Dynapac CC 82 User manual

DYNAPAC
CC 82/92
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
M092EN3
MAINTENANCE

19
ILF015WO1

1CC82/92 M092EN3 Reservation for changes.
Printed in Sweden.
Vibratory Roller
CC82/92
Maintenance
M092EN3, January 2002
Diesel engine:
HATZ 2G40
These instructions apply from:
CC 82: PIN (S/N) *60620504*
CC 92: PIN (S/N) *60610500*
The CC 82/92 is an articulated, vibratory tandem roller in the 1.5 tonne range.
These rollers are designed for the compaction of both earth masses and asphalt compounds,
and are suitable for repair and maintenance work and for the construction of pedestrian
paths and cycle tracks, minor streets and roads, parking lots and yards.
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2CC82/92 M092EN3
Safety instructions—Personal safety.
Special caution—Machine or component
damage.
CONTENTS
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.
It is essential that the machine is properly cared for 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.
PROTECT THE ENVIRONMENT!
Do not leave behind any oil, fuel or other substances that are
harmfultotheenvironment.
This manual contains instructions for periodic measures that
should normally be performed by the operator.
The manufacturer’s instructions 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
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
WARNING
WARNING
WARNING
CAUTION
CAUTION
Page
Lubricants and symbols ................................................... 3
Technical specifications................................................4-6
Maintenance schedule ..................................................... 7
Maintenance measures................................................ 8, 9
Every 10 hours of operation (Daily) .......................... 10-12
Every 50 hours of operation (Weekly) ..................... 13, 14
Every 250 hours of operation (Monthly) .................... 15-18
Every 500 hours of operation (Every three months) ...... 19
Every 1000 hours of operation (Every six months) ....... 20
Every 2000 hours of operation (Yearly) ................... 21, 22
Long-term parking .......................................................... 23
Special instructions ........................................................ 24
Electrical system, fuses................................................. 25

3CC82/92 M092EN3
Other lubricants are required for operation in
extremely high or extremely low ambient
temperature. See, chapter ”Special
instructions”, or get in touch with Dynapac.
Always use high-quality lubricants in the
amounts recommended. Too much grease or
oil can cause overheating and subsequent
increased wear
ENGINE OIL, Shell Rimula Super SAE 15W/40 or equivalent
Ambient temp. -10° C - +50°C ACEA-E3, API-CH-4, CG-4, CF-4, CF
(14 to 122°F)
HYDRAULIC FLUID,
Ambient temp.-10° C - +40° C Shell Tellus Oil TX68 or equivalent
(14 to 104°F)
Ambient temp. above +40° C
(104°F) Shell Tellus Oil TX100 or equivalent
DRUM OIL,
Ambient temp. 15° C - +40° C Shell Spirax SAE 80W/90, HD API, GL-5
(5 to 104°F)
Ambient temp. above +40° C Shell Spirax HD85W/140 or equivalent
GREASE Shell Calithia EPT2 or equivalent
FUEL Seeenginemanual
Engine oil level Air cleaner
Engineoil filter Battery
Hydraulic reservoir level Sprinkler
Hydraulic fluid filter Sprinkler water
Transmission oil level Recyclable
Lubricatingoil Fuelfilter
LUBRICANTS AND SYMBOLS
CAUTION
CAUTION

4CC82/92 M092EN3
Weight and sizes CC 82 CC 82H CC 92
Service weight, with ROPS, EN500 (kg/lbs).. 1570/3461 1630/3594 1590/3505
Length, standard equipped roller
with ROPS (mm/inch) ........................................ 2050/81 2050/81 2050/81
Width, standard equipped roller
with ROPS (mm/inch) ........................................ 1058/42 1058/42 1058/42
Height, standard equipped roller
with ROPS (mm/inch) ........................................ 2405/95 2405/95 2405/95
Height, standard equipped roller
without ROPS (mm/inch).................................... 1600/63 1600/63 1600/63
Fluid volumes (Litres)
Hydraulic reservoir (gal)........................................ 30/7.9 30/7.9 30/7.9
Fuel tank (gal)........................................................ 30/7.9 30/7.9 30/7.9
Water tank (gal)................................................... 75/19.8 75/19.8 80/21.1
Diesel engine (Hatz 2G40) (qts) .......................... 3.0/3.2 3.0/3.2 3.0/3.2
Drum (qts) ............................................................ 3.5/3.7 3.5/3.7 3.5/3.7
Electricalsystem
Battery.................................12V, 75Ah
Alternator.............................. 14V, 55A
Fuses ................................... 8A & 16A
Vibration data CC 82 CC 82H CC 92
Static linear load, front/rear (kg/cm) ................... 9,4/10,2 10,2/10,2 8,5/9,1
Amplitude(mm/inch)....................................... 0,27/0.010 0,27/0.010 0,27/0.010
Frequency (Hz) ........................................................... 68 68 68
Centrifugal force (kN/lb) .................................... 13/2.925 13/2.925 13/2.925
Propulsion data
Speed range (km/h)...............................0-10 (0-0.6 mph)
Climbing capacity - theoretical (%).............................. 60
Diesel engine
Model.............................................................Hatz 2G 40
Max. power, DIN at 2700 r/min (kW)............ 13 (18.0 hp)
TECHNICAL SPECIFICATIONS

5CC82/92 M092EN3
Bolt size: M16 (P/N 90 37 45)
Strength class: 10,9
Tighteningtorque: 240 Nm (for Dacromet treated)
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.
ROPS ROPS bolts must always be tightened dry.
Opening pressure, MPa (psi)
Drive system .............................. 33,0 (4,800)
Charge system................................ 2,0 (348)
Vibration system......................... 31,0 (4,500)
Steering system .............................. 6,5 (943)
Brake release .................................. 1,4 (203)
Hydraulic system
CAUTION

6CC82/92 M092EN3
TECHNICAL SPECIFICATIONS
Measured with vibration switched ON and on soft
polymer material, standard roller
Vibration – Operator’s station
(ISO 2631)
Noise levels – Operator’s station
(ISO 6394) Acoustic pressure levels with vibration
switched OFF, (dB(A))
(Measured on hard surface/standard roller)
Standard roller
Operator’s station.......................................84
7 yards from the machine...........................82
Noise-suppressed roller
Operator’s station.......................................80
7 yards from the machine...........................74
Vibration in the operator’s seat is 0.26 m/s2
(0.853 ft/s2) (without cab)
Vibration in the operator’s seat is 0.74 m/s2
(2.428 ft/s2) (with cab)
Limit value for declaration according to the Machine
Directive 98/37/EC is 0.5 m/s2 (1.641 ft/s2)
CC 82 103 –
CC 92 103 –
The acoustic values are measured in conformance
with EU directive 2000/14/EC on EU-equipped
machines, on soft polymer material with vibration
switched ON and the operator’s seat in transport
mode.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A)
Acoustic
pressure level,
operator’s ear
(ROPS) dB(A)
Noise level can vary when driving on different
courses and with different seat positions.
CAUTION

7CC82/92 M092EN3
Fig. 1 Service and maintenance points
9
10
123 45678
1. Water tank, filling
2. Forward/reverse lever
3. Emergency brake
4. Battery
5. Air cleaner
6. Diesel engine
7. Hydraulic fluid cooler
8. Alternator belt
9. Sprinkler
10. Scrapers
11. Rubber elements
12. Toothed belt
13. Hydraulic fluid filter
14. Hydraulic reservoir, filling
19 18 17 16 15 14 13 12 11
MAINTENANCE SCHEDULE
15. Articulated steering
16. Steering cylinder
17. Fuel tank, filling
18. Drums, oil filling
19. ROPS

8CC82/92 M092EN3
The periodic measures are intended to be performed
primarily with the specified hours of operation,
secondarily for the periods: daily, weekly, etc.
Remove all dirt before filling, when checking
oils and fuel, and when lubricating with oil or
grease.
The manufacturer’s instructions noted in the
engine manual also apply.
Items Action See page Comments
in fig. 1
Before starting each day
6 Check level of engine oil 10 Seeengine manual
14 Check level in hydraulic reservoir 10
17 Refuel 11
Fill the water tank
9 Check sprinkler system 11
6 Check that cooling air is unrestricted 12
10 Check setting of scrapers 12
3 Test the brakes 12
Every 10 hours of operation (Daily)
Items Action See page Comments
in fig. 1
15 Lubricate the articulation 13
16 Lubricate the steering cylinder mounts 13
5 Empty the air cleaner dust trap 13
4 Check the battery 14
11 Check rubber elements and bolted joints 14
After the first 50 hours of operation, change all oil and hydraulic fluid filters and the
lubricating oil, but not the hydraulic fluid.
Every 50 hours of operation (Weekly)
MAINTENANCE MEASURES
CAUTION
CAUTION
CAUTION

9CC82/92 M092EN3
Items Action See page Comments
in fig. 1
6 Change the fuel filter Seeengine manual
13 Change the hydraulic fluid filter 19
Items Action See page Comments
in fig. 1
5 Change or clean filter element of air cleaner,
ensure that hoses and connections are tight 15
6 Clean the engine cooling fins Seeenginemanual
6 Check engine valve clearance Seeenginemanual
6 Change engine oil and oil filter 16 Seeengine manual
7 Clean outside of hydraulic fluid cooler 16
2 Lubricate controls and pivots 17
18 Check oil level in drums 17
14 Check cap/venting on hydraulic reservoir 18
8 Check alternator belt tension 18
Every 250 hours of operation (Monthly)
Every 500 hours of operation (Every three months)
Items Action See page Comments
in fig. 1
14 Drain condense water from hydr. reservoir 20
5 Change the air filter 20
12 Check toothed belt on vibration pump 20
Every 1000 hours of operation (Every six months)
Every 2000 hours of operation (Yearly)
Items Action See page Comments
in fig. 1
14 Change fluid in hydraulic reservoir 21
18 Change oil in drums 21
1 Empty and clean the water tank 22
17 Empty and clean the fuel tank 22
Check the condition of the steering joints 22
MAINTENANCE MEASURES

10 CC82/92 M092EN3
Fig.2 Diesel engine
1. Dipstick
2. Filler cap
Turn the engine hood catch and open the hood forward.
Ensure that the engine hood is fully open.
Check the oil level with the dipstick (1). The level
should be between the two marks. If the level is close
to the lower mark, top up with fresh engine oil through
the filler cap (2). See under the heading Lubricants for
the correct grade of oil.
Never fill too much oil, it may damage the
engine.
Fig.4 Right-handsideinengine
compartment
1. Filler hose
Top up with fresh hydraulic fluid through the filler hose
(1), until the level is visible in the sight glass.
See under the heading Lubricants for the correct grade
offluid.
Diesel engine
– Checking the oil level
2
Fig.3 Hydraulic reservoir
1. Sight glass
Hydraulic reservoir
– Checking the level
1
1
1
Wipe the sight glass (1). Make sure that the oil level is
between the max. and min. marks.
Hydraulic reservoir
– Topping up
EVERY 10 HOURS OF OPERATION (Daily)
Place the roller on a level base. The engine
must be switched off and the reserve/
parking brake knob pushed in for all check-
ing and adjustments on the roller unless
otherwise specified.
WARNING
WARNING
CAUTION

11CC82/92 M092EN3
Fig.5 Floor of operator’s platform
1. Floor cover
2. Filler pipe/cap
Fuel tank – Refueling Fill the fuel tank every day before work begins. Open
the floor hatch (1) for refueling, using the hatch key
provided.
Fill through the fuel filler pipe (2).
Never refuel while the engine is running, do
not smoke, and avoid spilling fuel.
Stop the engine. Short the refuelling nozzle
by pressing it against the filler pipe (2)
when refuelling.
The tank holds 30 quarts of fuel.
1
2
Sprinkler system
– Checking, cleaning
1
Fig.7 Sprinkler system
1. Water filter
Ensure that the water filter (1) and holes in the sprinkler
pipes are not clogged. Clean as required.
Clean the water filter by lifting it out of its holder, screw
off the lower part of the filter and clean the strainer and
filter housing. Reassemble in the reverse order.
11
EVERY 10 HOURS OF OPERATION (Daily)
Water tank – Filling Screw off the tank cap (1) and fill with pure
water, do not remove the strainer.
Fill the water tank; it holds 75–80 litres.
Sole additive: Small amount of
environment-friendlyantifreezeliquid.
Fig.6 Water tank
1. Tank cap
1
WARNING
WARNING
CAUTION

12 CC82/92 M092EN3
Scrapers
– Checking, adjustment Check that the scrapers are undamaged. Adjust the
scrapers as follows, if needed:
To set the scraper harder, loosen the lock nut (2) and
turn the adjusting nut (1) clockwise to the desired
setting.
Tighten the lock nut against the mounting bracket (3) to
fix the setting.
Adjust the tension on both scraper mountings.
To set the scraper looser, adjust in the reverse order to
the above.
The scrapers can suitably be released from the drum
for transport driving, ie, by raising the scraper with the
handle (4) and the catch (5).
3 1
2
54
Fig.9 Front scraper in transport mode
1. Adjusting nut
2. Lock nut
3. Mounting bracket
4. Handle
5. Catch
69
Fig.10 Instrument panel
6. Reserve/parking brake knob
9. Brake warning lamp
Brakes – Check Check operation of the brakes as follows:
Drive the roller slowly forward.
Push in the reserve/parking brake knob (6).
The brake warning lamp (9) on the instrument panel
should light and the roller should stop.
After testing the brakes, set the forward/reverse lever
inneutral.
Pull up the reserve/parking brake knob.
The roller is now ready for operation.
EVERY 10 HOURS OF OPERATION (Daily)
Fig.8 Enginehood
1. Cooling-air grille/engine
2. Cooling-air grille/oil cooler
Air circulation – Checking Ensure that circulation of cooling air to the diesel
engine through the protective grille on the engine hood
is unrestricted.
1
2
WARNING

13CC82/92 M092EN3
EVERY 50 HOURS OF OPERATION (Weekly)
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.
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 befo-
re lubricating.
Turn the steering wheel fully to the right to gain access
to all five grease nipples (1) from the left side of the
machine.
Wipe the grease nipples (1). Grease each nipple with
three strokes of the hand-operated grease gun. Make
sure that grease penetrates the bearings. If not, it may
be necessary to relieve the articulation joint with a jack
while repeating the greasing process.
1
Steering cylinder and articulated
steering – Lubrication
1
Press the rubber bellows with your fingers to empty the
dust trap (1) in the air cleaner. Make sure that the air
hoses are intact.
Air cleaner – Emptying
Fig. 11 Steering joint, left side
1. Lubricating nipples
Fig.12 Air cleaner
1. Dust trap
WARNING
WARNING

14 CC82/92 M092EN3
Never use a naked flame when checking
the battery. The electrolyte emits explosive
gas while the alternator is charging.
Raise the engine hood to the fully open mode.
Wipe the top of the battery.
Wear safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.
Take off the cell caps and make sure that electrolyte is
about 10 mm (0.4 in) above the plates. Check the level
of all cells. Top off with distilled water to the right level if
the level is low. The engine should be run for a while
before topping off with distilled water if the ambient
temperature is below freezing. Otherwise, the electro-
lyte might freeze.
Make sure that ventilation holes in the cell cover are
not clogged. Then put the cover back on.
The cable shoes should be clean and well tightened.
Clean corroded cable shoes and grease them with
acid-free Vaseline.
When disconnecting the battery, always
disconnect the negative cable first. When
connecting the battery, always connect the
positive cable first.
Discard used batteries properly. Batteries
contain lead, which is detrimental to the envi-
ronment.
Before doing any electric welding on the
machine, disconnect the battery ground
cable and then all electrical connections to
the alternator.
Battery – Checking the
electrolytelevel
Fig.15 Drum suspension
1. Rubber element
2. Fastening bolts
Fig.14 Electrolyte level in battery
1. Cell cap
2. Electrolyte level
3. Plate
Battery cell
Fig.13 Battery shelf
1. Battery
1
Rubber elements and fastening
bolts – Checking
21
Check all rubber elements (1), replace all of the ele-
ments if more than 25% of them on one side of the
drum are cracked deeper than 10-15 mm (0.4-0.6 in).
Use the blade of a knife or pointed object to assist
when checking.
Make sure that the fastening screws (2) are tightened.
The bolts holding the rubber elements to the
drum are sealed with Loctite. Check the
rubber elements on both sides of the drum.
EVERY 50 HOURS OF OPERATION (Weekly)
WARNING
WARNING
WARNING
CAUTION
CAUTION

15CC82/92 M092EN3
Air cleaner
– Dismantling Turn the machine in position for a left-hand turn.
Loosen the screw (1) by turning it a ¼ turn, lift the
cover (2) and take out the filter through the opening
after carrying out the following items.
Fig.16 Air cleaner
1. Securing screw
2. Cover
Loosen the nut (1), cover (2), nut (3) and remove the
backup filter (4). Make sure that the backup filter is
undamaged. Clear the filter element by knocking it
against your hand or other soft object. Then blow with
compressed air from the inside of the filter. See below.
Clean the filter housing (5) and the cover (2).
Change the backup filter after cleaning it five
times.
Check the connections between engine and
air cleaner. The connecting items should be
checked and replaced if necessary if dust is
found in the intake pipe of the engine.
Backup filter – Cleaning
with compressed air
Fig.17 Air cleaner
1. Wing nut
2. Cover
3. Nut
4. Backup filter
5. Filter housing
Blow up and down along the paper pleats on the inside
of the filter element. Hold the nozzle 20 to 30 mm (³ 1")
from the pleats to avoid tearing the paper.
Wear protective goggles when working
with compressed air.
4
1
3
5
2
Air Cleaner – Cleaning
Fig.18 Backup filter
1
2
EVERY 250 HOURS OF OPERATION (Monthly)
WARNING
CAUTION
CAUTION

16 CC82/92 M092EN3
Changing the engine oil
andoil filter
Fig.20 Enginecompartment, left-handside
3. Filler cap
4. Oil filter
Fig.19 Enginecompartment,right-hand
side
1. Drain hose
2. Plug
4
1
Fig.21 Engine compartment
1. Hydraulic fluid cooler
Hydraulic fluid cooler – Cleaning Clean the fins of the fluid cooler, preferably using
compressed air. Blow the cooler clean in the opposite
direction to the normal flow of air. Check that the
thermostat that regulates the radiator fan is working. It
should switch on at 60°C (140°F).
Wear protective goggles when working
with compressed air.
Run the engine warm before draining the oil.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors (risk
of carbon monoxide poisoning).
Switch off the engine and apply the park-
ing brake.
Place a receptacle that holds at least 15 liters
of under the drain plug. Save the oil and de-
posit it in an approved manner.
Danger of being burned when draining hot
oil. Protect your hands.
Release the oil filler cap (3) and the plug (2) in the end
of the drain hose; allow all engine oil to run out.
Release the drain hose (1) from the holder on the
engine and move out the hose by the front scraper.
See the engine manual for detailed instructions
concerning changing the oil and filter.
Remove the oil filter (4) and replace with a new one.
Refit the plug (2) in the end of the drain hose, and hang
the hose in the holder on the engine.
Fill with fresh engine oil, see under the heading
Lubricants for the correct grade of oil, and put the filler
cap (3) on again. Ensure that the level is correct on the
dipstick, start the engine and check round the oil filter
for tightness.
2
3
1
EVERY 250 HOURS OF OPERATION (Monthly)
WARNING
WARNING
WARNING
WARNING
CAUTION

17CC82/92 M092EN3
Drum
– Checking the oil level Position the roller on a flat surface and drive slowly until
the oil plug (1) is opposite the semi-circular recess in
the drum suspension.
Switch off the engine, break the electric
power supply and press the parking brake/
emergency stop knob.
Unscrew the plug and check that the oil level reaches
up to the lower edge of the filler hole. Fill as required
with fresh transmission oil, see under the heading
Lubricants for the correct grade of oil.
Clean off any metal particles from the magnetic oil plug
(1) and screw in the plug.
Forward/Reverse controls
– Checking and lubrication
Fig.22 Forward/reverse controls
1. Friction screws
2. Screw
3. Operating wire
Check friction of the forward/reverse controls. Adjust
the friction screws (1) as required to retain the forward/
reverse controls at the set position during operation of
the roller. The zero mode of the controls is determined
by screw (2) gripping the groove in the spindle between
the two control levers.
If the controls begin to bind after a long period of use,
lubricate them at the bearings (1), and also lubricate the
control cable (3) with a few drops of oil at each position.
1
If the forward/reverse control is still stiff after the above
adjustment, lubricate the other end of the control cable
as well with a few drops of oil. The cable is located on
top of the propulsion pump.
Fig.24 Drive side of drum
1. Oil plug
2
3
1
EVERY 250 HOURS OF OPERATION (Monthly)
Fig.23 Engine compartment
1. F/R controls
2. Propulsion pump
1
2
WARNING

18 CC82/92 M092EN3
Hydraulic reservoir
– Checking/venting
Fig.25 Enginecompartment,right-hand
side
1. Hydraulic reservoir, filler cap
Lift up the engine hood to its fully open position.
Unscrew and ensure that the reservoir cap is not
clogged; air must have unobstructed passage through
the cap in both directions.
If clogged in either direction, clean with a little diesel oil
and blow with compressed air until free passage is
assured, or replace the cap with a new one.
Wear protective goggles when working
with compressed air.
Switch off the engine, break the electric
power supply and press the parking brake/
emergency stop knob.
The alternator belt (3) is correctly stretched if it can be
pressed down about 10 mm (³3/8") at a position half
way between the pulleys. Proceed as follows if the belt
needs to be stretched.
Loosen the two hexagonal socket screws (1) and (2).
Push the alternator over to tension the belt to the size
mentionedabove.
Tighten screw (1) first and then screw (2). Check to
make sure that the belt is stretched properly after
tightening the screws.
Fig.26 Alternator viewed from the front
1. Adjusting screw
2. Mounting screw
3. Alternator belt
1
Alternator
– Checking and belt tension
3
2
1
EVERY 250 HOURS OF OPERATION (Monthly)
WARNING
WARNING