Fayat Group DYNAPAC CC424 Instruction Manual

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Operating & Maintenance

4812159401_G.pdf

Vibratory roller

CC424/524/624HF

CC4200/5200/6200

Cummins QSB 4.5 (IIIA/T3)

Cummins QSB 4.5 (IIIB/T4i)

Serial number

10000320xxA009391 - 019994

10000322xxA009395 - 019453

10000324xxA009522 - 020130

10000345xxA010586 - 020132

10000347xxA010744 - 020189

10000349xxA010895 - 020047

Translation of original instruction

Reservation for changes

Printed in Sweden

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Summary of Contents for Fayat Group DYNAPAC CC424

Page 1 Instruction manual Instruction manual Operating & Maintenance Operating & Maintenance 4812159401_G.pdf 4812159401_G.pdf Vibratory roller Vibratory roller CC424/524/624HF CC424/524/624HF CC4200/5200/6200 CC4200/5200/6200 Engine Engine Cummins QSB 4.5 (IIIA/T3) Cummins QSB 4.5 (IIIA/T3) Cummins QSB 4.5 (IIIB/T4i) Cummins QSB 4.5 (IIIB/T4i) Serial number Serial number 10000320xxA009391 - 019994 10000320xxA009391 - 019994...
Page 3 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 Dimensions, side view................16 Dimensions, top view ................17 Weights and volumes................18 Working capacity..................18 General ..................... 20 Hydraulic system..................21 Air Conditioning / Automatic Climate Control (ACC) (Optional) ....21 Tightening torque ..................22 Machine description ....................... 23 Diesel engine ....................
Page 5 Forward & Reverse lever ................37 Function descriptions ................37 Forward & Reverse lever ................38 Function descriptions ................38 Display explanations ................. 38 Machine alarm................... 42 "MAIN MENU" ................... 43 "USER SETTINGS" ..............44 "MACHINE SETTINGS".............. 45 "SERVICE MENU" ..............45 "ABOUT"..................
Page 6 Operator's seat - Adjustment..............56 Belt reminder..................... 56 Operator's seat, comfort - Adjustments............. 57 Parking brake .................... 57 Display - Control..................58 Interlock..................... 59 Operator position..................60 View ......................60 Starting ........................61 Starting the engine ..................61 Display when activating choice via the button set........62 Alarm descriptions..................
Page 7 Battery....................... 71 Air cleaner, exhaust pipe................71 Watering system ..................71 Fuel tank ....................71 Hydraulic reservoir ..................71 Hoods, tarpaulin ..................72 Steering cylinder, hinges, etc..............72 Miscellaneous ........................73 Lifting ........................73 Locking the articulation ................73 Lifting the roller..................
Page 8 After the FIRST 50 hours of operation ............88 Every 50 hours of operation (Weekly)............89 Every 250/750/1250/1750..hours of operation ........89 Every 500/1500 hours of operation ............90 Every 1000 hours of operation ..............91 Every 2000 hours of operation ..............92 Maintenance, 10h ........................
Page 9 Air conditioning (Optional) Drying filter - Inspection ................105 Edge cutter (Optional) - Lubrication .................... 105 Maintenance measures - 500 h ................... 107 Hydraulic fluid cooler Checking - Cleaning................107 Air cleaner Checking - Change the main air filter............107 Backup filter - Change................
Page 10 The engine fuel filter - replacement/cleaning .......... 118 Drum - Oil change ................... 119 Drum gear - Oil change................119 Drum gear - Checking the oil level ............120 Hydraulic filter Change....................120 Hydraulic reservoir cap - Check .............. 121 Rubber elements and attachment screws Check ......................
Page 11 Drum gear - Oil change................131 Drum gear - Checking the oil level ............132 Hydraulic filter Change....................132 Hydraulic reservoir cap - Check .............. 133 Hydraulic reservoir Fluid change.................... 134 Rubber elements and attachment screws Check ...................... 134 Seat bearing - Lubrication ............... 135 Watering system - Draining....................
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Page 13 Introduction Introduction The machine Dynapac CC424/524/624HF, CC4200/5200/6200 is a self-propelled vibratory tandem roller in the 10/12/13 tonnes class with 1730/1950/2130 mm (68/77/84 in) wide drums. It features power drive, brakes, vibration and timer controlled water sprinklers on both drums. CC424/524HF, CC4200/5200 is also available as a Combo, with four rubber wheels at the rear instead of steel drums.
Page 14 Introduction We recommend that the operator reads the We recommend that the operator reads the safety instructions in this manual carefully. safety instructions in this manual carefully. Always follow the safety instructions. Ensure Always follow the safety instructions. Ensure that this manual is always easily accessible. that this manual is always easily accessible.
Page 15 Introduction 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 personnel. Additional instructions for the engine can be Additional instructions for the engine can be found in the manufactuer's engine manual.
Page 16 Introduction 4812159401_G.pdf 2018-01-30...
Page 17 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 Safety - General instructions 16. Hearing protection is recommended if the noise level exceeds 80 dB(A). The 16. Hearing protection is recommended if the noise level exceeds 80 dB(A). The noise level can vary depending on the equipment on the machine and the noise level can vary depending on the equipment on the machine and the surface the machine is being used on.
Page 19 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) Air conditioning The system contains pressurized refrigerant. It is The system contains pressurized refrigerant. It is forbidden to release refrigerants into the forbidden to release refrigerants into the atmosphere. atmosphere. Work on the refrigerant circuit is only to be carried Work on the refrigerant circuit is only to be carried out by authorized companies.
Page 22 Safety (Optional) Working lights - Xenon Warning, high voltage! Warning, high voltage! The working lights of the Xenon type have a secondary high-voltage source. Work on the lighting should only be conducted by an authorized electrician and with the primary voltage disconnected.
Page 23 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 Special instructions High pressure cleaning Do not spray directly onto electrical components. Do not use high pressure cleaning for Do not use high pressure cleaning for dashboard/display. dashboard/display. The Electrical Drive Control and the computer The Electrical Drive Control and the computer box may not be washed with high pressure box may not be washed with high pressure cleaning and not at all with water.
Page 25 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 4812159401_G.pdf 2018-01-30...
Page 27 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 Technical specifications Slopes This angle has been measured on a hard, flat surface with the machine stationary. The steering angle was zero, the vibration was switched OFF and all tanks were full. Max 20° or 36% Max 20° or 36% Always take into consideration that loose ground, steering the machine, vibration on, machine speed across the ground and raising the center of gravity can...
Page 29 Technical specifications Dimensions, top view Dimensions Dimensions Machine width, standard Machine width, standard CC424HF, CC4200 CC424HF, CC4200 1890 1890 74.5 74.5 CC524HF, CC5200 CC524HF, CC5200 2110 2110 83.1 83.1 CC624HF, CC6200 CC624HF, CC6200 2290 2290 90.2 90.2 Machine width, asymmetrical Machine width, asymmetrical 2345 2345...
Page 30 Technical specifications Weights and volumes Weights Weights Service weight Service weight without ROPS without ROPS ROPS ROPS (EN500) (EN500) CC424HF, CC4200 CC424HF, CC4200 (kg) (kg) 9 900 9 900 10 200 10 200 10 400 10 400 (lbs) (lbs) 21 830 21 830 22 490 22 490...
Page 31 Technical specifications Amplitude Amplitude High High Low (CE2006) Low (CE2006) 0,2 (mm) 0,2 (mm) 0.031 0.031 0.012 0.012 0.008 (in) 0.008 (in) Vibration frequency Vibration frequency High High High High amplitude amplitude amplitude amplitude amplitude amplitude amplitude amplitude (CE-2006) (CE-2006) (CE-2006) (CE-2006) 62 (Hz)
Page 32 Technical specifications General Engine Engine Manufacturer/Model Manufacturer/Model Cummins QSB 4.5 Cummins QSB 4.5 Water-cooled turbo diesel Water-cooled turbo diesel Power output (SAE J1995), 2200 rpm 82 kW (IIIA/T3, IIIB/T4i) Power output (SAE J1995), 2200 rpm 82 kW (IIIA/T3, IIIB/T4i) 110 hp 110 hp 93 kW (IIIA/T3) 93 kW (IIIA/T3)
Page 33 Technical specifications Hydraulic system Opening pressure Opening pressure Drive system Drive system 5 800 5 800 Supply system Supply system Vibration system Vibration system 4 800 4 800 Control systems Control systems 2 900 2 900 Brake release Brake release Air Conditioning / Automatic Climate Control (ACC) (Optional) The system described in this manual is an AC/ACC...
Page 34 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 35 Machine description Machine description Diesel engine The machine is equipped with a completely electronically controlled water-cooled four-cylinder, turbocharged (WGT) diesel engine with direct injection (HPCR) and intercooler. WGT - Waste Gate Turbo HPCR - High Pressure Common Rail fuel injection (IIIB/T4i) The engine is also equipped with cooled exhaust gas recirculation (ceGR) and electronically controlled...
Page 36 Machine description Brake system The brake system comprises a service brake, secondary brake and parking brake. The service brake system produces retardation of the propulsion system, i.e. hydrostatic braking. Secondary/Parking brake The secondary and parking brake system comprises sprung disc brakes to each drum, drum half respectively wheel pair.The disc brakes are disengaged by hydraulic pressure.
Page 37 Machine description The cab is approved as a protective cab in accordance with the ROPS standard. If any part of the cab's or the FOPS/ROPS structure's protective construction displays plastic deformation or cracks, the cab or the ROPS structure must be replaced immediately.
Page 38 Machine description Product identification number on the frame The machine PIN (Product Identification Number) (1) is punched on the right edge of the front frame. Fig. PIN Front frame Machine plate The machine type plate (1) is attached to the front left side of the frame, beside the steering joint.
Page 39 Machine description 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. Please specify the engine serial number when ordering spares.
Page 40 Machine description Decals Location - decals Fig. Location, decals and signs Warning, Crush zone Warning, Crush zone 4700903422 4700903422 12. Master switch 12. Master switch 4700904835 4700904835 Warning, Rotating engine Warning, Rotating engine 4700903423 4700903423 13. Coolant 13. Coolant 4700388449 4700388449 components components...
Page 41 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 42 Machine description 4700908229 Warning - Risk of crushing The articulation must be locked when lifting. Read the instruction manual. 4812125363 Warning - Locking The articulation must be locked during transport and lifting, but be open during operation. Read the instruction manual. 4700904165 Warning - Toxic gas (option, ACC) Read the instruction manual.
Page 43 Machine description Info decals Manual compartment Manual compartment Battery voltage Battery voltage Master switch Master switch Coolant Coolant Water Water Hydraulic fluid level Hydraulic fluid level Hydraulic fluid Hydraulic fluid Biological hydraulic fluid Biological hydraulic fluid Diesel fuel Diesel fuel Bio hydraulic fluid PANOLIN Bio hydraulic fluid PANOLIN Fuel with low sulphur content (IIIB/T4i)
Page 44 Machine description Instruments/Controls Control panel and controls 28/30/35 29/31 Fig. Control panel Ignition switch Ignition switch Vibration rear drum Vibration rear drum Parking brake Parking brake Forward & Reverse lever Forward & Reverse lever Work mode (Off-set and Work mode (Off-set and Hazard lights Hazard lights vibration permitted plus soft...
Page 45 Machine description Functions Functions Direction indicators Direction indicators Driving lights Driving lights Full/Dipped beam Full/Dipped beam Parking lights Parking lights Horn Horn Figure. Steering column switch (optional) Function descriptions Designation Designation Symbol Symbol Function Function Ignition key Ignition key The electric circuit is broken. The electric circuit is broken.
Page 46 Machine description Designation Designation Symbol Symbol Function Function Vibration rear drum Vibration rear drum Activation of vibration on rear drum. Activation of vibration on rear drum. If Working mode (14) is not activated, there will be no vibration If Working mode (14) is not activated, there will be no vibration NEVERactivate the switch NEVERactivate the switch on the drum.
Page 47 Machine description Designation Designation Symbol Symbol Function Function Parking brake Parking brake When pressed, the parking brake is activated. When pressed, the parking brake is activated. To release the brakes, slide the red part back (towards you) To release the brakes, slide the red part back (towards you) and change the position of the lever.
Page 48 Machine description Designation Designation Symbol Symbol Function Function Edge press/cutter, UP/DOWN Edge press/cutter, UP/DOWN The edge cutter can be moved up and down when the The edge cutter can be moved up and down when the machine is in the operating position. The edge cutter can only machine is in the operating position.
Page 49 Machine description Forward & Reverse lever Vibration on/off Vibration on/off Edge cutter, Up Edge cutter, Up Panic sprinkler (ON as long as Panic sprinkler (ON as long as Edge cutter, Down Edge cutter, Down button depressed) button depressed) Offset left Offset left Offset right Offset right...
Page 50 Machine description Forward & Reverse lever Vibration on/off Vibration on/off Edge cutter, Up Edge cutter, Up Panic sprinkler (ON as long as Panic sprinkler (ON as long as Edge cutter, Down Edge cutter, Down button depressed) button depressed) Offset left Offset left Offset right Offset right...
Page 51 Machine description A status screen provides information on the fuel level, water level in the sprinkler tank, machine hours and voltage level. Fuel and water levels are specified in per cent (%). This screen is active until the Diesel engine is started or an active screen choice is made via the function buttons below the display.
Page 52 Machine description Scroll/Selection buttons to choose Scroll/Selection buttons to choose between available functions. between available functions. Alarm log button to display engine and Alarm log button to display engine and machine alarms. machine alarms. Settings/Button select menu, which opens Settings/Button select menu, which opens the main menu.
Page 53 Machine description When an engine alarm is activated, the alarm is shown on the display. The engine alarm is sent out from the engine ECM, which handles the monitoring of the engine functions. The message, which consists of an SPN and FMI code, can be interpreted via the engine supplier error code list.
Page 54 Machine description Machine alarm Symbol Symbol Designation Designation Function Function Warning symbol, hydraulic fluid filter Warning symbol, hydraulic fluid filter If the symbol is shown when the diesel engine is running at If the symbol is shown when the diesel engine is running at full speed, the hydraulic fluid filter must be changed.
Page 55 Machine description Alarms received are saved/logged and can be seen by selecting Display alarms. Selection of Display alarms. "ENGINE ALARM" Saved/Logged engine alarms. "MACHINE ALARM" Saved/Logged machine alarms. These alarms come from the other systems on the machine. "MAIN MENU" In the main menu it is also possible to change some user and machine settings, access the service menu for calibration purposes (special service personnel...
Page 56 Machine description "USER SETTINGS" Users can change the light settings, choose between the Metric or Imperial system, and set warning sounds On/Off. Adjustment of the light and contrast settings on the display, including brightness of the panel light. 4812159401_G.pdf 2018-01-30...
Page 57 Machine description "MACHINE SETTINGS" The selection "Sprinkler Pump: 1 & 2" is in machine settings. If the machine is fitted with double sprinkler pumps (Option) this is the menu in which the selection is made for which of the sprinkler pumps are to be activated to water the drum(s).
Page 58 Machine description "ADJUSTMENTS" "TESTMODES" - Installation personnel only, requires pin code. "CALIBRATION" - service personnel only, requires password. "EDC Calibration" used to calibrate the joystick and speed potentiometer. "TX Program" only used to change software in the display and requires special equipment and know-how. "EDC CALIBRATION"...
Page 59 Machine description "ABOUT" It is also possible to see the version of the installed software. Operator help when starting When trying to start the machine without having set one, two or three of the conditions required to start machine, the missing conditions are shown in the display.
Page 60 Machine description Instruments and controls, cab Radio/CD Fig. Cab roof, front Fig. Right rear cab post 4812159401_G.pdf 2018-01-30...
Page 61 Machine description Function description of instruments and controls in the cab Designation Designation Symbol Symbol Function Function Heater control Heater control Turn to the right to increase heating. Turn to the right to increase heating. Turn to the left to reduce heating. Turn to the left to reduce heating.
Page 62 Machine description Using the cab controls. Defroster To quickly remove ice or mist, make sure that only the front and rear air nozzles are open. Turn the heater and fan dial (1 and 2) to max. Adjust the nozzle so that it blows on the window to be de-iced, or to remove mist.
Page 63 Machine description Electrical system (version 1) The machine's main switchbox (1) is located on the rear of the operator platform. There is a plastic cover over the distribution box and fuses. On the plastic cover there is a 24V socket. Fig.
Page 64 Machine description Electrical system (version 2) The machine's main switchbox (1) is located on the rear of the operator platform. There is a plastic cover over the distribution box and fuses. On the plastic cover there is a 24V socket and a 12V socket (optional).
Page 65 Machine description Power in engine compartment/battery compartment The fuses in the engine compartment are located alongside the master switch. The roller is equipped with 24 V electrical system and an AC alternator. Connect the correct polarities (ground) to the Connect the correct polarities (ground) to the battery.
Page 66 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 (F7) All fuses are flat pin fuses. 1.
Page 67 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. If the main battery/master switch is covered, the If the main battery/master switch is covered, the engine hood must be unlocked during operation,...
Page 68 Operation Operator's seat - Adjustment Adjust the operator’s seat so that the position is comfortable and so that the controls are within easy reach. The seat can be adjusted as follows. - Length adjustment (1) - Weight adjustment (2) Fig. Operator's seat - Back support angle (3) 1.
Page 69 Operation Operator's seat, comfort - Adjustments Adjust the operator's seat so that the position is comfortable and so that the controls are within easy reach. The seat can be adjusted as follows: - Length adjustment (1) - Height adjustment (2) - Seat-cushion inclination (3) - Backrest inclination (4) - Armrest inclination (5)
Page 70 Operation Display - Control Sit down for all operations. Turn the ignition key (1) to position I, the start screen will be shown in display. Fig. Control panel 1. Ignition key 2. Status screen Check that the voltmeter (6) shows at least 24 volts and the levels for fuel (3) and water (4) indicates a percentage value.
Page 71 Operation Interlock The roller is equipped with Interlock. The diesel engine with switch off after 7 seconds if the operator gets off the seat when going forwards/backwards. If the control is in neutral when the operator stands up a buzzer will go on until the parking brake is activated. If the parking brake is activated, the diesel engine will not stop if the forward/reverse lever is moved out of neutral.
Page 72 Operation Operator position If a ROPS (Roll Over Protective Structure) or a cab is fitted to the roller, always wear the seat belt (1) provided and wear a protective helmet. Replace the seat belt (1) if it shows signs of Replace the seat belt (1) if it shows signs of wear or has been subjected to high levels of wear or has been subjected to high levels of...
Page 73 Operation Starting Starting the engine Make sure that the emergency stop is OFF and the parking brake ON. Set the forward/reverse lever (1) in neutral position, and set the speed selector (2) in the idling position (LO) or (ECO) if that option is installed on the machine. The diesel engine cannot be started in any other position of the controls.
Page 74 Operation When starting and driving a machine that is cold, When starting and driving a machine that is cold, remember that the hydraulic fluid is also cold and remember that the hydraulic fluid is also cold and that braking distances can be longer than normal that braking distances can be longer than normal until the machine reaches the working temperature.
Page 75 Operation Alarm descriptions Symbol Symbol Designation Designation Function Function Warning lamp, hydraulic filter Warning lamp, hydraulic filter If the lamp comes on while the engine is running at full If the lamp comes on while the engine is running at full speed, the hydraulic filter must be changed.
Page 76 Operation When compacting asphalt, remember to turn on the sprinkler system (4) or (5). Make sure that the area in front of and behind the Make sure that the area in front of and behind the roller is clear. roller is clear. Release the parking brake (2).
Page 77 Operation The machine's gear position is shown in the center of the speedometer; select the gear/speed for the task. The machine does not need to be stopped to change gear position. Max. speed Max. speed = Position 1 = Position 1 6 km/h 6 km/h 3.8 mph...
Page 78 Operation Pivotal steering (Optional) The machine must be in the operating position to activate the pivotal steering. Use the two front buttons (1) on the forward/reverse lever to operate the pivotal steering. To reset the rear drum to neutral, adjust the buttons (1) until the display (2) shows that the machine has aligned the drums.
Page 79 Operation The operator can choose between two tools, the edge cutter or edge compactor. The edge cutter (1) in the figure is shown in the operating position. The edge compactor (1) can easily be replaced with the edge cutter by releasing the bolted joint (3). Fig.
Page 80 Operation Manual vibration - Switching on Never activate vibration when the roller is Never activate vibration when the roller is stationary. This can damage both the surface and stationary. This can damage both the surface and the machine. the machine. Engage and disengage vibration using the switch (1) on the front of the forward/reverse lever.
Page 81 Operation If the forward/reverse lever is moved quickly (forwards or backwards) toward/past neutral, the system switches to a rapid braking Mode and the machine stops. Activate normal driving Mode again by moving the forward/reverse lever back to neutral. Emergency braking Braking is normally activated using the forward/reverse lever.
Page 82 Operation Parking Chocking the drums Never disembark from the machine when the Never disembark from the machine when the diesel engine is running, unless the parking brake diesel engine is running, unless the parking brake is activated. is activated. Make sure that the roller is parked in a safe place Make sure that the roller is parked in a safe place with respect to other road users.
Page 83 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 84 Long-term parking Hoods, tarpaulin * Lower the instrument cover over the instrument panel. * Cover the entire roller with a tarpaulin. A gap must be left between the tarpaulin and the ground. * If possible, store the roller indoors and ideally in a building where the temperature is constant.
Page 85 Miscellaneous Miscellaneous Lifting 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 so the roller is straight forward. Activate the parking brake and switch off the machine.
Page 86 Miscellaneous Weight: refer to the hoisting plate on the Lifting the roller 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 87 Miscellaneous Unlocking the articulation Remember to unlock the articulation before Remember to unlock the articulation before operating. operating. Insecure and remove the locking devices and put them in the storing place. Figure. Articulation in open position 2. Lock 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.
Page 88 Miscellaneous Short distance towing with the engine running Activate the parking brake, and temporarily stop Activate the parking brake, and temporarily stop the diesel engine. Chock the drums to prevent the the diesel engine. Chock the drums to prevent the roller from moving roller from moving Open the left door to the engine compartment to...
Page 89 Miscellaneous Short distance towing when the engine is inoperative. 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. Open both towing valves as described earlier. The brake disengagement pump is located behind the left door of the engine compartment.
Page 90 Miscellaneous Trailer eye The roller can be fitted with a trailer eye. The trailer eye is not designed to be used for towing/recovering. It is designed for trailers and other towed objects weighing no more than 2 600 kg (5 750 lbs).
Page 91 Miscellaneous Loading CC224-624, CC2200-6200 Securing vibratory roller CC224-624, CC2200-6200 from Dynapac for transport. (The instructions also apply to Combi machines) Roller loaded in forward direction Direct of travel Lashing 2 to be moved to a rear lashing point if side beam on the trailer is missing. Lashing 2 to be moved to a rear lashing point if side beam on the trailer is missing.
Page 92 Operating instructions - Summary Load carrier Load carrier When loaded, the vibratory roller is centered laterally on the platform (± 5 cm). When loaded, the vibratory roller is centered laterally on the platform (± 5 cm). The parking brake is applied and in good working condition, and the articulated joint lock is The parking brake is applied and in good working condition, and the articulated joint lock is closed.
Page 93 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 and the Make sure that all instructions in the MAINTENANCE section are followed and the steering hitch lock is unlocked.
Page 94 Operating instructions - Summary 21. When recovering - Refer to the relevant section in the Instruction Manual. 21. When recovering - Refer to the relevant section in the Instruction Manual. 4812159401_G.pdf 2018-01-30...
Page 95 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 96 Preventive maintenance 4812159401_G.pdf 2018-01-30...
Page 97 Maintenance - Lubricants and symbols Maintenance - Lubricants and symbols Always use high-quality lubricants and the Always use high-quality lubricants and the amounts recommended. Too much grease or amounts recommended. Too much grease or oil can cause overheating, resulting in rapid oil can cause overheating, resulting in rapid wear.
Page 98 Maintenance - Lubricants and symbols TRANSMISSION OIL TRANSMISSION OIL Air temperature -15°C (5°F) - Air temperature -15°C (5°F) - Dynapac Gear oil Dynapac Gear oil P/N 4812161891 (5 liters), P/N 4812161891 (5 liters), above +40°C (104°F) above +40°C (104°F) 1000 1000 P/N 4812161892 (20 liters) P/N 4812161892 (20 liters)
Page 99 Maintenance - Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points 6, 7 Fig. Service and maintenance points Engine oil Engine oil Coolant Coolant 17. Steering joint 17. Steering joint Oil filter Oil filter 10. Air cleaner 10. Air cleaner 18.
Page 100 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 101 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 the oil level in the drum gears Check the oil level in the drum gears Draining the fuel prefilter Draining the fuel prefilter...
Page 102 Maintenance - Maintenance schedule Every 500/1500 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 hydraulic fluid cooler/water cooler Clean the hydraulic fluid cooler/water cooler Or when necessary Or when necessary...
Page 103 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 Check the filter element in the air cleaner Check the filter element in the air cleaner Replace when necessary Replace when necessary Check the condition of the batteries...
Page 104 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 Check the filter element in the air cleaner Check the filter element in the air cleaner Replace when necessary Replace when necessary...
Page 105 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 106 Maintenance, 10h Coolant level - Check Check that the coolant level is between the max. and min. marks (2). Observe great caution if the cap has to be opened Observe great caution if the cap has to be opened while the engine is hot. Wear protective gloves and while the engine is hot.
Page 107 Maintenance, 10h Hydraulic reservoir - Check fluid level Place the roller on a level surface and check that the oil level in the sight glass (1) is between the max and min markings. Top up with the type of hydraulic fluid specified in the lubricant specification, if the level is too low.
Page 108 Maintenance, 10h Sprinkler system/Drum Check Start the sprinkler system and make sure that none of the nozzles (1) are clogged. If necessary, clean blocked nozzles and the coarse filter placed by the water pump (2). See next section. Figure. Front drum 1.
Page 109 Maintenance, 10h Sprinkler system/Drum Cleaning of sprinkler nozzle Dismantle the blocked nozzle by hand. Blow the nozzle and fine filter (1) clean using compressed air. Alternatively, fit replacement parts and clean the blocked parts later on. Nozzle Nozzle Colour Colour Ø...
Page 110 Maintenance, 10h Emergency watering (Accessory) - Extra pump in pump system If the water pump stops, an extra pump will keep the sprinkler system in operation. Connect the electric cable and water hoses to the extra pump instead of the standard pump. The water hoses are connected to the pump with quick couplings to simplify draining and where appropriate replacement to a reserve pump (option).
Page 111 Maintenance, 10h Scrapers Setting - Adjustment Release the retaining unit (1) for the scraper bracket and unscrew the adjusting screw (2) to release. Push in the scraper bracket and tighten. Adjust the screw (2) so that the scraper blade lies approx.
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Page 113 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 114 Maintenance - 50h Fuel filter - Draining Unscrew the drain plug (1) at the bottom of the fuel filter. With the aid of the secondary hand-operated pump, make certain that all sediment comes out. See Cummins service manual. Tighten the drain plug as soon as uncontaminated fuel runs out.
Page 115 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 116 Maintenance measures - 250 h Battery - Check condition The batteries are sealed and maintenance-free. Make sure there is no open flame in the vicinity Make sure there is no open flame in the vicinity when checking the electrolyte level. Explosive gas when checking the electrolyte level.
Page 117 Maintenance measures - 250 h Air conditioning (Optional) Drying filter - Inspection With the unit in operation, check using the sight glass (1) that bubbles are not visible on the drying filter. Park the roller on a level surface, chock the wheels Park the roller on a level surface, chock the wheels and activate the parking brake.
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Page 119 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 120 Maintenance measures - 500 h Release the clips (1), pull off the cover (2), and pull out the main filter (3). Do not remove the backup filter (4). Clean the air cleaner if necessary, see section Air cleaner - Cleaning. When replacing the main filter (3), insert a new filter and refit the air cleaner in the reverse order.
Page 121 Maintenance measures - 500 h Air cleaner - Cleaning Wipe clean on both sides of the outlet Wipe clean the inside of the cover (2) and the filter pipe. housing (5). See the previous illustration. Wipe also both surfaces for the outlet pipe; see adjacent figure.
Page 122 Maintenance measures - 500 h Fill with fresh engine oil, see Lubricant specification or the engine manual for the correct grade of oil. Fill with the requisite volume of engine oil. See technical specifications before starting the machine. Allow the engine to idle for a few minutes, and then switch off the engine.
Page 123 Maintenance measures - 500 h The engine fuel filter - replacement/cleaning The fuel filter is placed on the left side of the engine compartment. Unscrew the bottom and drain off any water, and then replace the filter unit. Figure. Engine compartment, left side 1.
Page 124 Maintenance measures - 500 h Rubber elements and attachment screws Check Check all rubber elements (1). Replace all elements if 25% or more than 25% of the number on one side of the drum have cracks deeper than 10-15 mm (0.4-0.6 in).
Page 125 Maintenance measures - 500 h Pivot bearing (Optional) - Lubrication Grease each nipple (1) with five strokes of a hand-operated grease gun. Use grease as specified in the lubricant specification. Fig. Rear drum 1. Grease nipples x 4 Edge cutter (Optional) - Lubrication Refer to the operation section for information on Refer to the operation section for information on...
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Page 127 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 128 Maintenance - 1000h Backup filter - Change Change the backup filter with a new filter after every second 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 129 Maintenance - 1000h Diesel engine Oil change The engine's oil drain plug is located under the rear frame on the machine on the right side.The drain plug is accessed by first removing the rubber plug on the underside of the frame. Drain the oil when the engine is warm.
Page 130 Maintenance - 1000h The engine fuel filter - replacement/cleaning The fuel filter is placed on the left side of the engine compartment. Unscrew the bottom and drain off any water, and then replace the filter unit. Figure. Engine compartment, left side 1.
Page 131 Maintenance - 1000h Drum - Oil change Take great care when draining the fluid. Wear Take great care when draining the fluid. Wear protective gloves and goggles. protective gloves and goggles. Set the roller so that the drain plug (1), the large plug, is at the lowest position in its rotation.
Page 132 Maintenance - 1000h Drum gear - Checking the oil level Move the machine until the inspection/filling holes are in position for filling. Fig. Drum gear Fill with the requisite volume of new oil. See technical specifications. Use transmission oil, see lubricant specifications.
Page 133 Maintenance - 1000h Check the hydraulic fluid level in the sight glass (3) and top off as required. See under the heading 'Every 10 hours of operation' for more information. Start the engine and check that the filter does not leak. Figure.
Page 134 Maintenance - 1000h Rubber elements and attachment screws Check Check all rubber elements (1). Replace all elements if 25% or more than 25% of the number on one side of the drum have cracks deeper than 10-15 mm (0.4-0.6 in). Check using a knife blade or pointed object.
Page 135 Maintenance - 1000h Pivot bearing (Optional) - Lubrication Grease each nipple (1) with five strokes of a hand-operated grease gun. Use grease as specified in the lubricant specification. Fig. Rear drum 1. Grease nipples x 4 Fresh air filter - Replacing There is one fresh air filter (1), placed on the front of the cab.
Page 136 Maintenance - 1000h Air conditioning (Optional) - Overhaul Regular inspection and maintenance is necessary to ensure satisfactory long-term operation. Clean all dust from the condenser element (1) using compressed air. Blow from above downwards. The air jet can damage the element flanges if it is The air jet can damage the element flanges if it is too powerful.
Page 137 Maintenance - 1000h Edge cutter (Optional) - Lubrication Refer to the operation section for information on Refer to the operation section for information on how to operate the edge cutter. how to operate the edge cutter. Grease the two points as shown in the figure. Grease should always be used for lubrication, see the lubricant specifications.
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Page 139 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 140 Maintenance - 2000h Backup filter - Change Change the backup filter with a new filter after every second 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 141 Maintenance - 2000h Diesel engine Oil change The engine's oil drain plug is located under the rear frame on the machine on the right side.The drain plug is accessed by first removing the rubber plug on the underside of the frame. Drain the oil when the engine is warm.
Page 142 Maintenance - 2000h The engine fuel filter - replacement/cleaning The fuel filter is placed on the left side of the engine compartment. Unscrew the bottom and drain off any water, and then replace the filter unit. Figure. Engine compartment, left side 1.
Page 143 Maintenance - 2000h Drum - Oil change Take great care when draining the fluid. Wear Take great care when draining the fluid. Wear protective gloves and goggles. protective gloves and goggles. Set the roller so that the drain plug (1), the large plug, is at the lowest position in its rotation.
Page 144 Maintenance - 2000h Drum gear - Checking the oil level Move the machine until the inspection/filling holes are in position for filling. Fig. Drum gear Fill with the requisite volume of new oil. See technical specifications. Use transmission oil, see lubricant specifications.
Page 145 Maintenance - 2000h Check the hydraulic fluid level in the sight glass (3) and top off as required. See under the heading 'Every 10 hours of operation' for more information. Start the engine and check that the filter does not leak. Figure.
Page 146 Maintenance - 2000h Hydraulic reservoir Fluid change Take care when draining the hydraulic fluid. Wear Take care when draining the hydraulic fluid. Wear protective gloves and goggles. protective gloves and goggles. Open left engine compartment. The drain plug/valve is in the area under the hydraulic tank. Place a receptacle that holds at least 50 liters (13.2 gal) under the engine compartment.
Page 147 Maintenance - 2000h Seat bearing - Lubrication 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 148 Maintenance - 2000h Water tank - Cleaning Clean the tank/tanks with water and a suitable detergent for plastic surfaces. Close the drain cock (2), fill with water and check for leaks. The water tanks are made of plastic The water tanks are made of plastic (polyethylene) and are recyclable.
Page 149 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 150 Maintenance - 2000h Fresh air filter - Replacing There is one fresh air filter (1), placed on the front of the cab. Remove the protective cover. Undo the screws (2) and remove the complete holder. Remove the filter insert and replace with a new filter. The filter may need to be changed more often if the machine is operated in a dusty environment.
Page 151 Maintenance - 2000h Air conditioning (Optional) Drying filter - Inspection With the unit in operation, check using the sight glass (1) that bubbles are not visible on the drying filter. Park the roller on a level surface, chock the wheels Park the roller on a level surface, chock the wheels and activate the parking brake.
Page 152 Dynapac Compaction Equipment AB Box 504, SE 371 23 Karlskrona, Sweden www.dynapac.com...

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Dynapac cc524 Dynapac cc624hf Dynapac cc4200 Dynapac cc5200 Dynapac cc6200