Dynapac CC1200C User manual

Instruction manualInstruction manual
ICC1200C-1EN3.pdfICC1200C-1EN3.pdf
Operation & MaintenanceOperation & Maintenance
Vibratory rollerVibratory roller
CC1200CCC1200C
EngineEngine
Kubota D1703Kubota D1703
Serial numberSerial number
10000333x0A000001 -10000333x0A000001 -
Translation of original instructionsTranslation of original instructions
Subject to changesSubject to changes
Printed in SwedenPrinted in Sweden

2000h-Maintenance
ICC1200C-1EN3.pdf2012-05-16
Table of Contents
Introduction .............................................................................................................................. 1
Warning symbols......................................................................................... 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
CE marking and Declaration of conformity.................................................. 3
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Driving near edges ...................................................................................... 7
Slopes ......................................................................................................... 8
Special instructions .................................................................................................................. 9
Standard lubricants and other recommended oils and fluids ...................... 9
Higher ambient temperatures, above +40°C (104°F).................................. 9
Lower ambient temperature - Freeze risk ................................................... 9
Temperatures.............................................................................................. 9
High pressure cleaning ............................................................................... 9
Fire fighting ............................................................................................... 10
Roll Over Protective Structure (ROPS) ..................................................... 10
Battery handling ........................................................................................ 10
Jump starting............................................................................................. 11
Technical specifications ......................................................................................................... 13
Vibrations - Operator station ..................................................................... 13
Noise level................................................................................................. 13
Dimensions, top view ................................................................................ 14
Dimensions, side view............................................................................... 15
Weights and volumes................................................................................ 16
Working capacity....................................................................................... 16
General ..................................................................................................... 16
Tightening torque ...................................................................................... 18

2000h-Maintenance
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ROPS - bolts ............................................................................................. 19
Hydraulic system....................................................................................... 19
Machine description ............................................................................................................... 21
Identification ............................................................................................................ 21
Product identification number on the frame .............................................. 21
Explanation of 17PIN serial number.......................................................... 21
Machine plate............................................................................................ 22
Engine plates ............................................................................................ 22
Location - decals ....................................................................................... 24
Safety decals............................................................................................. 25
Info decals................................................................................................. 26
Instruments/Controls ............................................................................................... 28
Locations - Instruments and controls ........................................................ 28
Locations - Control panel and controls...................................................... 29
Function description .................................................................................. 30
Electrical system...................................................................................................... 33
Fuses ........................................................................................................ 33
Operation ............................................................................................................................... 35
Before starting ......................................................................................................... 35
Master switch - Switching on..................................................................... 35
Driver seat (Std) - Adjustment................................................................... 35
Driver seat (Option) - Adjustment.............................................................. 36
Instruments and lamps - Checking............................................................ 36
Interlock..................................................................................................... 37
Operator position....................................................................................... 37
Parking brake - Check............................................................................... 38
Starting .................................................................................................................... 39
Starting the engine .................................................................................... 39
Driving ..................................................................................................................... 41
Operating the roller ................................................................................... 41

2000h-Maintenance
ICC1200C-1EN3.pdf2012-05-16
Interlock/Emergency stop/Parking brake - Check ..................................... 42
Vibration .................................................................................................................. 42
Manual/Automatic vibration....................................................................... 42
Braking .................................................................................................................... 43
Normal braking.......................................................................................... 43
Emergency braking ................................................................................... 43
Switching off.............................................................................................. 44
Parking .................................................................................................................... 44
Chocking the wheels/drum........................................................................ 44
Battery disconnector ................................................................................. 45
Long-term parking.................................................................................................................. 47
Engine ....................................................................................................... 47
Battery....................................................................................................... 47
Air cleaner, exhaust pipe........................................................................... 47
Fuel tank ................................................................................................... 47
Hydraulic reservoir .................................................................................... 47
Water tank................................................................................................. 47
Steering cylinder, hinges, etc. ................................................................... 48
Hoods, tarpaulin ........................................................................................ 48
Miscellaneous ........................................................................................................................ 49
Lifting ....................................................................................................................... 49
Locking the articulation ............................................................................. 49
Lifting the roller.......................................................................................... 49
Unlocking the articulation .......................................................................... 50
Towing/Recovering.................................................................................................. 51
Release the brakes ................................................................................... 51
Releasing the brake, wheel motors (Optional) .......................................... 52
Towing the roller........................................................................................ 53
Retractable ROPS (Optional).................................................................... 54
Roller prepared for transport ..................................................................... 55

2000h-Maintenance
ICC1200C-1EN3.pdf 2012-05-16
Operating instructions - Summary ......................................................................................... 57
Preventive maintenance ........................................................................................................ 59
Acceptance and delivery inspection.......................................................... 59
Warranty.................................................................................................... 59
Maintenance - Lubricants and symbols ................................................................................. 61
Maintenance symbols ............................................................................... 62
Maintenance - Maintenance schedule ................................................................................... 63
General ..................................................................................................... 63
Service and maintenance points ............................................................... 63
Every 10 hours of operation (Daily)........................................................... 64
After the FIRST 50 hours of operation ...................................................... 64
Every 50 hours of operation (Weekly)....................................................... 65
Every 250 hours of operation (Monthly) .................................................... 65
Every 500 hours of operation (Every three months) ................................. 65
Every 1000 hours of operation (Every six months) ................................... 66
Every 2000 hours of operation (Yearly) .................................................... 66
Maintenance, 10h .................................................................................................................. 67
Check - Coolant system ............................................................................ 67
Hydraulic reservoir, Level check - Filling................................................... 68
Lowering of engine hood........................................................................... 69
Air circulation - Check ............................................................................... 69
Fuel tank - Filling....................................................................................... 70
Sprinkler system/Drum
Checking - Cleaning.................................................................................. 70
Sprinkler system / Wheels
Check - Cleaning....................................................................................... 71
Water tank - Filling .................................................................................... 72
Scrapers, fixed
Checking - Setting..................................................................................... 72
Scrapers, spring-action (Optional)
Checking - Adjustment .............................................................................. 72

2000h-Maintenance
ICC1200C-1EN3.pdf2012-05-16
Scrapers
Check - Adjustment................................................................................... 73
Brakes - Check.......................................................................................... 73
Pump system / Tire
Check - Cleaning....................................................................................... 74
Maintenance - 50h ................................................................................................................. 75
Air cleaner indicator .................................................................................. 75
Air cleaner
Check - Replacement of main filter ........................................................... 75
Air filter indicator - Resetting ..................................................................... 76
Backup filter - Change............................................................................... 76
Air cleaner
- Cleaning.................................................................................................. 77
Steering cylinder and steering joint - Lubrication ...................................... 77
Tires - Tire pressure.................................................................................. 78
Maintenance - 250h ............................................................................................................... 79
Coolers
Checking - Cleaning.................................................................................. 79
Battery
- Check condition ...................................................................................... 80
Engine oil and oil filter - Change ............................................................... 81
Maintenance - 500h ............................................................................................................... 83
Drum - oil level
Inspection - filling ...................................................................................... 83
Rubber elements and attachment screws
Check ........................................................................................................ 84
Hydraulic reservoir cap - Check ................................................................ 84
Controls - Lubrication ................................................................................ 84
Check - Coolant system ............................................................................ 85
Maintenance - 1000h ............................................................................................................. 87
Replacing the hydraulic oil filter ................................................................ 87
Hydraulic fluid reservoir - Draining ............................................................ 89
Replacing the fuel filter.............................................................................. 89

2000h-Maintenance
ICC1200C-1EN3.pdf 2012-05-16
Replacing the pre-filter .............................................................................. 90
Maintenance - 2000h ............................................................................................................. 91
Hydraulic tank - Changing the fluid ........................................................... 91
Drum - Oil change ..................................................................................... 92
Water tank - Draining ................................................................................ 92
Water pump - Draining .............................................................................. 93
Water tank - Cleaning ............................................................................... 93
Emulsion tank - Draining ........................................................................... 94
Fuel tank - Cleaning .................................................................................. 94
Steering joint - Check................................................................................ 95

Introduction
ICC1200C-1EN3.pdf2012-05-16
Introduction
Warning symbols
The machine
Dynapac CC1200C is a self-propelled vibratory combi
roller in 2,5 metric tonnes class featuring a 1200 mm
(47 in) wide drum and 1180 mm (46 in.) wide wheels.
The machine is equipped with drive and brakes both
front and rear and vibrations on front drum.
Intended use
The CC1200C is a small combi roller as are used for
compacting of thin layers and soft asphalt compounds.
The roller is mainly intended for smaller construction
works, such as compacting asphalt on minor roads,
sidewalks, cycle ways and garage driveways. The four
rubber wheels on the CC1200C gives the asphalt a
different surface structure, as sometimes aim at in
comparison with a vibrating tandem roller.
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
Safety information
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
1

Introduction
ICC1200C-1EN3.pdf 2012-05-16
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
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.
General
This manual contains instructions for machine
operation and maintenance.
The machine must be correctly maintained for
maximal performance.
The machine should be kept clean so that any
leakages, loose bolts and loose connections are
discovered at as early a point in time as possible.
Do not spray with high-pressure cleaner directly onto
gaskets and bearing spacings in steering hitch and
drum.
Inspect the machine every day, before starting.
Inspect the entire machine so that any leakages or
other faults are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
This manual contains instructions for periodic
maintenance normally carried out by the operator.
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Introduction
ICC1200C-1EN3.pdf2012-05-16
Additional instructions for the engine can be
found in the manufactuer's engine manual.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
CE marking and Declaration of conformity
(Applies to machines marketed in EU/EEC)
This machine is CE marked. This shows that on
delivery it complies with the basic health and safety
directives applicable for the machine in accordance
with machinery directive 2006/42/EC and that it also
complies with other directives applicable for this
machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable directives and
supplements, as well as the harmonized standards
and other regulations that are applied.
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Introduction
ICC1200C-1EN3.pdf 2012-05-16
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Safety - General instructions
ICC1200C-1EN3.pdf2012-05-16
Safety - General instructions
(Also read the safety manual)
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
2. Ensure that all instructions in the MAINTENANCE section are followed.2. Ensure that all instructions in the MAINTENANCE section are followed.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
4. Never use the roller if it is in need of adjustment or repair.4. Never use the roller if it is in need of adjustment or repair.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
7. Drive slowly in sharp bends.7. Drive slowly in sharp bends.
8. Avoid driving across slopes. Drive straight up or straight down the slope.8. Avoid driving across slopes. Drive straight up or straight down the slope.
9. When driving close to edges, ditches or holes, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
9. When driving close to edges, ditches or holes, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
11. Drive particularly carefully on uneven ground.11. Drive particularly carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
14. Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
14. Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
15. Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
15. Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
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Safety - General instructions
ICC1200C-1EN3.pdf 2012-05-16
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. See instructions in the STOP section.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. See instructions in the STOP section.
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
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Safety - when operating
ICC1200C-1EN3.pdf2012-05-16
Safety - when operating
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
Driving near edges
Fig. Position of drum when driving
near an edge
≥ 2/3
When driving near an edge, minimum 2/3 of the drum
width must be on solid ground.
Keep in mind that the machine's center of
gravity moves outwards when steering. For
example, the center of gravity moves to the right
when you steer to the left.
Keep in mind that the machine's center of
gravity moves outwards when steering. For
example, the center of gravity moves to the right
when you steer to the left.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
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Safety - when operating
ICC1200C-1EN3.pdf 2012-05-16
Slopes
Fig. Operating on slopes
Max 20° or 36%
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.
Always take into consideration that loose ground,
steering the machine, vibration on, machine speed
across the ground and raising the center of gravity can
all cause the machine to topple at smaller slope
angles than those specified here.
It is recommended that ROPS (Roll Over
Protective Structure) or a ROPS approved cab,
is always used when driving on slopes or
unsafe ground.
It is recommended that ROPS (Roll Over
Protective Structure) or a ROPS approved cab,
is always used when driving on slopes or
unsafe ground.
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Special instructions
ICC1200C-1EN3.pdf2012-05-16
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).
The maximum temperature for biological
hydraulic fluid is +35°C (95°F).
The maximum temperature for biological
hydraulic fluid is +35°C (95°F).
Higher ambient temperatures, above +40°C
(104°F)
For operation of the machine at higher ambient
temperatures, however maximum +50°C (122°F), the
following recommendations apply:
The diesel engine can be run at this temperature using
normal oil. However, the following fluids must be used
for other components:
Hydraulic system - mineral oil Shell Tellus T100 or
similar.
Lower ambient temperature - Freeze risk
Make sure that the watering system is empty/drained
of water (sprinkler, hoses, tank/s) or that anti-freeze
has been added, to prevent the system freezing.
Temperatures
The temperature limits apply to standard versions of
rollers.
Rollers equipped with additional equipment, such as
noise suppression, may need to be more carefully
monitored in the higher temperature ranges.
High pressure cleaning
Do not spray water directly onto electrical components
or the instrument panels.
Place a plastic bag over the fuel filler cap and secure
with a rubber band. This is to avoid high pressure
water entering the vent hole in the filler cap. This could
cause malfunctions, such as the blocking of filters.
Do not spray with high-pressure cleaner directly onto
gaskets and bearing spacings in steering hitch and
drum.
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Special instructions
ICC1200C-1EN3.pdf 2012-05-16
Never aim the water jet directly at the fuel tank
cap. This is particularly important when using a
high-pressure cleaner.
Never aim the water jet directly at the fuel tank
cap. This is particularly important when using a
high-pressure cleaner.
Fire fighting
If the machine catches fire, use an ABC-class powder
fire extinguisher.
A BE-class carbon dioxide fire extinguisher can also
be used.
Roll Over Protective Structure (ROPS)
If the machine is fitted with a Roll Over
Protective Structure (ROPS) never carry out any
welding or drilling in the structure or cab.
If the machine is fitted with a Roll Over
Protective Structure (ROPS) never carry out any
welding or drilling in the structure or cab.
Never attempt to repair a damaged ROPS
structure or cab. These must be replaced with
new ROPS structure or cabs.
Never attempt to repair a damaged ROPS
structure or cab. These must be replaced with
new ROPS structure or cabs.
Battery handling
When removing batteries, always disconnect the
negative cable first.
When removing batteries, always disconnect the
negative cable first.
When fitting batteries, always connect the
positive cable first.
When fitting batteries, always connect the
positive cable first.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
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Special instructions
ICC1200C-1EN3.pdf2012-05-16
Jump starting
Do not connect the negative cable to the
negative terminal on the dead battery. A spark
can ignite the oxy-hydrogen gas formed
around the battery.
Do not connect the negative cable to the
negative terminal on the dead battery. A spark
can ignite the oxy-hydrogen gas formed
around the battery.
Check that the battery used for jump starting
has the same voltage as the dead battery.
Check that the battery used for jump starting
has the same voltage as the dead battery.
Fig. Jump starting
1
2
3
4
Turn the ignition and all power consuming equipment
off. Switch off the engine on the machine which is
providing jump start power.
First connect the jump start battery's positive terminal
(1) to the flat battery's positive terminal (2).Then
connect the jump start battery's negative terminal (3)
to, for example, a bolt (4) or the lifting eye on the
machine with the flat battery.
Start the engine on the power providing machine. Let it
run for a while. Now try to start the other machine.
Disconnect the cables in the reverse order.
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Special instructions
ICC1200C-1EN3.pdf 2012-05-16
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