Dynapac CC 622 Guide

DYNAPAC
CC622/622HF
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
M622EN3
MAINTENANCE

19
ILF015WO1

Reservation for changes.
Printed in Sweden.
The Dynapac CC 622/622HF is a vibratory roller in the 12-tonne class, with articulated
steering and with propulsion, brakes and vibration on both drums.
Vibratoryroller
CC622/622HF
Maintenance
M622EN3,August2003
Diesel engine:
Cummins B 3.9 TAA
These instructions apply from:
CC 622 PIN (S/N) *43120622*
CC 622HF PIN (S/N) *43920622*
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2CC 622/622HF M622EN3
CONTENTS
Safety instructions - Personal safety
Special caution - Machine or component damage
WARNING SYMBOLS
GENERAL
Read the entire manual before starting any
service work.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors.
The machine must be cared for properly to ensure
satisfactory operation. Keep the machine clean to
facilitate quick and timely detection of any leakage, loose
bolts and loose connections.
Make a habit each day, before starting up, of checking the
roller to detect any leakage or damage. Also check the
ground underneath the roller, where it is most often easier
to detect any leakage.
TAKE CARE OF THE ENVIRONMENT! Do not
leave behind any oil, fuel or other substances
that are detrimental to the environment.
This manual contains instructions for periodic measures
that should normally be performed by the operator.
The manufacturer’s instructions noted in the
engine manual also apply. This is placed under a
separate flap in the product folder for the roller.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Page
Lubricants and symbols ................................................... 3
Technical specifications ................................................ 4-6
Maintenance schedule ..................................................... 7
Maintenance mesures .................................................. 8, 9
Every 10 hours of operation (Daily) .......................... 10-14
Every 50 hours of operation (Weekly) ...................... 15-18
Every 250 hours of operation (Monthly) ................... 19, 20
Every 500 hours of operation (Every three months) . 21-25
Every 1000 hours of operation (Every six months) . 26, 27
Every 2000 hours of operation (Yearly) .................... 28-32
Long-term storage .......................................................... 33
Special instructions ........................................................ 34
Electrical system, fuses ............................................ 35-37

3CC 622/622HF M622EN3
LUBRICANTS AND SYMBOLS
ENGINE OIL
ambient temperature Shell Rimula SAE 15W/40 or equivalent.
-10°C-+40°C (14°F-104°F) API CF-4/SG (CD/CE)
HYDRAULIC FLUID
ambient temperature
-10°C to +40°C (14°F-104°F) Shell Tellus TX68 or equivalent
above +40°C (above 104°F) Shell Tellus TX100 or equivalent
BIOLOGICAL Shell Naturelle HF-E46
HYDRAULIC FLUID When it leaves the factory, the machine may be filled
with biologically degradable fluid. The same type of
fluid must be used when changing or topping off.
DRUM OIL
ambient temperature
-15°C to +40°C (5°F-104°F) Mobil SHC 629 or equivalent
TRANSMISSION OIL
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
GREASE SKF LGHB2 (NLGI Class 2) or equivalent for the
articulated joint.
Shell Retinax LX2 or equivalent for other grease points.
FUEL See engine manual.
COOLANT GlycoShell or corresponding.
mixed 50/50 with water Anti-freeze protection down to about -41°C (-106°F).
Other fuel and lubricants are required for operation in extremely high or extremely low
ambient temperature. See the “Special instructions” chapter, or consult Dynapac.
Always use high-quality lubricants in the recommended amounts. Too much grease or oil can
cause overheating and subsequent increased wear.
Engine, oil level Air filter
Engine, oil filter Battery
Hydraulic reservoir, level Sprinkler
Hydraulic fluid filter Sprinkler water
Drum, oil level Recycling
Lubricating oil Fuel filter
Air pressure Sprinkler, tyres
Coolant, level Transmission, oil level

4CC 622/622HF M622EN3
TECHNICAL SPECIFICATIONS
Fluid volumes, Litres CC 622/622HF
Drum (qts) ...................................................................... 17 (17.9)
Hydraulic reservoir (qts) ................................................. 40 (42.3)
Fuel tank (gal) ............................................................... 200 (52.8)
Water tank (gal) ............................................................. 485 (128)
Diesel engine, lubr. oil (qts) ............................................ 11 (11.6)
Transmission (qts) ..................................................................... 0,8 (0.9)
Diesel engine, coolant (qts) ....................................................... 7,9 (8.4)
Electrical system CC 622/622HF
Battery ....................... 12 V 170 Ah
Alternator ................... 12 V 95A
Fuses ........................ 5, 7,5, 15, 20 och 25 Ampére
Vibration data CC 622 CC 622HF
Static linear load, kg/cm (pli)
Front: ................................................. 28,5 (159.6) 28,6 (160.2)
Rear: .................................................. 28,2 (157.9) 28 (156.8)
Amplitude mm (in)
High: .................................................. 0,61 (0,024) 0,62 (0.024)
Low: ................................................... 0,31 (0,012) 0,22 (0.009)
Frequency, Hz (vpm)
At High amplitude:................................ 49 (2940) 62 (3720)
At Low amplitude: ................................ 49 (2940) 49 (2940)
Centrifugal force, kN (Ib)
At High amplitude: ............................. 127 (28,575) 127 (28,575)
At Low amplitude: .............................. 65 (14,625) 71,4 (16.051)
Traction CC 622 CC 622HF
Speed range, km/h (mph) .................... 0-11 (0-7) 0-11 (0-7)
Climbing ability (theoretical) % ............. 32 (at 11km/h (7 mph)) 32 (at 11km/h (7 mph))
Weights & dimensions CC 622/622HF
Operating mass with ROPS, EN500, kg (lbs) ....... 12550 (27,672)
Operating mass without ROPS, kg (lbs) ............... 11900 (26,239)
Operating mass with cab, kg (lbs) ......................... 12300 (27,121)
Length, standard equipped roller, mm (in) ..................... 5090 (200)
Width, standard equipped roller, mm (in) ........................ 2270 (89)
Width, with cab, mm (in) .................................................. 2270 (89)
Height, without cab (Shipping height), mm (in)................ 2240 (88)
Height, with cab, mm (in) .............................................. 3040 (120)
Height, with AC, mm (in) ............................................... 3040 (120)
Height, with AC and hazard beacon, mm (in) ............... 3385 (133)

5CC 622/622HF M622EN3
Opening pressure, MPa (psi)
Drive system 42,0 (6,100)
Charge system 2,4 (350)
Vibration system 35,0 (5,100)
Steering system 20,0 (2,900)
Brake release 1,5 (220)
TECHNICAL SPECIFICATIONS
Tightening torque
M STRENGTH CLASS
thread 8.8 10.9 12.9
M6 8,4 12 14,6
M8 21 28 34
M10 40 56 68
M12 70 98 117
M16 169 240 290
M20 330 470 560
M24 570 800 960
M30 1130 1580 1900
M36 1960 2800 –
Tightening torque in Nm (lbf.ft) for oiled, bright
galvanized bolts tightened with a torque wrench.
Hydraulic system
ROPS
Bolt size: M24 (P/N 903792)
Strength class: 10,9
Tightening torque: 800 Nm (590lbf.ft)
(for Dacromet treated)
ROPS bolts must always be tightened dry.
AirCondition (Optional) The system described in this manual is of the ACC
type (Automatic Climate Control), ie, a system that
maintains the set temperature in the cab, on condition
that windows and door are kept closed.
Refrigerant designation: HFC-R134:A
Weight of refrigerant newly filled: 1600 gram

6CC 622/622HF M622EN3
Vibration
(ISO 2631)
TECHNICAL SPECIFICATIONS
The vibration levels are measured in conformance
with the operation cycle described in EU directive
2000/14/EC on EU equipped machines, on soft
polymer material with vibration switched ON and
operator’s seat in the transport mode.
Whole-body vibration is measured at less than the
action value of 0.5 m/s2specified in EU directive
2002/44/EC. (The limit value is 1.15 m/s2.)
Hand/arm vibration is measured at less than the
action value of 2.5 m/s2specified in the same
directive. (The limit value is 5 m/s2.)
Vibration levels may vary when driving on
different courses and with different seat
positions.
CC622 109 – –
The acoustic values are measured in conformance with the operation
cycle described in EU directive 2000/14/EC on EU-equipped
machines, on soft polymer material with vibration switched ON and
operator's seat in the transport mode.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A)
Acoustic
pressure level,
operator’s ear
(platform) dB(A)
Acoustic
pressure level,
operator’s ear
(cab) dB(A)
Noise level can vary when driving on different
courses and with different seat positions.
CC622HF 109 – –

7CC 622/622HF M622EN3
MAINTENANCE SCHEDULE
Fig. 1 Service and maintenance points
19. Rubber element
20. Pivot bearing
21. Battery
22. Radiator
23. Pump gearing
24. Rail catch
1. Air cleaner
2. Engine oil
3. Fuel cap
4. Seat bearing
5. Water tanks
6. Watering system
7. Scrapers
8. Drums
9. Fuel tank
10. Articulated steering
11. Steering cylinder
12. Hydraulic fluid filter
13. Hydraulic fluid level
14. Hydraulic reservoir cap
15. Hydraulic reservoir
16. Diesel engine
17. Hinge
18. Pivot cylinder
1 2 3 4 5
6
7
20
5
23
819 18 7 17 16 15 14 13 12 11 10 9 7
6
7
8
19
21,22
24
23

8CC 622/622HF M622EN3
MAINTENANCE MESURES
Item in Measure See page Comments
fig. 1
Before starting each day
2 Check level of engine oil 10 See engine manual
22 Check level of engine coolant 10
13 Check level in hydraulic reservoir 11
3 Refuel 11
5 Fill the water tanks 11
6 Check the watering system/drum 12
6 Emergency watering 13
7 Check setting of scrapers/drum 13
Inspect spring-action scrapers 13
Check brakes 14
Every 10 hours of operation (Daily)
Item in Measure See page Comments
fig. 1
10 Lubricate the steering articulation 15
11 Lubricate steering cylinder mounts 15
18 Lubricate control cylinder for pivot steering 15 Optional
1 Inspect and if necessary clean the filter
element in the air cleaner 16 Replace as required
23 Check oil level in pump gearing 17
Inspect the air conditioning 18 Optional
IMPORTANT ! After the first 50 hours of operation with the roller change
all the oil filters and lubricating oil, but not the hydraulic fluid.
Every 50 hours of operation (Weekly)
The periodic measures should be performed primarily
after the specified hours of operation. Use the daily,
weekly, etc. time periods only where this is not possible.
Remove all dirt before filling, when checking
oils and fuel, and when lubricating with oil or
grease.
The engine manual specifies additional ser-
vice/maintenance instructions which relate to
the diesel engine.

9CC 622/622HF M622EN3
Item in Measure See page Comments
fig. 1
2 Change the engine oil and oil filter 21 See engine manual
16 Change engine fuel filter See engine manual
8 Check oil level in drums 22
20 Lubricate the pivot bearing 23 Optional
19 Check the rubber elements and bolted joints 23
14 Check the cap/vent of the hydraulic reservoir 23
17 Lubricate hinges and controls 24
4 Lubricate the seat bearing 24
Grease the steering chain 25
16 Change/clean the engine prefilter 25
Every 500 hours of operation (Every three months)
Every 1000 hours of operation (Every six months)
Item in Measure See page Comments
fig. 1
15 Change fluid in hydraulic reservoir 28
8 Change oil in drum/drums 28
9 Empty and clean the fuel tank 28
5 Empty and clean the water tanks 29
Lubricate the Forward/Reverse control 29
10 Check the condition of the articulation 30
Overhaul air conditioning 31 Optional
Fresh air filter – Replacement 32 Optional
Air conditioning – Overhaul 32 Optional
Every 2000 hours of operation (Yearly)
Every 250 hours of operation (Monthly)
Item in Measure See page Comments
fig. 1
12 Change hydraulic filter 26
1 Change main filter of the air cleaner 26
23 Change oil in the pump gearing 27
Replace air cleaner filter in cab 27
8 Change oil in drum/drums (HF version) 27
16 Check engine valve clearance See engine manual
16 Check the engine belt-drive system See engine manual
Item in Measure See page Comments
fig. 1
22 Clean the hydraulic cooler and the
water radiator 19 Or when required
Inspect the air conditioning 19
21 Check level of battery fluid 20
MAINTENANCE MESURES

10 CC 622/622HF M622EN3
EVERY 10 HOURS OF OPERATION (Daily)
Diesel engine,
oil level – Check
Fig.2 Engine compartment
1. Oil dipstick
2. Filler cap
Place the roller on a level surface. Switch
the engine off and push in the reserve/
parking brake knob for all checking and
adjustments on the roller, unless otherwise
specified.
The oil dipstick is accessible through the right door of
the engine compartment.
Beware of hot parts of the engine and ex-
haust pipe when taking out the oil dipstick.
Observe caution. Wear gloves and safety
goggles.
The dipstick is located on the short side of the engine
above the hydraulic pumps.
Pull up the dipstick (1) and ensure that the oil level is
between the upper and lower mark. For further details,
see the engine manual.
Coolant level – Check
Check that level of the coolant is between the max. and
min. marks.
Observe caution if the filler cap must be
opened while the engine is hot. Wear glo-
ves and safety goggles.
Fill with a mixture of 50% water and 50% anti freeze.
See page 3 in these instructions and in the engine
manual.
Flush the system every other year and
change the coolant. Ensure also that air can
flow unrestricted through the radiator.
12
12
6
5
4
3
Fig.3 Radiator
1. Filler cap
2. Level/max. mark
3. Level/min. mark
4. Intercooler
5. Radiator
6. Hydraulic fluid cooler

11CC 622/622HF M622EN3
Hydraulic reservoir,
level check – Filling
EVERY 10 HOURS OF OPERATION (Daily)
Water tanks – Filling
Screw off the tank cap (1) and fill with pure
water. Do not remove the strainer (2).
Fill both water tanks; they hold 485 liters (128 gal)
each.
A step is located on the hydraulic reservoir behind the
right door of the engine compartment to facilitate ac-
cess to the tank cap, and also a retractable step on the
right front drum fork.
Sole additive: Small amount of environment
friendly anti-freeze fluid.
Fig.6 Rear water tank
1. Tank cap
2. Strainer
Fuel tank – Refueling
Refuel every day before starting to work. Screw off the
lockable tank cap (1) and fill diesel fuel to the lower
edge of the filler pipe (2).
Never refuel while the engine is running,
do not smoke, and avoid spilling fuel.
See the engine handbook for the grade of diesel fuel.
The tank holds 200 litres (52 gal) of fuel.
Fig.5 Fuel tank
1. Tank cap
2. Filler pipe
Fig.4 Hydraulic reservoir
1. Oil sight glass
2. Filler hose
3. Filler cap
1
2
1
2
Open the right door of the engine compartment.
Make sure that the oil level is between the max/min
marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.
Place the roller on a level surface. Switch
the engine off and push in the reserve/
parking brake knob for all checking and
adjustments on the roller, unless otherwise
specified.
3
1
2

12 CC 622/622HF M622EN3
Dismantle the clogged nozzle by hand. Blow the nozzle
(2) and fine filter (4) clean with compressed air, or
install replacement parts and clean the clogged parts at
a later opportunity.
Use protective goggles when working with
compressed air.
4
3
2
1
Fig.9 Pump system
1. Coarse filter
2. Stop cock
3. Filter housing
4. Water pump
5. Drain cock
Sprinkler system/Drum
– Checking/Cleaning
Fig.8 Nozzle
1. Sleeve
2. Nozzle
3. Seal
4. Fine filter
EVERY 10 HOURS OF OPERATION (Daily)
21
3
3
Fig.7 Rear drum
1. Nozzle
2. Pump system/cover
3. Quick-screws
Start the sprinkler system and make sure that no
nozzle (1) is clogged. If necessary, clean clogged
nozzles and the coarse filter located adjacent to the
water pump (2); see figures below.
A pump system is located underneath each water tank
behind the cover (2), which is opened by turning the
quick-screws (3) a 1/4 turn counter-clockwise. To lock
the cover, place the screws with the slot vertical and
push straight in.
When cleaning the coarse filter (1), close the stopcock
(2) and loosen the filter housing (3).
Clean the filter and filter housing, ensure that the rubber
gasket in the filter housing is intact.
After inspection and any cleaning, start the system and
check that it works.
A drain cock (5) is located in the left part of the pump
system area. This facilitates draining of both tank and
pump system.
3
54 21

13CC 622/622HF M622EN3
EVERY 10 HOURS OF OPERATION (Daily)
Fig.11 Rear drum scrapers
1. Scraper blade
2. Adjusting screws
3. Adjusting screws
Emergency watering
Scrapers, fixed
– Checking/Setting
If one of the water pumps stops, the remaining pump
will be able to keep the sprinkler system operating -
however, at reduced capacity.
To operate with only one pump, open the stopcock (1)
in the water hose in the engine compartment, and also
the stopcock on the coarse filter by the pump that has
stopped, see pump system.
33
2
1
2
1
Make sure that the scrapers are undamaged. Adjust the
scrapers so that they lie 1–2 mm (0.04-0.08 in) from the
drum. For special asphalt compounds, it may be better if
the scraper blades (1) lie lightly against the drums.
Asphalt remnants can accumulate on the scraper and
affect the contact force.
Loosen the screws (2) to adjust the scraper blade up or
down.
Loosen the screws (3) to adjust the contact pressure of
the scraper blade against the drum.
Remember to tighten all the screws after any
adjustment.
Fig.10 Engine compartment, right side
1. Stopcock
Scrapers, spring loaded
(Optional) – Checking
Fig.12 Spring loaded scrapers
1. Spring mechanism
2. Scraper blade
Make sure that the scrapers are undamaged. The
spring loaded scrapers require no adjustment because
the spring force provides the correct contact force.
Asphalt remnants can accumulate on the scraper and
affect the contact force.
Clean as needed.
The scrapers must be retracted from the drum
during transport driving.
1
2
1-2 mm 1-2 mm
1

14 CC 622/622HF M622EN3
EVERY 10 HOURS OF OPERATION (Daily)
Brake function
– Check
Fig.13 Controlpanel
38. Reserve/parking brake knob
40. Forward/reverse lever
38 40
Check operation of the brakes as follows:
Drive the roller slowly forward.
Push the reserve/parking brake knob (38); the warning
lamp on the instrument panel should light and the roller
should stop.
After testing the brakes, set the forward/reverse lever
(40) in neutral.
Pull up the reserve/parking brake knob.
The roller is now ready for operation.

15CC 622/622HF M622EN3
EVERY 50 HOURS OF OPERATION (Weekly)
Allow no one to get near the steering joint
when the engine is running. Danger of
being crushed when steering is operated.
Push the reserve/parking brake knob before
lubricating.
Turn the steering wheel fully to the left to gain access
to all four grease nipples (1) from the right side of the
machine.
Wipe the grease nipples (1). Grease each nipple with
five strokes of the hand-operated grease gun. Make
sure that grease penetrates the bearings. If grease
does not penetrate the bearings, it may be necessary
to relieve the articulation joint with a jack while repea-
ting the greasing process.
1
1
Turn the machine back for driving straight ahead. This
makes the two grease nipples of the steering cylinder
accessible from the left side of the machine.
Wipe the nipples (1) and grease each one with three
strokes of the hand-operated grease gun.
Pivotcylinder(Optional)
– Lubrication Allow no one near the rear drum while the
engine is running. Danger of being crus-
hed when the drum is operated.
Turn the rear drum for turning left to make the two
grease nipples (1) accessible from the right side of the
machine.
Wipe the nipples and lubricate in the same way as for
the steering cylinder above.
Fig.16 Pivot cylinder
1. Grease nipples
Place the roller on a level surface. Switch the
engine off and push in the reserve/parking-
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Fig.15 Left side of articulation
1. Grease nipples
1
Fig. 14 Right side of articulation
1. Grease nipples
1
1
Steeringjoint
– Lubrication
Steering cylinder
– Lubrication

16 CC 622/622HF M622EN3
Backup filter
– Replacement
EVERY 50 HOURS OF OPERATION (Weekly)
Air cleaner
– Check/Cleaning
Main filter – Cleaning with
compressed air
Fig.18 Main filter
23
Fig.17 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
Replace or clean the main filter of the air
cleaner when the warning lamp on the instru-
ment panel lights at full engine revs.
Release the three locking braces (1) and pull off the
cover (2), pull out the main filter (3).
Do not remove the backup filter (4).
1 4 5
Fig.19 Air filter
4. Backup filter
4
Use compressed air at a maximum pressure of 5 bar
(72 psi) to clean the main filter by blowing up and down
along the inside of the pleated paper filter.
Hold the air nozzle at least 2 to 3 cm (0.8-1.2 in) from
the paper pleats so as not to tear the paper.
Use protective goggles when working with
compressed air.
Wipe the inside of the cover (2) and the filter housing (5).
Ensure that the hose clips between the filter
housing and the intake hose are tightened and
that the hoses are intact. Inspect the entire
hose system all the way to the engine.
Change the main filter after cleaning it five
times.
Replace the backup filter with a new one after cleaning
or changing the main filter five times. The backup filter
cannot be cleaned and reused.
To change the backup filter (4), pull the old filter out
from its holder, insert a new one and reassemble the air
cleaner in the reverse order.

17CC 622/622HF M622EN3
EVERY 50 HOURS OF OPERATION (Weekly)
Pump drive, oil level
– Checking/Topping up
Position the roller on a flat surface.
When checking the oil level, the engine must
be switched OFF and the parking brake
applied.
Open the right door of the engine compartment and
screw off the dipstick (1).
The oil level must be between the two marks at the
bottom of the dipstick.
Fill with transmission oil if required; see lubricant
specification.
Ensure that the rubber packing between the dipstick
and gear housing is in place, and firmly screw in the
dipstick.
Fig.20 Pump gearing
1. Dipstick
1

18 CC 622/622HF M622EN3
EVERY 50 HOURS OF OPERATION (Weekly)
Never work under the roller with the engi-
ne running. Park on a level surface, chock
the wheels and press the parking brake
control.
When the unit is in operation, check in the sight glass
(1) that no bubbles are visible in the dryer filter.
Steer the roller fully to the right for easier access to the
dryer filter.
Always push the parking brake knob.
The filter is located on the left side underneath the cab.
If bubbles are visible in the sight glass it is a sign that
the level of refrigerant is too low. The sight glass is
visible where the hoses go in under the cab floor, see
figure. If so, stop the unit. There is a risk of damage to
the unit if it is run with insufficient level of refrigerant. Fill
with refrigerant.
Airconditioning
–Inspection(Optional)
Fig.21 Drying filter
1. Sight glass
2. Filter housing
Fig.22 Cab
1. Condenser element
In the event of noticeable deterioration of cooling capa-
city, clean the condenser element (1), which is located
at the rear of the cab roof. Also clean the cooling unit
inside the cab.
1
1
2