Fayat Group Dynapac CA25 Instruction Manual
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Fayat Group Dynapac CA25 Instruction Manual

Vibratory roller
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Instruction manual
4812325897EN
Operating & Maintenance
Vibratory Roller
CA25 / 30 / 35
Engine
Cummins QSF 3.8
From the serial number
10000179xxB006062 –
10000181xxB005992 –
10000183xxB006276 –
Reservation for changes
Printed in Brasil

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Summary of Contents for Fayat Group Dynapac CA25

  • Page 1 Instruction manual 4812325897EN Operating & Maintenance Vibratory Roller CA25 / 30 / 35 Engine Cummins QSF 3.8 From the serial number 10000179xxB006062 – 10000181xxB005992 – 10000183xxB006276 – Reservation for changes Printed in Brasil...

  • Page 3: Table Of Contents

    Introduction TABLE OF CONTENTS OPERATION Page Introduction ..........................4 Safety - General instructions ....................6 Safety - When operating ......................8 Special Instructions ........................9 Technical specifications ......................12 Noise/Vibrations/Electrical ..................... 12 Technical specifications - Dimensions ................... 13 Technical specifications – Weights and volumes ..............15 Technical specifications –...

  • Page 4: Introduction

    Introduction Introduction The machine CA25 / 30 / 35 are models of Dynapac's medium-heavy soil compaction rollers. They are available in a D (smooth drum) and PD (padfoot) version. Intended use All types of base courses and subbase courses can be compacted.
  • Page 5 Introduction General This manual contains instructions machine operation and maintenance. The machine must be correctly maintained for maximal performance. The machine should be kept clean so that any leakages, loose bolts and loose connections are discovered at as early a point in time as possible. Inspect the machine every day, before starting.

  • Page 6: Safety - General Instructions

    Safety - General instructions Safety - General instructions (Also read the safety manual) Read and understand this manual before starting and operate the machine. The operator must be familiar with the contents of the OPERATION section before starting the roller. Ensure that all instructions in the MAINTENANCE section are followed.
  • Page 7 Safety - General instructions 15. Before repairs or service: - -Chock the drums/wheels; - -Lock the articulation if necessary. 16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The noise level can vary depending on the equipment on the machine and the surface the machine is being used on.

  • Page 8: Safety - When Operating

    Special instructions Safety - When operating Operating on slopes When driving near the start of slopes, at least 2/3 of the width of the machine should be on land with full load capacity. Keep in mind that the machine's center of gravity moves outwards when steering.

  • Page 9: 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). Higher ambient temperatures, above +40°C (104°F) For operation of the machine at higher ambient...
  • Page 10 Special instructions High pressure cleaning Do not spray directly onto electrical components or control panel. Place a plastic bag over the reservoir lid and seal with a rubber band. This prevents the water under pressure from passing through the vent hole in the lid. This could cause malfunctions, e.g.
  • Page 11 Special instructions Battery handling When removing batteries, always disconnect the negative cable first. When fitting batteries, always connect the positive cable first. Dispose of old batteries in an environmentally friendly way. Batteries contain toxic lead. Do not use a quick-charger for charging the battery.

  • Page 12: Technical Specifications

    Technical specifications – Noise/Vibrations/Electrical Technical specifications Noise/Vibrations/Electrical Vibrations - Operator station (ISO 2631) 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 on, on soft polymer material and with the operator’s seat in the transport position.

  • Page 13: Technical Specifications - Dimensions

    Technical specifications – Dimensions Technical specifications - Dimensions Dimensions – Side view Dimensions Wheelbase, drum and wheel 2990 117,7 Length, standard equipped roller 5560 218,9 Height, with ROPS/cab (D) 2890 113,8 Height, with ROPS/cab (PD) 2890 113,8 Height, without ROPS (D) 2400 94,5 Height, without ROPS (PD)
  • Page 14 Technical specifications – Dimensions Dimensions – Top view Dimensions Width, front CA25(PD/D), CA30(PD/D), and CA35 (PD) 2256 88,8 CA35D 2276 89,6 Width, rear 2130 83,9 Overhang, left frame side CA25(PD/D), CA30(PD/D), and CA35(PD) 2,48 CA35 (D) 2,87 Overhang, right frame side CA25, CA30, and CA35 (PD) 2,48 CA35 (D)

  • Page 15: Technical Specifications - Weights And Volumes

    Technical specifications – Weights and volumes Technical specifications – Weights and volumes Operational weight Canopy ROPS CA25D (kg) 10.300 10400 10500 (lb) 22707 22928 23148 CA25PD (kg) 10.500 10600 23369 (lb) 23148 10700 23589 CA30D (kg) 11.100 11.200 11.300 (lb) 22471 24691 24912...

  • Page 16: Technical Specifications - Working Capacity

    Technical specifications – Working capacity Technical specifications – Working capacity Compaction data Static linear load (D) CA25 26 kg/cm 146 pli CA30 30 kg/cm 168 pli CA35 35 kg/cm 196 pli Amplitude, High (D) CA25, CA30 1,8 mm 0,071 pol CA35 1,7 mm 0,07 pol...

  • Page 17: Technical Specifications - General

    Technical specifications – General Technical specifications – General Engine Manufacturer/Model Cummins QSF 3.8 Water-cooled turbo diesel engine Power (SAE J1995) RPM engine, idling RPM engine, loading/unloading 1.600 RPM engine, work/transport 2.200 Traction Speed range CA25 0 - 8 km/h (Dual Speed) 0 - 5 CA30 e CA35 0 - 11...
  • Page 18 Technical specifications – General ROPS bolts Bolts dimensions: Front fixing M20x150 (PN 903633) Rear fixing M20x130 (PN 902282) Strength class: 10.9 800 Nm (With Tightening torque Dacromet® treatment) The ROPS bolts that will be tightened should be dry. Air Conditioning / Automatic Climate Control (ACC) (Optional) The system described in this manual is an AC/ACC type (Automatic Climate Control).
  • Page 19 Technical specifications – General 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: M - Thread 8,8 - Oiled 8,8 - Dry 10,9 - Oiled 10,9 - Dry 12,9 - Oiled 12,9 - Dry 13,4 14,6 16,3...

  • Page 20: Machine Description

    Machine description Machine description Diesel engine The machine is equipped with a water-cooled, in-line four cylinders, four-stroke, turbocharged Diesel engine with direct injection and a charge air cooler. Electrical system The machine has the following control units (ECU, Electronic Control Unit) and electronic units. •ECU (for the machine) •...
  • Page 21 Machine description Steering system The steering system is a load-sensing hydrostatic system. The control valve on the steering column distributes the flow to the steering cylinders at the articulated joint. The steering angle is proportional to the amount the steering wheel is turned.

  • Page 22: Product Plate - Identification

    Product plate – Identification Product plate – Identification Product identification number on the frame The machine PIN (product identification number) (1) is punched on the right edge of the front frame. Fig. Front frame Machine data plate The machine data plate (1) is attached to the left side of the rear frame, beside the steering joint.
  • Page 23 Product plate – Identification Engine plate The engine plate (1) are affixed to the top of the engine. The plate specifies the type of engine, serial number and the engine specifications. Please specify the engine serial number when ordering spares. Refer also to the engine manual. Fig.

  • Page 24: Machine Description - Decals

    Machine description – Decals Machine description – Decals Location – decals 1. Warning, Crush zone Hydraulic fluid 15. Coolant Warning, Rotating engine Lifting point 16. Hydraulic oil level parts 3. Warning, Hot surfaces Fixing point 17. Articulation lock 4. Warning, Ballasted tires Master switch 5.
  • Page 25 Machine description – Decals Safety decals 4700903422 Warning - Crush zone, articulation/drum. Maintain a safe distance from the crush zone. 4700903423 Warning - Rotating engine components. Keep your hands at a safe distance. 4700903424 Warning - Hot surfaces in the engine compartment. Keep your hands at a safe distance.
  • Page 26 Machine description – Decals Info decals Coolant Diesel fuel Lifting point Hoisting plate Manual compartment Master switch Hydraulic oil Tire pressure Securing point Hydraulic oil level Fire extinguisher 02-17-2021 4812325897EN...

  • Page 27: Machine Description - Instruments/Controls

    Machine description – Instruments/Controls Machine description – Instruments/Controls Locations – Instruments and controls Fig. Instruments and control panel Ignition switch Membrane panel Emergency stop Traffic lights switch Vibration on/off Warning lights switch Manual compartment Direction indicators switch Forward & Reverse lever Parking brake switch Seat switch Control panel...
  • Page 28 Machine description – Instruments/Controls Designation Symbol Function Ignition key Positions 1-2: Off position, the key can be removed. Position 3a: All instruments and electrical controls receive power. The machine is equipped with automatic heating, which occurs in this position. Position 3c: Starter motor activation. Emergency stop Brakes the roller and switches off the engine.
  • Page 29 Machine description – Instruments/Controls Designation Symbol Function 10 Warning lights switch When pressed, the warning lights will be on. (optional) 11. Direction indicators switch When pressed to one side, the respective indication (optional) lights up. In the central position, the function is turned off.
  • Page 30 Machine description – Instruments/Controls Functional description - Membrane panel Work mode Amplitude high/low Work lights Rotating beacon Gear Selector - reduce Gear Selector - increase Horn Engine speed selector Symbol Designation Function LED Color Activates the working mode, which makes it possible to vibration use TURN OFF LED ...
  • Page 31 Machine description – Instruments/Controls Symbol Designation Function LED Color Press to activate the rotating beacon Rotating TURN OFF LED  beacon LEFT LED  Turn on Yellow TURN OFF LED  Work mode Gear Selector LEFT LED  – reduce “Turtle”...
  • Page 32 Machine description – Instruments/Controls Functional description – Display When the ignition key is activated to position 1, a start screen is visible in display (Fig. 1). This is shown for a few seconds and then switches over to the status screen. The transport mode menu appears when one of the three function keys on the right of the screen is activated.
  • Page 33 Machine description – Instruments/Controls User settings Users can change the light settings (6), choose between the Metric or Imperial system (7). Fig. User settings Work mode - Vibration The selection of the different work modes takes place by pressing the respective button (2) on the Control Panel. Compaction mode Compacting status active on the roller (8).
  • Page 34 Machine description – Instruments/Controls Submenu - Fault codes 1. The alarm symbols are on the left side of the control panel. The red warning symbol is on the top and the yellow symbol is on the bottom (1). The side menu appears when the submenu is selected.
  • Page 35 Machine description – Instruments/Controls Functions description Symbol Designation and Function Warning lamp (Red) Serious fault: Shut down the engine immediately! It turns on along with a message on the screen. Warning lamp (Yellow) Less serious fault: Correct as soon as possible! It turns on along with a message on the screen.
  • Page 36 Machine description – Instruments/Controls Locations – Control panel / controls / cab Switch and Fuses Designation Symbol Function 1. Front wiper switch Press to operate the front windshield wiper. 2. Front and rear windshield Press the top to activate the front washers. Press the washers switch bottom to activate the rear washers.

  • Page 37: A/C - System Operation

    Machine description – Instruments/Controls A/C – System operation Introduction This air conditioning system is designed to provide the operator of the equipment with safety and comfort during the performance of his work and, consequently, increase his productivity. Commands The air conditioning/heating system is operated through the control panel located on the right roof of the cabin.
  • Page 38 Machine description – Instruments/Controls  Set the selector A at the desired speed;  Keep the switch B turn off (top region);  Set the selector C at the desired position;  Set the selector D at the desired temperature. Air Conditioning To use the air conditioning: ...
  • Page 39 Machine description – Electrical System Control unit The control unit (ECU) (1) is located behind the front cover below the operator seat. This unit is responsible for the operation of the steering electrical system, vibration, start / stop, etc. Fig. Steering compartment Control unit (ECU) Main fuses There are three main fuses.
  • Page 40 Machine description – Electrical System Relay The table below shows the amperage and function of the fuses. Fig. Relays and fuse board Fuse Amperage Function Machine ECU 7,5A Machine ECU Display, Keypad, Dyn@link, P-Brake Switch Neutral switch, Seat switch, alternator, vibration switch (joystick) Compaction Meter, Speed Sensor Stereo System, Left Work Lights Right Work Lights...

  • Page 41: Operation - Starting

    Operation - Starting Operation - Starting Before starting Master switch - Switching on Remember to carry out daily maintenance. Refer to the maintenance instructions. The battery master switch is located in the engine compartment. Open the engine cover and insert the key in Fig.
  • Page 42 Operation - Starting Before starting Check whether the emergency stop button (2) is pulled out. When the machine is in neutral or when there is no load on the operator's seat, the automatic brake function is activated. Pull out the emergency button (2). Fig.
  • Page 43 Operation - Starting 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 Interlock The roller is equipped with Interlock. The Diesel engine with switch off after 4-7 seconds if the operator gets off the seat when going forwards/backwards.
  • Page 44 Operation - Starting Starting the Diesel engine Make sure the emergency stop button (2) is pulled. Make sure the parking brake switch (12) is on. The forward/reverse lever (5) shall be in the neutral position. The Diesel engine cannot be started if the lever is not in this position.

  • Page 45: Operation - Driving

    Operation - Driving Operation - Driving Operating the roller Under no circumstances is the machine to be operated from the ground. The operator must be seated inside the machine during all operation. Set the speed selector (8) to the high operating position.

  • Page 46: Operation - Vibration

    Operation - Vibration Operation – Vibration Vibration switch To activate or deactivate the vibration, activate the high or low amplitude selector (8). The operator must activate it by the vibration switch, located on the underside of the forward-reverse lever. Fig. Control panel: Amplitude switch.
  • Page 47 Operation - Vibration Dynapac Compaction Meter (DCM) including Active Bouncing Control (ABC) - Optional The Compaction Meter is an accessory used to ensure the compaction result and enables optimal material processing. Your system allows you to choose different types of materials as a parameter, adapting the system to the material being compacted.
  • Page 48 Operation - Vibration Operation CMV The Compaction Meter measures the dynamic stiffness of the ground and presents a value based on this. The CMV is influenced by the rolling speed, rolling direction (forward or reverse), amplitude setting and vibration frequency. The Dynapac Compaction Meter (DCM) is less sensitive to small variation in vibration frequency.

  • Page 49: Operation - Braking

    Operation – Braking Operation – Braking 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. There is also a brake on the engine and rear axle of the machine which acts as an emergency brake during operation.
  • Page 50 Operation – Braking Switching off Check the controls and warning lamps to see if there are any indications of malfunction (13). Turn off all lights and other electrical functions. Set the speed selector (8) to neutral and let the engine run for about one minute. Activate the parking brake (3).
  • Page 51 Long-term parking Long-term parking The following instructions should be followed when long term parking (more than one month). These measures apply when parking for a period of up to 6 months. Wash the machine and touch up the paint finish to avoid rusting.
  • Page 52 Long-term parking Steering cylinder, hinges, etc. Lubricate the joint bearings with grease. Lubricate steering cylinder piston with preservative grease. Also lubricate the hinges of the engine compartment and cab doors. Lubricate both ends of the forward- reverse lever (chrome parts). Hoods, tarpaulin Lower the instrument cover over the instrument panel.

  • Page 53: Miscellaneous

    Miscellaneous Miscellaneous Lifting Locking the articulation Articulation must be locked to prevent inadvertent turning before lifting the roller. Turn the steering wheel to the straight-ahead position. Activate the parking/emergency brake. Fig. Steering joint lock. Pull out the safety pin (1) fitted with a wire. Safety pin Lock arm Articulation lock...
  • Page 54 Miscellaneous Unlocking the articulation Remember to restore the steering joint lock on the steering joint to open before operating Return the lock arm (2) to the starting position and secure it with the lock pin (1) to the articulation lock (4).
  • Page 55 Miscellaneous Alternative 2 Short distance towing when the engine is inoperative Chock the wheels to prevent the roller from moving when the brakes are hydraulically disengaged. Press button (1) and move the hand pump (2) horizontally until you feel resistance to movement, keep moving several times until the brake is released.
  • Page 56 Miscellaneous Transport Before lifting or transport, lock the steering joint. Follow the instructions in the respective sections. Apply the chocks to the cylinders (1) and then attach them to the transport vehicle. Place supports under the cylinder frame (2) to avoid overloading the roller suspension when it is held by tensioning cables.

  • Page 57: Operating Instructions - Summary

    Operating instructions - Summary Operating instructions - Summary Follow the SAFETY INSTRUCTIONS specified in the Safety Manual; 2. Ensure that all instructions in the MAINTENANCE section; 3. Turn the master switch to the ON position; 4. Move the forward/reverse lever to the NEUTRAL position; 5.

  • Page 58: 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 59: Maintenance - Lubricants And Symbols

    Maintenance - Lubricants and symbols Maintenance - Lubricants and symbols Always use high-quality lubricants and the amounts recommended. Too much grease or oil can cause overheating, resulting in rapid wear. P/N 4812161855 (5L) P/N 4812161856 (20L) Air temperature -15°C - +50°C ENGINE OIL Dynapac Engine oil 200 (5°F-122°F)
  • Page 60 Maintenance - Lubricants and symbols Maintenance symbols Engine, oil level Tire pressure Engine, oil filter Air filter Hydraulic reservoir, level Battery Hydraulic fluid, filter Recycling Transmission, oil level Fuel filter Drum, oil level Coolant, level Oil for lubrication 02-17-2021 4812325897EN...

  • Page 61: Maintenance - Maintenance Schedule

    Maintenance – Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points Read this section of the manual carefully before performing any maintenance or lubrication work on the machine. Get used to examining the areas around and below the equipment. It's a common and easy way to detect leaks in their early stage and likely anomalies.

  • Page 62: Scheduled Maintenance And Lubrication

    Maintenance – Maintenance schedule Scheduled maintenance and lubrication Periodic maintenance should be carried out after the number of hours specified. Use the daily, weekly etc. periods where number of hours cannot be used. Remove all dirt before filling, when checking oils and fuel and when lubricating using oil or grease.

  • Page 63: Maintenance, After The First 50 Hours Of Operation

    Maintenance – Maintenance schedule Maintenance, after the FIRST 50 hours of operation Refer the figure "Revision and Inspection Points” to find the page number of the sections referred to! Pos. in Action Comment figure Replace the hydraulic oil filter Replace the drum cartridge oil Replace the oil in the drum gearbox Steering hitch - Tightening Every 50 hours of operation (Weekly)

  • Page 64: Maintenance, Every 500 Hours Of Operation

    Maintenance – Maintenance schedule Maintenance, every 500 hours of operation Refer the figure "Revision and Inspection Points” to find the page number of the sections referred to! Replace the Diesel engine oil and oil filter Refer to the engine manual Replace the fuel filter and fuel pre-filter Refer to the engine manual Replace the primary air filter...

  • Page 65: Maintenance, Every 2000 Hours Of Operation

    Maintenance – Maintenance schedule Maintenance, every 2000 hours of operation Refer the figure "Revision and Inspection Points” to find the page number of the sections referred to! Replace the hydraulic fluid filter Check the air conditioning filter Replace the Diesel engine oil and oil filter Refer to the engine manual Replace the fuel filter and fuel pre-filter Refer to the engine manual...
  • Page 66 Maintenance – Maintenance schedule Maintenance Schedule Check the machine's hour meter for the type of maintenance required. 02-17-2021 4812325897EN...
  • Page 67 Maintenance, 10 h Maintenance, 10 hours Every 10 hours of operation (Daily) Scrapers - Check, adjustment It is important to consider movement of the drum when the machine turns, i.e., the scrapers can be damaged or wear of the drum may increase if adjustment is made closer than the values stated.
  • Page 68 Maintenance, 10 h Check fluids levels Coolant level - Check The coolant reservoir is located beside the hydraulic oil reservoir and is easier to observe from the right side of the machine The filler cap (2) is accessible from above the engine hood.
  • Page 69 Maintenance, 10 h Fuel tank - Filling Top up the fuel tank every day to the lower edge of the pipe (1). Follow the engine manufacturer's specifications for Diesel fuel. Stop the engine. Short-circuit (press) the filler gun against a non-insulated part of the roller before refueling, and against the filler pipe (1) while refueling.
  • Page 70 Maintenance, first 50 h Maintenance, first 50 hours Park the roller on a level surface. The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.
  • Page 71 Maintenance, first 50 h Cartridge – Oil change Park the machine on a flat surface so that the filler plug (1) is perpendicular. Place a container of approximately 5 liters capacity under the drain plug (2). Fig. Drum, left side Observe care when draining drum oil/hot drum oil.
  • Page 72 Maintenance, first 50 h Steering hitch – Tightening Nobody must be allowed near the steering joint when the engine is running Risk of being crushed when the steering is operated. Switch off the engine and activate the parking brake before lubrificating. The easiest way to identify if you have this type of steering hitch is that has a new type of nut (1) at the top as shown.
  • Page 73 Maintenance, 50 h Maintenance, 50 hours Every 50 hours of operation (Weekly) Park the roller on a level surface. The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.
  • Page 74 Maintenance, 50 h Central Articulation / Steering - Lubrication Personnel are not allowed near the steering joint when the engine is running. Danger of crushing when maneuvering with the steering. Before lubricating, apply the emergency/parking brake. Clean dirt and grease from lubrication points. Use grease according to the lubricant specification.
  • Page 75 Maintenance, 50 h Tires - Air pressure check / 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: refer Technical Specifications.
  • Page 76 Maintenance – 250 h Maintenance, 250 hours Every 250/750/1250/1750 hours of operation (monthly) Diesel engine - Oil and filter change Take great care when draining warm fluid and oil. Wear protective gloves and goggles. The oil drain plug (1) can be accessed most easily under the engine.
  • Page 77 Maintenance – 250 h Air conditioning (Optional) Fresh air filter – Change/Clean There is a fresh air filter (1), located at the front of the cab. Remove the three screws (2) and remove the protective cover. Clean or replace them with new filters It may be necessary to change the filters more often if the machine is working in a dusty environment.
  • Page 78 Maintenance – 250 h Rear axle planetary gears - Check oil level Position the roller so that the level plug (1) in the planetary gear is at "9 o'clock". Wipe clean and remove the level plug (1) and check that the oil level reaches the lower edge of the plug hole.
  • Page 79 Maintenance – 250 h Battery - Check condition Remove the cap (1) and check that the electrolyte level (2) is about 10 mm above the plates. If the level is low, fill up with distilled water to the correct level. If the ambient temperature is below freezing point, the engine should be running for some time after adding the distilled water.
  • Page 80 Maintenance – 250 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 81 Maintenance – 500 h Maintenance, 500 hours Every 500 hours of operation (every three months) Diesel engine - Oil and filter change Take great care when draining warm fluid and oil. Wear protective gloves and goggles. The oil drain plug (1) can be accessed most easily under the engine.
  • Page 82 Maintenance – 500 h Air filter – Replace the primary air filter Change the air cleaner's main filter when the warning lamp on the display lights when the diesel engine is operating at full speed Release the clips (1), pull off the cover (2), and pull out the main filter (3).
  • Page 83 Maintenance – 500 h Rear axle planetary gears - Check oil level Position the roller so that the level plug (1) in the planetary gear is at "9 o'clock". Wipe clean and remove the level plug (1) and check that the oil level reaches the lower edge of the plug hole.
  • Page 84 Maintenance – 500 h Battery - Check condition Remove the cap (1) and check that the electrolyte level (2) is about 10 mm above the plates. If the level is low, fill up with distilled water to the correct level. If the ambient temperature is below freezing point, the engine should be running for some time after adding the distilled water.
  • Page 85 Maintenance – 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 86 Maintenance – 1000 h Maintenance, 1.000 hours Every 1.000 hours of operation (every six months) Hydraulic filter - Replacement Wear protective goggles when working with compressed air. Clean carefully around the hydraulic oil filter. Remove the oil filter (1) and hand in to an environment-friendly waste disposal station.
  • Page 87 Maintenance – 1000 h Diesel engine - Oil and filter change Take great care when draining warm fluid and oil. Wear protective gloves and goggles. The oil drain plug (1) can be accessed most easily under the engine. Shut down the machine and drain the oil when the engine is warm.
  • Page 88 Maintenance – 1000 h Air filter – Replace the primary and secondary air filters Change the air cleaner's main filter when the warning lamp on the display lights when the diesel engine is operating at full speed Release the clips (1), pull off the cover (2), and pull out the main filter (3).
  • Page 89 Maintenance – 1000 h Rear axle planetary gear - Oil drain Position the roller with the plug (1) at its lowest position. Clean, unscrew the plug (1) and drain the oil into a suitable receptacle. The volume is approximately 2 liters (2,1 qts). Deliver the drain oil to environmentally correct handling.
  • Page 90 Maintenance – 1000 h Drum cartridge - Checking the oil level Position the roller on a flat surface with the plug (1) and drum number plate (2) are visible on the right side. The oil level should now reach the sight glass (3). If necessary, remove the plug (1) and fill to the middle of Fig.
  • Page 91 Maintenance – 1000 h Battery - Check condition Remove the cap (1) and check that the electrolyte level (2) is about 10 mm above the plates. If the level is low, fill up with distilled water to the correct level. If the ambient temperature is below freezing point, the engine should be running for some time after adding the distilled water.
  • Page 92 Maintenance – 1000 h Drum cartridge - Cleaning the ventilation Clean the drum's ventilation hole and ventilation screw (1). The hole is required to eliminate excess pressure inside the drum. Fig. Drum Ventilation screw Fuel tank - Draining Water and sediment in the fuel tank are removed via the drainage plug (1) in the bottom of the fuel tank.
  • Page 93 Maintenance – 1000 h Hydraulic reservoir - Draining The condensate from the hydraulic reservoir is drained through the drain cock (1). Drain the roller after it has been stationary for a long time, e.g. after standing overnight. Drain as follows: Remove the plug (2);...
  • Page 94 Maintenance – 1000 h 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 95 Maintenance – 2000 h Maintenance, 2000 hours Every 2.000 hours of operation (annually) Hydraulic filter - Replacement Wear protective goggles when working with compressed air. Clean carefully around the hydraulic oil filter. Remove the oil filter (1) and hand in to an environment-friendly waste disposal station.
  • Page 96 Maintenance – 2000 h Diesel engine - Oil and filter change Take great care when draining warm fluid and oil. Wear protective gloves and goggles. The oil drain plug (1) can be accessed most easily under the engine. Shut down the machine and drain the oil when the engine is warm.
  • Page 97 Maintenance – 2000 h Air filter – Replace the primary and secondary air filters Change the air cleaner's main filter when the warning lamp on the display lights when the diesel engine is operating at full speed Release the clips (1), pull off the cover (2), and pull out the main filter (3).
  • Page 98 Maintenance – 2000 h Rear axle planetary gear - Oil drain Position the roller with the plug (1) at its lowest position. Clean, unscrew the plug (1) and drain the oil into a suitable receptacle. The volume is approximately 2 liters (2,1 qts). Deliver the drain oil to environmentally correct handling.
  • Page 99 Maintenance – 2000 h Hydraulic reservoir - Oil change Fill with the new hydraulic oil (1). See the lubricant specifications for more information on quality. Start the diesel engine and test the hydraulic functions. Check the oil level in the reservoir (2) and, if necessary, complete the level.
  • Page 100 Maintenance – 2000 h Drum gearbox - Oil change Place the machine on a flat surface so that the plugs (1) and (2) are in the position shown in the figure. Clean and remove the plugs (1) (2) (3) and drain the oil into a container with a capacity of approximately 3,0 liters.
  • Page 101 Maintenance – 2000 h joints – Check Bolted Steering pump to Diesel engine (1), 55 N.m, lightly lubricated. Rear axle suspension (2), 330 N.m (243 ft/lbf), oiled. Engine suspension (3). Check if all M12 bolts (20 pieces) are tightened with 70 N.m and lightly greased. Wheel nuts (4).
  • Page 102 Maintenance – 2000 h Fuel tank - Draining Water and sediment in the fuel tank are removed via the drainage plug (1) in the bottom of the fuel tank. Be very careful during draining. Do not drop the plug or else all the fuel will flow out.
  • Page 103 Maintenance – 2000 h Diesel engine - Check the belt tension Check the position of the belt in the tension pulley, it should be centered, if the belt has too much wear replace Refer the engine manual for more information. Fig.
  • Page 104 Steering hitch – Tightening Nobody must be allowed near the steering joint when the engine is running Risk of being crushed when the steering is operated. Switch off the engine and activate the parking brake before lubrificating. The easiest way to identify if you have this type of steering hitch is that has a new type of nut (1) at the top as shown.

  • Page 105: Revision

    Revision History Revision DATE VERSION MODIFICATION 08/07/2020 0 General 10/07/2020 1 Dynapac oils part number added in symbols and lubrificants. 02/17/2021 2 Steering hitch torque adjustment added 02-17-2021 4812325897EN...
  • Page 107 Dynapac do Brasil Industria e Comercio de Maquinas Ltda. Rua Georg Schaeffler, 430, Sorocaba/SP, Brasil Tel.: +55 (15) 3412-7500 Fax.: +55 (15) 3412-7522 www.dynapac.com...

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