 98: ...ered using the same procedure mentioned above air filter Fuel tank Refuel completely the tank in order to avoid water condensation and corrosion Hydraulic oil reservoir Drain the accumulated water on the bottom of the reservoir Caps plastic canvas Hydraulic cylinder joints etc Apply grease on the steering joint on both cylinder edges Cover the cylinder steering rod with grease to avoid oxidation A...

Page 99: ...nvolved systems and possible clogging in the filters NEVER drive the water jet under pressure into electrical or electronic components or into the instrument panel always keep them covered with caps or plastic wrappers Fire extinguishers In case of fire on the equipment use the carbon powder or carbon dioxide class ABC fire extinguisher Roll Over Protective Structure ROPS NEVER perform welding or ...

Page 100: ...transmission ECM Multifunction display etc or remove the grounded cables from the machine 3 on chassis and 2 on the cab Refer to the chapter Electric System in order to find the location of these points 4 Attach the ground connecting cable of the welding machine to the structural component to be welded Put the fastening element as near as possible to the welding Make sure that the ground connectin...

Page 101: ...as 8 pressure measurement points and maintenance and verification can be performed through them POINT 1 Steering system pressure measurement point It is located on the front chassis at the left side next to the joint Measurement pressure Maximum of 170 bar 2 466 psi Fig Measurement point 1 1 1 7 6 8 2 3 4 5 ...

Page 102: ...d point from the rear to the front part Measurement pressure 280 bar 4 061 psi with the fan working at 2 200 RPM to perform the measurement disconnect the fan pump solenoid POINTS 4 5 Radiator pressure measurement point It is located on the rear chassis input and output at the right side on the engine s cap 3rd and 4th points from the rear to the front part Measurement maximum pressure 4 bar 60 ps...

Page 103: ...rear chassis at the right side next to the joint and transmission Measurement pressure Maximum of 40 bar 580 psi POINT 8 Front brake measurement point It is located on the front chassis at the right side next to the joint Measurement pressure Maximum of 40 bar 580 psi 8 Fig Measurement point 8 Fig Measurement point 7 7 ...

Page 104: ...the mass The cable between the batteries and the alternator shall never be disconnected while the engine is running Before performing repairs with electric welding on the machine disconnect the negative terminal of the battery and all the alternator cables Fuses Fuse box F1 It is located on the engine compartment at the left side 1 Key starter switch main relay 5A 2 Main ECM I O unit screen 5A 3 M...

Page 105: ...dshield washer and wiper 10A 6 Rear windshield washer and wiper 10A 7 Free 8 Free Main fuse panel The main fuse panel is located behind the battery main switch on the batteries compartment 1 Main switch 2 Pre heating relay 120A 3 Fuse F20 pre heating 125A 4 Starting relay 50A 5 Fuses F13 Engine 30A ECM F10 main 50A and F11 cabin 50A 6 Fuse F5 cabin CD radio 10A 7 Electric jack 24 V Fig Cabin s fus...

Page 106: ... are located on the engine compartment at the left side of the machine and can be accessed by opening the cap with a belt wrench The engine electronic module 1 is located on its right side next to the diagnostic connector DLC 2 Fig Electronic modules compartment Fig Electronic modules compartment 1 2 ...

Page 107: ...2018 02 20 4812325559EN 103 ...

Page 108: ...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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