Dynapac CA702 Instruction Manual
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Dynapac CA702 Instruction Manual

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Instruction manual
Instruction manual
Operating & Maintenance
Operating & Maintenance
4812161901_B.pdf
4812161901_B.pdf
Vibratory roller
Vibratory roller
Cummins QSB 6.7C
Cummins QSB 6.7C
Serial number
Serial number
10000125xxA013326 -
10000125xxA013326 -
Translation of original instruction
Translation of original instruction
Reservation for changes
Reservation for changes
Printed in Sweden
Printed in Sweden
CA702
CA702
Engine
Engine

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  • Page 1 Instruction manual Instruction manual Operating & Maintenance Operating & Maintenance 4812161901_B.pdf 4812161901_B.pdf Vibratory roller Vibratory roller CA702 CA702 Engine Engine Cummins QSB 6.7C Cummins QSB 6.7C Serial number Serial number 10000125xxA013326 - 10000125xxA013326 - Translation of original instruction Translation of original instruction...

  • Page 3: Table Of Contents

    Table of Contents Introduction ..........................1 The machine ....................1 Intended use ....................1 Warning symbols..................1 Safety information ..................1 General ....................... 2 CE marking and Declaration of conformity..........3 Safety - General instructions....................5 Safety - when operating ......................7 Driving near edges ..................
  • Page 4 Working capacity..................18 General ..................... 18 Tightening torque ..................20 Hydraulic system..................21 Automatic Climate Control (ACC) (Optional)..........21 Machine description ....................... 23 Identification ......................23 Product identification number on the frame ..........23 Machine plate.................... 23 Explanation of 17PIN serial number............24 Engine plates ....................
  • Page 5 Master switch - Switching on..............41 Operator’s seat - Adjusting............... 41 Control unit - Setting ................. 42 Operator’s seat in cab - Adjusting ............. 42 Instruments and lamps - Checking............43 Parking brake - Check................43 Interlock..................... 44 Operator position..................44 View ......................
  • Page 6 Tires (All-weather)..................53 Steering cylinder, hinges, etc..............54 Hoods, tarpaulin ..................54 Miscellaneous ........................55 Lifting ........................55 Lifting the roller..................55 Locking the articulation ................55 Unlocking the articulation ................56 Towing/Recovering....................57 Alternative 1 ....................57 Short distance towing with the engine running.......... 57 Alternative 2 ....................
  • Page 7 Every 1000 hours of operation ..............73 Every 2000 hours of operation ..............74 Every other year..................75 Service - Checklist....................76 Maintenance, 10h ........................77 Scrapers - Check, adjustment..............77 Scrapers, Pad-drum .................. 78 Flexible scrapers (Optional) ..............78 Air circulation - Check ................
  • Page 8 Bolted joints - Checking tightening torque..........91 Rubber elements and fastening screws - Check........91 Battery - Check electrolyte level..............91 Battery cell ....................92 Air conditioning (Optional) - Inspection....................92 Maintenance measures - 500 h ..................... 93 Replacing the fuel filter................93 Rear axle differential - Check oil level............
  • Page 9 Rear axle planetary gears - Check oil level..........105 Drum gearbox - Checking the oil level ............ 105 Drum cartridge - Checking the oil level ........... 106 Drum cartridge - Cleaning the ventilation screw ........107 Radiator - Check/Cleaning ..............107 Rubber elements and fastening screws - Check........
  • Page 10 Drum gearbox - Checking the oil level ............ 121 Hydraulic reservoir - Oil change.............. 122 Drum cartridge - Checking the oil level ........... 122 Drum cartridge - Cleaning the ventilation screw ........123 Rubber elements and fastening screws - Check........124 Battery - Check electrolyte level..............
  • Page 11 Seat bearing - Lubrication ............... 137 Steering chain and seat bearing - Lubrication......... 138 Diesel engine - Oil and Filter change ............138 2018-07-10 4812161901_B.pdf...
  • Page 12 4812161901_B.pdf 2018-07-10...

  • Page 13: Introduction

    Introduction Introduction The machine CA702 is one of Dynapac's heavy soil compaction rollers. It is available in D (smooth drum) and PD (padfoot drum) versions. Intended use The D version is intended for the compaction of rockfill. The main area of application for the PD version is on cohesive material and weathered stone material.

  • Page 14: General

    This manual 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 4812161901_B.pdf 2018-07-10...

  • Page 15: Ce Marking And Declaration Of Conformity

    Introduction personnel. Additional instructions for the engine can be Additional instructions for the engine can be found in the manufactuer's engine manual. found in the manufactuer's engine manual. Specific maintenance and checks on diesel Specific maintenance and checks on diesel engines must be carried out by the engine engines must be carried out by the engine supplier’s certified personnel.
  • Page 16 Introduction 4812161901_B.pdf 2018-07-10...

  • Page 17: Safety - General Instructions

    Safety - General instructions Safety - General instructions (Also read the safety manual) The operator must be familiar with the contents of the OPERATION section The operator must be familiar with the contents of the OPERATION section before starting the roller. before starting the roller.
  • Page 18 Changes are only to be made after written approval has been given safety. Changes are only to be made after written approval has been given by Dynapac. by Dynapac. 18. Avoid using the roller before the hydraulic fluid has reached its normal 18.

  • Page 19: Safety - When Operating

    Safety - when operating Safety - when operating Prevent persons from entering or remaining in Prevent persons from entering or remaining in the danger area, i.e. a distance of at least 7 m the danger area, i.e. a distance of at least 7 m (23 ft) in all directions from operating machines.
  • Page 20 Safety - when operating To exit the cab in an emergency, release the To exit the cab in an emergency, release the hammer on the rear right post and break the rear hammer on the rear right post and break the rear window.

  • Page 21: Safety (Optional)

    Safety (Optional) Safety (Optional) Air conditioning The system described in this manual is type ACC (Automatic Climate Control) The system contains pressurized refrigerant. It The system contains pressurized refrigerant. It is forbidden to release refrigerants into the is forbidden to release refrigerants into the atmosphere.
  • Page 22 Safety (Optional) 4812161901_B.pdf 2018-07-10...

  • Page 23: Special Instructions

    Special instructions Special instructions Standard lubricants and other recommended oils and fluids Before leaving the factory, the systems and components are filled with the oils and fluids specified in the lubricant specification. These are suitable for ambient temperatures in the range -15°C to +40°C (5°F - 105°F).

  • Page 24: Fire Fighting

    Special instructions Do not use a high-pressure water jet on the Do not use a high-pressure water jet on the instrument panel/display. instrument panel/display. Detergent that can destroy electrical parts, or Detergent that can destroy electrical parts, or which is conductive, must not be used. which is conductive, must not be used.

  • Page 25: Jump Starting

    Special instructions When fitting batteries, always connect the When fitting batteries, always connect the positive cable first. positive cable first. Dispose of old batteries in an environmentally Dispose of old batteries in an environmentally friendly way. Batteries contain toxic lead. friendly way.
  • Page 26 Special instructions 4812161901_B.pdf 2018-07-10...

  • Page 27: Technical Specifications

    Technical specifications Technical specifications Vibrations - Operator station (ISO 2631) The vibration levels are measured in accordance with the operational cycle described in The vibration levels are measured in accordance with the operational cycle described in EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched on, on soft polymer material and with the operator’s seat in the transport position.

  • Page 28: Dimensions, Side View

    Technical specifications Dimensions, side view Dimensions Dimensions Wheelbase, drum and wheel Wheelbase, drum and wheel 3341 3341 131,5 131,5 Length, standard equipped roller Length, standard equipped roller 6535 / 6535 6535 / 6535 257,28 / 257,28 257,28 / 257,28 (D/PD) (D/PD) Height with cab (D/PD) Height with cab (D/PD)

  • Page 29: Dimensions, Top View

    Technical specifications Dimensions, top view Dimensions Dimensions Width, standard equipped roller Width, standard equipped roller 2420 2420 95,27 95,27 Overhang, left frame side Overhang, left frame side 5,31 5,31 Overhang, right frame side Overhang, right frame side Turn radius, external Turn radius, external 6000 6000...

  • Page 30: Weights And Volumes

    Technical specifications Weights and volumes Weights Weights Service weight without cab (D/PD) Service weight without cab (D/PD) 26350 / 26500 kg 26350 / 26500 kg 58091 / 58422 lbs 58091 / 58422 lbs Service weight with cab (D/PD) Service weight with cab (D/PD) 26900 / 27050 kg 26900 / 27050 kg 59304 / 59635 lbs...
  • Page 31 Technical specifications Tire Tire Tire dimensions Tire dimensions Tire pressure Tire pressure Std type Std type 23.1 x 26.0 12 ply 23.1 x 26.0 12 ply 220 kPa (2,2 kp/cm) (32 psi) 220 kPa (2,2 kp/cm) (32 psi) Tractor type Tractor type 23.1 x 26.0 12 ply 23.1 x 26.0 12 ply...

  • Page 32: Tightening Torque

    Technical specifications Tightening torque Tightening torque in Nm for oiled or dry bolts tightened with a torque wrench. Metric coarse screw thread, bright galvanized (fzb): STRENGTH CLASS: 8.8, Oiled 8.8, Oiled 8.8, Dry 8.8, Dry 10.9, Oiled 10.9, Oiled 10.9, Dry 10.9, Dry 12.9, Oiled 12.9, Oiled...

  • Page 33: Hydraulic System

    Technical specifications Hydraulic system Opening pressure Opening pressure Drive system Drive system 42,0 42,0 Supply system Supply system Vibration system Vibration system 42,0 42,0 Control systems Control systems 17,5 17,5 Brake release Brake release Automatic Climate Control (ACC) (Optional) The system described in this manual is type ACC (Automatic Climate Control), i.e.
  • Page 34 Technical specifications 4812161901_B.pdf 2018-07-10...

  • Page 35: Machine Description

    Machine description Machine description Identification Product identification number on the frame The machine PIN (product identification number) (1) is punched on the right edge of the front frame or the upper edge of the right frameside. Fig. Front frame 1. PIN Machine plate The machine type plate (1) is attached to the front left side of the frame, beside the steering joint.

  • Page 36: Explanation Of 17Pin Serial Number

    Machine description Explanation of 17PIN serial number A= Manufacturer 00123 00123 123456 123456 B= Family/Model C= Check letter F= Serial number Engine plates The engine type plates (1) are affixed to the top and on the right side of the engine. The plates specify the type of engine, serial number and the engine specification.

  • Page 37: Decals

    Machine description Decals Location - decals 2, 3 1. Warning, Crush zone 4700903422 1. Warning, Crush zone 4700903422 7. Warning, Locking 7. Warning, Locking 4700908229 4700908229 13. Sound power 13. Sound power 4700791279 4700791279 level level 2. Warning, Rotating 2. Warning, Rotating 4700903423 4700903423 8.

  • Page 38: Safety Decals

    Machine description Safety decals Always make sure that all safety decals are 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.
  • Page 39 Machine description 4700903590 -Emergency exit 4700903985 Warning - Ballasted tire. Read the instruction manual. More information in section in Technical specifications. 4700904895 Warning - Brake disengagement Study the towing chapter before disengaging the brakes. Danger of being crushed. 2018-07-10 4812161901_B.pdf...

  • Page 40: Info Decals

    Machine description Info decals Sound power level Sound power level Diesel fuel Diesel fuel Lift point Lift point Hoisting plate Hoisting plate Handbook compartment Handbook compartment Master switch Master switch Hydraulic fluid Hydraulic fluid Biological hydraulic fluid Biological hydraulic fluid Tie down point Tie down point Tire pressure...

  • Page 41: Instruments/Controls

    Machine description Instruments/Controls Locations - Instruments and controls Fig. Instruments and control panel Starter switch Starter switch Rpm/Frequency selector Rpm/Frequency selector Working lights Working lights Hazard beacon Hazard beacon Direction indicator switch Direction indicator switch Hazard warning lights Hazard warning lights Main beam switch Main beam switch Parking/dipped beam switch...

  • Page 42: Locations - Control Panel And Controls

    Machine description Locations - Control panel and controls Fig. Control panel Hourmeter Hourmeter Warning lamp, fuel level Warning lamp, fuel level Brake warning lamp Brake warning lamp Speed selector, drum/wheel Speed selector, drum/wheel Warning lamp, engine oil pressure Warning lamp, engine oil pressure Reserve Reserve Warning lamp, hydraulic fluid filter...

  • Page 43: Function Descriptions

    Machine description Function descriptions No Designation No Designation Symbol Symbol Function Function Starter switch Starter switch The electric circuit is broken. The electric circuit is broken. All instruments and electric controls are supplied with All instruments and electric controls are supplied with power.
  • Page 44 Machine description No Designation No Designation Symbol Symbol Function Function Fuel gauge Fuel gauge Shows level in the fuel tank. Shows level in the fuel tank. Preheating lamp Preheating lamp Lights up when the diesel engine is being preheated Lights up when the diesel engine is being preheated and the switch is in position I.
  • Page 45 Machine description No Designation No Designation Symbol Symbol Function Function Warning light, engine coolant Warning light, engine coolant If the lamp comes on, the engine is too hot. Stop the If the lamp comes on, the engine is too hot. Stop the temperature temperature engine immediately and locate the fault.

  • Page 46: Controls In The Cab

    Machine description Controls in the cab 1 2 3 4 5 First-aid kit (optional) Fig. Cab roof, front Fig. Cab right side (AC optional) Fig. Cab, right side Fig. Cab roof, rear Fig. Cab, rear 4812161901_B.pdf 2018-07-10...

  • Page 47: Function Description Of Instruments And Controls In The Cab

    Machine description Function description of instruments and controls in the cab Designation Designation Symbol Symbol Function Function Front working lights, switch Front working lights, switch Press to switch on the front working lights. Press to switch on the front working lights. Rear working lights, switch Rear working lights, switch Press to switch on the rear working lights.

  • Page 48: Electrical System

    Machine description Electrical system Fuses The electrical regulating and control system is protected against overload by 27 fuses and 12 relays. The quantity depends on how much extra equipment the machine has. The four fuse boxes (1) and relays (3) are located behind the lower instrument plate, which is opened by turning the four quick-fit screws (2) a 1/4 turn counter-clockwise.
  • Page 49 Machine description Fuses The figure shows the position of the fuses. The table below gives fuse amperage and function. All fuses are flat pin fuses. The tachograph and memory for the radio are protected at the battery master disconnect switch by a 0.5 A and 3 A fuse, respectively.

  • Page 50: Fuses In Cab

    Machine description Fuses in cab The electrical system in the cab has a separate fuse box located on the front right side of the cab roof. The figure shows fuse amperage and function. Fig. Cab roof fuse box All fuses are flat pin fuses. 1.

  • Page 51: Fuses At Battery Master Disconnect Switch

    Machine description Fuses at battery master disconnect switch Positioning of fuses at battery master disconnect switch in the engine compartment. QSB engine (ignition) QSB engine (ignition) Diagnostics lamps, engine Diagnostics lamps, engine ECM electronics ECM electronics Power socket, 12V Power socket, 12V Fig.

  • Page 52: Relays In Cab

    Machine description Relays in cab To replace the relays for the air conditioning fan, the condensor fan on the cab roof and the radio, remove instrumentpanel (1). Fig. Cab roof, front 1. Instrument plate 2. K30 Relay for air conditioning fan 3.

  • Page 53: Operation

    Operation Operation Before starting Master switch - Switching on Remember to carry out daily maintenance. Refer to the maintenance instructions. The master switch is located in the engine compartment. Turn the key (1) to the on position. The entire roller is now supplied with power. The engine hood must be unlocked when The engine hood must be unlocked when operating, so that the battery can be quickly...

  • Page 54: Control Unit - Setting

    Operation Control unit - Setting The control unit has two adjustment options, rotation and steering column angle. Pull the lever (1) upwards to allow rotation. Release the locking lever (2) to adjust the steering column to the desired slope and then lock the steering column in its new position.

  • Page 55: Instruments And Lamps - Checking

    Operation Instruments and lamps - Checking Turn the switch (1) to the mid-position. All warning lamps should light for about 5 seconds and the beeper should sound. During this time check that the warning lamps light up. Check that the voltmeter (10) reads at least 12 volts, and that the fuel gauge (15) shows a reading.

  • Page 56: Interlock

    Operation Interlock The roller is equipped with Interlock. The engine switches off 4 seconds after the operator rises from the seat. The engine stops whether the forward/reverse lever is in the neutral or the drive position. The engine does not stop if the parking brake is activated.

  • Page 57: View

    Operation 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 adjusted. Fig. view 2018-07-10 4812161901_B.pdf...

  • Page 58: Starting

    Operation Starting Starting the engine Pull up the emergency stop (37) and activate the parking brake (42). Set the forward/reverse lever (39) in neutral. The diesel engine cannot be started in any other position on the control. Set the amplitude selector (24) for Low/High vibration in position O.

  • Page 59: Operating

    Operation Operating Operating the roller Under no circumstances is the machine to be Under no circumstances is the machine to be operated from the ground. The operator must be operated from the ground. The operator must be seated inside the machine during all operation. seated inside the machine during all operation.
  • Page 60 Operation Deactivate the parking brake knob (42) and check Deactivate the parking brake knob (42) and check that the parking brake warning lamp is off. that the parking brake warning lamp is off. Remember that the roller can start rolling, if it is on Remember that the roller can start rolling, if it is on a slope.

  • Page 61: Operating On Difficult Surfaces

    Operation Check while driving that the gauges show normal readings. In the event of abnormal values or if the buzzer sounds, immediately stop the roller and the diesel engine. Check and remedy any fault; see also the chapter on maintenance and the engine manual. If the warning lamp for the air filter (30) comes on If the warning lamp for the air filter (30) comes on during operation (when the diesel engine is...

  • Page 62: Vibration

    Operation Vibration Amplitude/frequency - Changeover There are two drum vibration settings. Use the switch (24) to adjust. Turn the knob to the left for low amplitude/high frequency and to the right for high amplitude/low frequency. Setting the amplitude may not be performed Setting the amplitude may not be performed when vibration is in operation.

  • Page 63: Braking

    Operation Braking Emergency braking 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 the drum motor and rear axle acts as an emergency brake when in motion and as a parking brake when stationary.

  • Page 64: Switching Off

    Operation Switching off Check instruments and warning lamps to see if any faults are indicated. Switch off all lights and other electrical functions. Turn the starter switch (1) to the left to the shut off position. On rollers without a cab, lower and lock the instrument cover.

  • Page 65: Long-Term Parking

    Long-term parking Long-term parking The following instructions should be followed The following instructions should be followed when long term parking (more than one month). when long term parking (more than one month). These measures apply when parking for a period of up to 6 months.

  • Page 66: Steering Cylinder, Hinges, Etc

    Long-term parking Steering cylinder, hinges, etc. Grease the steering cylinder piston with conservation grease. Grease the hinges on the doors to the engine compartment and the cab. Grease both ends of the forward/reverse control (bright parts) (see under the heading 'Every 500 hours of operation'). Hoods, tarpaulin * Lower the instrument cover over the instrument panel.

  • Page 67: Miscellaneous

    Miscellaneous Miscellaneous Lifting Weight: refer to the hoisting plate on the roller Lifting the roller The machine’s gross weight is specified on the The machine’s gross weight is specified on the hoisting plate (1). Refer also to the Technical hoisting plate (1). Refer also to the Technical specifications.

  • Page 68: Unlocking The Articulation

    Miscellaneous Locking the articulation Articulation must be locked to prevent inadvertent Articulation must be locked to prevent inadvertent turning before lifting the roller. turning before lifting the roller. Turn the steering wheel to the straight ahead position. Activate the parking brake. Front frame shall be in line with the rear frame.

  • Page 69: Towing/Recovering

    Miscellaneous Unlocking the articulation Remember to restore the steering joint lock on the Remember to restore the steering joint lock on the steering joint to open before operating. steering joint to open before operating. Lift lock in the handle while turning it counterclockwise. Make sure lock gets in position on the dowel by trying to turn the handle clockwise or counterclockwise without lifting the lock.

  • Page 70: Alternative 2

    Miscellaneous Alternative 2 Towing short distances when the engine is inoperative Chock the drum and tires to prevent the roller Chock the drum and tires to prevent the roller moving when the brakes are mechanically moving when the brakes are mechanically disengaged.

  • Page 71: Brake Release Pump

    Miscellaneous Brake release pump Chock the drums to prevent the roller from moving Chock the drums to prevent the roller from moving when the brakes are hydraulically disengaged. when the brakes are hydraulically disengaged. The brake release pump has a protection (1) mounted which has to be removed before brake release.

  • Page 72: Towing The Roller

    Miscellaneous Towing the roller When towing/recovering, the roller must be braked When towing/recovering, the roller must be braked by the towing vehicle. A towing bar must be used by the towing vehicle. A towing bar must be used as the roller has no brakes. as the roller has no brakes.

  • Page 73: Operating Instructions - Summary

    Operating instructions - Summary Operating instructions - Summary Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Make sure that all instructions in the MAINTENANCE section are followed. Make sure that all instructions in the MAINTENANCE section are followed. Turn the master switch to the ON position.
  • Page 74 Operating instructions - Summary 4812161901_B.pdf 2018-07-10...

  • Page 75: Preventive Maintenance

    Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost. The Maintenance section includes the periodic maintenance that must be carried out on the machine. The recommended maintenance intervals assume that the machine is used in a normal environment and working conditions.
  • Page 76 Preventive maintenance 4812161901_B.pdf 2018-07-10...

  • Page 77: Maintenance - Lubricants And Symbols

    See the extremely low ambient temperatures. See the ‘Special instructions’ chapter, or consult ‘Special instructions’ chapter, or consult Dynapac. Dynapac. 2018-07-10 4812161901_B.pdf...
  • Page 78 Maintenance - Lubricants and symbols ENGINE OIL ENGINE OIL Air temperature -15°C - +50°C Air temperature -15°C - +50°C Dynapac Engine oil 200 P/N 4812161855 (5 liters), Dynapac Engine oil 200 P/N 4812161855 (5 liters), (5°F-122°F) (5°F-122°F) P/N 4812161856 (20...

  • Page 79: Maintenance Symbols

    Maintenance - Lubricants and symbols Maintenance symbols Engine, oil level Engine, oil level Tyre pressure Tyre pressure Engine, oil filter Engine, oil filter Air filter Air filter Hydraulic reservoir, level Hydraulic reservoir, level Battery Battery Hydraulic fluid, filter Hydraulic fluid, filter Recycling Recycling Transmission, oil level...
  • Page 80 Maintenance - Lubricants and symbols 4812161901_B.pdf 2018-07-10...

  • Page 81: Maintenance - Maintenance Schedule

    Maintenance - Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points Fig. Service and maintenance points Radiator grille Radiator grille Scrapers Scrapers Engine suspension, 4 pcs. Engine suspension, 4 pcs. Oil level, diesel engine Oil level, diesel engine Drum oil, level plug, x2 Drum oil, level plug, x2 Feed pump, fuel Feed pump, fuel...

  • Page 82: Every 10 Hours Of Operation (Daily)

    Maintenance - Maintenance schedule Remove all dirt before filling, when checking Remove all dirt before filling, when checking oils and fuel and when lubricating using oil or oils and fuel and when lubricating using oil or grease. grease. The manufacturer’s instructions found in the The manufacturer’s instructions found in the engine manual also apply.

  • Page 83: Every 50 Hours Of Operation (Weekly)

    Maintenance - Maintenance schedule Every 50 hours of operation (Weekly) Refer to the contents to find the page number of the sections referred to! Pos. Pos. Action Action Comment Comment in fig in fig Check that hoses and couplings are not leaking Check that hoses and couplings are not leaking Inspect/clean the filter element in the air cleaner Inspect/clean the filter element in the air cleaner...

  • Page 84: Every 500 / 1500 Hours Of Operation

    Maintenance - Maintenance schedule Every 500 / 1500 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Check oil level in rear axle differential and drop Check oil level in rear axle differential and drop Check oil level in rear axle planetary gearing Check oil level in rear axle planetary gearing...

  • Page 85: Every 1000 Hours Of Operation

    Maintenance - Maintenance schedule Every 1000 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. Pos. Action Action Comment Comment in fig in fig Check oil level in drum gearbox Check oil level in drum gearbox Check oil level in the drum cartridge Check oil level in the drum cartridge...

  • Page 86: Every 2000 Hours Of Operation

    Maintenance - Maintenance schedule Every 2000 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. Pos. Action Action Comment Comment in fig in fig Clean the coolers Clean the coolers 20, 24 20, 24 Check the bolted joints...

  • Page 87: Every Other Year

    Maintenance - Maintenance schedule Every other year Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Change the coolant (glycol) Change the coolant (glycol) 2018-07-10 4812161901_B.pdf...

  • Page 88: Service - Checklist

    Maintenance - Maintenance schedule Service - Checklist 4812161901_B.pdf 2018-07-10...

  • Page 89: Maintenance, 10H

    Maintenance, 10h Maintenance, 10h Every 10 hours of operation (Daily) Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 90: Scrapers, Pad-Drum

    Maintenance, 10h Scrapers, Pad-drum Undo the screws (1), then adjust each scraper 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). Fig. Scrapers 1. Screws 2.

  • Page 91: Air Circulation - Check

    Maintenance, 10h Air circulation - Check Ensure that the engine has free circulation of cooling air through the protective grille in the hood. To open the engine hood, turn the locking arm (1) upward. Raise the hood to its fully open position, checking that the red safety catch on the left gas spring is latched.

  • Page 92: Diesel Engine Check Oil Level

    Maintenance, 10h Diesel engine Check oil level Take care not to touch any hot parts of the engine Take care not to touch any hot parts of the engine or the radiator when removing the dipstick. Risk or the radiator when removing the dipstick. Risk for burns.

  • Page 93: Fuel Tank - Filling

    Maintenance, 10h Fuel tank - Filling Refuel daily with diesel fuel up to the lower edge of the filler pipe (1). Follow the engine manufacturer's specification with regard to the quality of diesel fuel. Stop the engine. Short-circuit (press) the filler gun Stop the engine.

  • Page 94: Brakes - Check

    Maintenance, 10h Brakes - Check Check the brakes by carrying out the following : Check the brakes by carrying out the following : Checking the emergency stop Operate the roller slowly forwards. Hold the steering wheel firmly and brace yourself for a sudden stop. Push in the emergency stop (1).

  • Page 95: Maintenance - 50H

    Maintenance - 50h Maintenance - 50h Every 50 hours of operation (Weekly) Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 96: Backup Filter - Change

    Maintenance - 50h Backup filter - Change Change the backup filter with a new filter after every third replacement of the main filter. To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.

  • Page 97: Tires - Air Pressure - Wheel Nuts - Tightening

    Maintenance - 50h Tires - Air pressure - Wheel nuts - Tightening Check the tire pressures using a pressure gauge. If the tires are filled with fluid, the air valve (1) must be in the "12 o'clock" position during pumping. Recommended pressure: See Technical Specifications.
  • Page 98 Maintenance - 50h Where cooling capacity is markedly reduced, clean the condensor element (1) located on the rear edge of the cab. Also clean the cooling unit in the cab. See under the heading 2000 hours, automatic climate control - overhaul.

  • Page 99: Maintenance Measures - 250 H

    Maintenance measures - 250 h Maintenance measures - 250 h Every 250/750/1250/1750..hours of operation (every 3 months) Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or...

  • Page 100: Rear Axle Drop Box - Check Oil Level

    Maintenance measures - 250 h Rear axle drop box - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running.

  • Page 101: Drum Gearbox - Checking The Oil Level

    Maintenance measures - 250 h Drum gearbox - Checking the oil level Wipe clean the area around the level plug (1) and then undo the plug. Ensure that the oil level reaches up to the lower edge of the plug hole. Top off with oil to the right level if the level is low.

  • Page 102: Drum Cartridge - Cleaning The Ventilation Screw

    Top off with oil through the filler plug (1), until oil begins to run out from the level plug's (3) hole. The level is correct when it stops running. Ensure that only Dynapac Drum oil 1000 is used Ensure that only Dynapac Drum oil 1000 is used in the cartridges..

  • Page 103: Bolted Joints - Checking Tightening Torque

    Maintenance measures - 250 h Bolted joints - Checking tightening torque Steering pump against engine (1) 38 Nm (28 lbf.ft). Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled. Engine mounting (3). Check that all M12 bolts (x20) are tightened, 78 Nm (57 lbf.ft). Wheel nuts (4).

  • Page 104: Battery Cell

    Maintenance measures - 250 h Battery cell Take off the cell caps (1) and make sure that electrolyte (2) is about 10 mm (0.4 in) above the plates (3). Check the level of all cells. Top off with distilled water to the right level if the level is low. 10 mm If the ambient temperature is below freezing, run the engine for a while before topping off with distilled...

  • Page 105: Maintenance Measures - 500 H

    Maintenance measures - 500 h Maintenance measures - 500 h Every 500/1500..hours of operation (every six months) Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or...

  • Page 106: Rear Axle Differential - Check Oil Level

    Maintenance measures - 500 h Rear axle differential - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.

  • Page 107: Rear Axle Planetary Gears - Check Oil Level

    Maintenance measures - 500 h Rear axle planetary gears - Check oil level Position the roller with the plug in the planetary gear (1) in the "9 o'clock" position. Wipe clean and remove the level plug (1) and check that the oil level reaches the lower edge of the plug hole.

  • Page 108: Drum Cartridge - Checking The Oil Level

    Top off with oil through the filler plug (1), until oil begins to run out from the level plug's (3) hole. The level is correct when it stops running. Ensure that only Dynapac Drum oil 1000 is used Ensure that only Dynapac Drum oil 1000 is used in the cartridges..

  • Page 109: Drum Cartridge - Cleaning The Ventilation Screw

    Maintenance measures - 500 h Drum cartridge - Cleaning the ventilation screw Clean the drum's ventilation hole and ventilation screw (1). The hole is required to eliminate excess pressure inside the drum. Fig. Drum 1. Ventilation screw Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1), (2) and (3).

  • Page 110: Rubber Elements And Fastening Screws - Check

    Maintenance measures - 500 h Rubber elements and fastening screws - Check Check all rubber elements (1), replace all of the elements if more than 25% of them on one side of the drum are cracked deeper than 10-15 mm (0.4-0.6 in). Check using a knife blade or pointed object.

  • Page 111: Battery Cell

    Maintenance measures - 500 h Battery cell Take off the cell caps (1) and make sure that electrolyte (2) is about 10 mm (0.4 in) above the plates (3). Check the level of all cells. Top off with distilled water to the right level if the level is low. 10 mm If the ambient temperature is below freezing, run the engine for a while before topping off with distilled...

  • Page 112: Controls And Moving Joints - Lubrication

    Maintenance measures - 500 h Controls and moving joints - Lubrication Lubricate engine hood hinges (1) and the slide rails of the operator's seat with grease, other joints and controls with oil. Lubricate the cab hinges with grease. See the lubrication specification. Fig.

  • Page 113: Diesel Engine - Oil And Filter Change

    Maintenance measures - 500 h Diesel engine - Oil and Filter change Take great care when draining warm fluid and oil. Take great care when draining warm fluid and oil. Wear protective gloves and goggles. Wear protective gloves and goggles. The oil drain plug (1) is most easily accessible from the bottom of the engine and is located attached to a hose on the rear axle..

  • Page 114: Seat Bearing - Lubrication

    Maintenance measures - 500 h Seat bearing - Lubrication Optional on rollers without cab Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism.

  • Page 115: Maintenance - 1000H

    Maintenance - 1000h Maintenance - 1000h Performed after 1000 operating hours (each year) Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 116: Rear Axle Differential - Check Oil Level

    Maintenance - 1000h Rear axle differential - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.

  • Page 117: Rear Axle Planetary Gears - Check Oil Level

    Maintenance - 1000h Rear axle planetary gears - Check oil level Position the roller with the plug in the planetary gear (1) in the "9 o'clock" position. Wipe clean and remove the level plug (1) and check that the oil level reaches the lower edge of the plug hole.

  • Page 118: Drum Cartridge - Checking The Oil Level

    Top off with oil through the filler plug (1), until oil begins to run out from the level plug's (3) hole. The level is correct when it stops running. Ensure that only Dynapac Drum oil 1000 is used Ensure that only Dynapac Drum oil 1000 is used in the cartridges..

  • Page 119: Drum Cartridge - Cleaning The Ventilation Screw

    Maintenance - 1000h Drum cartridge - Cleaning the ventilation screw Clean the drum's ventilation hole and ventilation screw (1). The hole is required to eliminate excess pressure inside the drum. Fig. Drum 1. Ventilation screw Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1), (2) and (3).

  • Page 120: Battery - Check Electrolyte Level

    Maintenance - 1000h Battery - Check electrolyte level Never use a naked flame when checking the Never use a naked flame when checking the battery as the electrolyte emits explosive gas while battery as the electrolyte emits explosive gas while the alternator is charging.

  • Page 121: Air Conditioning (Optional) - Inspection

    Maintenance - 1000h Air conditioning (Optional) - Inspection Inspect refrigerant hoses and connections and make sure that there are no signs of an oil film that can indicate a refrigerant leakage. Fig. Air conditioning 1. Refrigerant hoses 2. Condensor element Replacing the fuel filter Place a container underneath to collect fuel that Place a container underneath to collect fuel that...

  • Page 122: Controls And Moving Joints - Lubrication

    Maintenance - 1000h Controls and moving joints - Lubrication Lubricate engine hood hinges (1) and the slide rails of the operator's seat with grease, other joints and controls with oil. Lubricate the cab hinges with grease. See the lubrication specification. Fig.

  • Page 123: Diesel Engine - Oil And Filter Change

    Maintenance - 1000h Diesel engine - Oil and Filter change Take great care when draining warm fluid and oil. Take great care when draining warm fluid and oil. Wear protective gloves and goggles. Wear protective gloves and goggles. The oil drain plug (1) is most easily accessible from the bottom of the engine and is located attached to a hose on the rear axle..

  • Page 124: Seat Bearing - Lubrication

    Maintenance - 1000h Seat bearing - Lubrication Optional on rollers without cab Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism. Remove the cover (5) to access the lubrication nipple (1).

  • Page 125: Hydraulic Reservoir - Draining

    Maintenance - 1000h Clean thoroughly around the oil filters. Remove the oil filters (1) and dispose of them in Remove the oil filters (1) and dispose of them in an approved manner. They are single-use filters an approved manner. They are single-use filters and cannot be cleaned.

  • Page 126: Fuel Tank - Drainage

    Maintenance - 1000h Fuel tank - Drainage Water and sediment in the fuel tank are removed via the drainage plug in the bottom of the fuel tank. Be very careful during draining. Do not drop the Be very careful during draining. Do not drop the plug or else all the fuel will flow out.

  • Page 127: Rear Axle Drop Box - Oil Change

    Maintenance - 1000h Rear axle drop box - Oil change Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.

  • Page 128: Air Conditioning (Optional) Fresh Air Filter - Change

    Maintenance - 1000h Position the roller with the plug (1) in the planetary gear in the "9 o'clock" position. Fill with oil to lower edge of level hole. Use transmission oil. See the lubrication specification. Clean and refit the plug. Check the fluid level in the same way on the rear axle's other planetary gear.

  • Page 129: Steering Hitch - Tightening

    Maintenance - 1000h Steering hitch - Tightening Nobody must be allowed near the steering joint Nobody must be allowed near the steering joint when the engine is running. Risk of being when the engine is running. Risk of being crushed when the steering is operated. Switch crushed when the steering is operated.
  • Page 130 Maintenance - 1000h 4812161901_B.pdf 2018-07-10...

  • Page 131: Maintenance - 2000H

    Maintenance - 2000h Maintenance - 2000h Performed after 2000 operating hours (every two years) Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 132: Rear Axle Differential - Check Oil Level

    Maintenance - 2000h Rear axle differential - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.

  • Page 133: Rear Axle Planetary Gears - Check Oil Level

    Maintenance - 2000h Rear axle planetary gears - Check oil level Position the roller with the plug in the planetary gear (1) in the "9 o'clock" position. Wipe clean and remove the level plug (1) and check that the oil level reaches the lower edge of the plug hole.

  • Page 134: Hydraulic Reservoir - Oil Change

    Maintenance - 2000h Hydraulic reservoir - Oil change 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. Observe care when draining hot hydraulic fluid. Wear protective gloves and goggles.

  • Page 135: Drum Cartridge - Cleaning The Ventilation Screw

    Top off with oil through the filler plug (1), until oil begins to run out from the level plug's (3) hole. The level is correct when it stops running. Ensure that only Dynapac Drum oil 1000 is used Ensure that only Dynapac Drum oil 1000 is used in the cartridges..

  • Page 136: Rubber Elements And Fastening Screws - Check

    Maintenance - 2000h Rubber elements and fastening screws - Check Check all rubber elements (1), replace all of the elements if more than 25% of them on one side of the drum are cracked deeper than 10-15 mm (0.4-0.6 in). Check using a knife blade or pointed object.

  • Page 137: Replacing The Fuel Filter

    Maintenance - 2000h Replacing the fuel filter Place a container underneath to collect fuel that Place a container underneath to collect fuel that runs out when the filter is released. runs out when the filter is released. Screw off the fuel filter (1). The filter is of the disposable type and cannot be cleaned.

  • Page 138: Controls And Moving Joints - Lubrication

    Maintenance - 2000h Controls and moving joints - Lubrication Lubricate engine hood hinges (1) and the slide rails of the operator's seat with grease, other joints and controls with oil. Lubricate the cab hinges with grease. See the lubrication specification. Fig.

  • Page 139: Radiator - Check/Cleaning

    Maintenance - 2000h Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1), (2) and (3). Clean a dirty radiator using compressed air or a high-pressure water jet. Blow air or direct water through the cooler in the opposite direction to that of the cooling air.

  • Page 140: Drum Cartridge - Oil Change

    1. Filler plug level". 2. Drain plug 3. Level plug Repeat the procedure on the opposite side. Ensure that only Dynapac Drum oil 1000 is used Ensure that only Dynapac Drum oil 1000 is used in the cartridges.. in the cartridges.. 4812161901_B.pdf...

  • Page 141: Drum Gearbox - Oil Change

    Maintenance - 2000h Drum gearbox - Oil change Place the roller on a level surface with the plugs (1) and (2) as illustrated. Wipe clean, unscrew the plugs (1, 2 and 3) and drain the oil into a suitable receptacle, capacity about 5.0 liters (5,3 qts.).

  • Page 142: Steering Hitch - Tightening

    Maintenance - 2000h Steering hitch - Tightening Nobody must be allowed near the steering joint Nobody must be allowed near the steering joint when the engine is running. Risk of being when the engine is running. Risk of being crushed when the steering is operated. Switch crushed when the steering is operated.

  • Page 143: Compressor - Check (Optional)

    Maintenance - 2000h Compressor - Check (Optional) Inspect the attachment of the compressor (1). The compressor is located over the alternator in the engine compartment. The unit should, if possible, be run at least five minutes every week to ensure the lubrication of the gaskets and compressor in the system.

  • Page 144: Steering Hitch And Steering Cylinders - Check

    Maintenance - 2000h Steering hitch and Steering cylinders - Check Inspect the steering hitch to detect any damage or cracks. Inspect the steering cylinders to detect any damage, cracks or leakage. Check and tighten any loose bolts. Check also for any stiffness and play. Fig.

  • Page 145: Bolted Joints - Checking Tightening Torque

    Maintenance - 2000h Bolted joints - Checking tightening torque Steering pump against engine (1) 38 Nm (28 lbf.ft). Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled. Engine mounting (3). Check that all M12 bolts (x20) are tightened, 78 Nm (57 lbf.ft). Wheel nuts (4).

  • Page 146: Rear Axle Drop Box - Oil Change

    Maintenance - 2000h Rear axle drop box - Oil change Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.

  • Page 147: Fuel Tank - Drainage

    Maintenance - 2000h Fuel tank - Drainage Water and sediment in the fuel tank are removed via the drainage plug in the bottom of the fuel tank. Be very careful during draining. Do not drop the Be very careful during draining. Do not drop the plug or else all the fuel will flow out.
  • Page 148 Maintenance - 2000h Clean thoroughly around the oil filters. Remove the oil filters (1) and dispose of them in Remove the oil filters (1) and dispose of them in an approved manner. They are single-use filters an approved manner. They are single-use filters and cannot be cleaned.
  • Page 149 Maintenance - 2000h Seat bearing - Lubrication Optional on rollers without cab Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism. Remove the cover (5) to access the lubrication nipple (1).
  • Page 150 Maintenance - 2000h Steering chain and seat bearing - Lubrication Optional on rollers without cab Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism.
  • Page 152 Dynapac Compaction Equipment AB Box 504, SE 371 23 Karlskrona, Sweden www.dynapac.com...

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