Fayat Group DYNAPAC CC425 User manual

INSTRUCTION MANUAL
Operating and Maintenance
Vibratory rollers
CC425
Engine: KOEL-4R1190NA1 –CEV Stage IV
Serial number: *10300616CME010845-
4812332527_A
June-2021
K’

Manual Revisions
Table 1: Revision History
REV.
NO.
DATE
REVISION
1
June 2021
New release
Customer Acknowledgment
• Dynapac reserves the right to make any changes or modifications without prior
notice and without incurring any liability to retrofit machines previously shipped from
the factory.
• Dynapac will not be held responsible for any damages caused by unauthorized
modification of the machine and its associated equipment.
• The manufacturer is not liable for damages caused by inappropriate use.
• Damage that occurs as a result of substandard repairs, as well as injury topersonnel
or damage to equipment that is attributable to older un-repaired damage, is not
covered by the customer warranty policy. Always refer to your customer warranty
policy.
• Always refer to equipment documentation for correct operation and repair
procedures.

Table of Contents
Section 1: Introduction
1.1 General Information...........................................................................................1
Instruction Manual Location....................................................................................2
Receiving the Roller...............................................................................................2
Identification Data...................................................................................................2
Roller Identification.................................................................................................3
Engine Identification...............................................................................................4
1.2 Roller Description..............................................................................................5
Identification of Major Components ........................................................................5
Diesel Engine.........................................................................................................6
Electrical System....................................................................................................7
Main and Light Fuses ......................................................................................................7
Propulsion System/Transmission ...........................................................................9
Brake system .........................................................................................................9
Secondary/Parking Brake................................................................................................9
Steering System ..............................................................................................................9
Roller Applications..................................................................................................9
Designated Applications..................................................................................................9
Non-Designated Applications..........................................................................................9
Section 2: Safety First
2.1 General Information......................................................................................... 11
Warnings and Cautions........................................................................................12
Personnel Protective Equipment ..........................................................................12
Tools and Equipment.....................................................................................................12
Operating Safety ..................................................................................................13
Before Starting the Engine ............................................................................................13
Starting the Roller..........................................................................................................13
Parking the Roller ..........................................................................................................13
Driving Near Edges........................................................................................................13
Slopes............................................................................................................................14
Hydraulic Maintenance Safety..............................................................................14
Cylinder Repairs or Replacement..................................................................................14
Handling Fluids and Oil ........................................................................................14
Transporting.........................................................................................................15
2.2 Equipment Safety Decals................................................................................ 16

Table of Contents
Section 3: Special Instructions
3.1 Operational Limitations ....................................................................................17
Standard Lubricants and Other Recommended Oils and Fluids............................17
Higher Ambient Temperatures..............................................................................17
Lower Ambient Temperature - Freeze Risk...........................................................17
Temperatures.......................................................................................................17
High Pressure Cleaning........................................................................................18
Ambient Temperature Range................................................................................18
Operating Conditions For Stability ........................................................................18
Grade Limitations .................................................................................................18
Fire Fighting .........................................................................................................18
Battery Handling...................................................................................................18
Jump Starting.......................................................................................................19
Section 4: Specifications
4.1 Weight and Dimensions...................................................................................21
Diesel Engine .......................................................................................................22
Fluid Volume ........................................................................................................23
Working Capacity .................................................................................................23
Hydraulic System..................................................................................................23
Section 5: Operation Controls
5.1 Instruments and Controls.................................................................................25
Functional description - Keypad............................................................................26
Starter Switch.......................................................................................................27
Speed selector .....................................................................................................27
Work Transport mode...........................................................................................27
Emergency Stop...................................................................................................28
Forward/Reverse (FNR) Lever..............................................................................28
Sprinkler Switch....................................................................................................28
Seat Buzzer..........................................................................................................28
Horn Button..........................................................................................................29
Vibration High/Low Switch....................................................................................29
Drum Selector Switch...........................................................................................29
Fuse Box..............................................................................................................29
Driving Lights Switch ............................................................................................29
Working Light Switch............................................................................................30
Hazard Warning Lights Switch..............................................................................30

Table of Contents
Rotating Beacon Switch (Optional).......................................................................30
Direction Indicator Switch.....................................................................................30
Parking Brake On/Off Switch................................................................................30
Electrical Control Panel........................................................................................30
Functional description - Display.....................................................................................31
Transport mode .............................................................................................................31
Direction of work............................................................................................................31
Hour meter.....................................................................................................................31
Fuel level .......................................................................................................................31
User settings..................................................................................................................31
Work mode vibration......................................................................................................31
Vibration status..............................................................................................................32
Automatic vibration control - AVC..................................................................................32
Function description ......................................................................................................32
Control Panel Warnings Symbols..................................................................................33
Control Panel Notification Symbols ...............................................................................34
Section 6: Inspections and Operations
6.1 General Information......................................................................................... 37
General Checks....................................................................................................37
Operator Areas.....................................................................................................37
Check Engine Oil Level........................................................................................38
Check Engine Coolant Level ................................................................................38
Check Fuel Level..................................................................................................39
Check Batteries....................................................................................................39
Verify the Controls................................................................................................39
6.2 Before Starting the Engine .............................................................................. 40
Seat(Standard) Adjustment ..................................................................................40
Check the Instruments and Lamps.......................................................................41
Interlock ...............................................................................................................41
6.3 Operating the Roller........................................................................................ 42
Operation .............................................................................................................42
Vibration on Selected Drum...........................................................................................43
Braking.................................................................................................................43
Normal Braking..............................................................................................................43
Emergency Braking .......................................................................................................43
Switching Off........................................................................................................44
6.4 Lifting and Handling......................................................................................... 45
Locking the Articulation ........................................................................................45
Lifting the Roller ...................................................................................................45
6.5 Towing the Roller ............................................................................................ 46
Towing Information...............................................................................................46

Table of Contents
Towing...........................................................................................................................46
6.6 Transporting the Roller.....................................................................................48
Transportation Procedures ...................................................................................49
Safety Precautions........................................................................................................49
Operator Checklist ........................................................................................................49
Start Up.........................................................................................................................49
Before Driving ...............................................................................................................49
Roller preparation for Transport...................................................................................50
6.7 Special Conditions ...........................................................................................51
Cold Weather Conditions......................................................................................51
Hot Weather Conditions........................................................................................51
High Altitude Conditions .......................................................................................52
Long-term Parking................................................................................................52
Section 7: Maintenance
7.1 General Information .........................................................................................53
7.2 Maintenance Schedule.....................................................................................54
Maintenance Schedule Information.......................................................................54
7.3 Refill Capacities/Lubricants..............................................................................57
General Information..............................................................................................57
Lubrication Chart..................................................................................................58
Refill Capacities....................................................................................................58
7.4 Standard Torque Values..................................................................................60
Head Markings.....................................................................................................60
Recommended Torques................................................................................................60
7.5 Maintenance as Required................................................................................62
Service as Required.............................................................................................62
Clean the Roller....................................................................................................62
Loose Bolted Connections............................................................................................62
Air Cleaners..........................................................................................................62
Connections and Ducts.................................................................................................62
Air Cleaner Pre-Cleaner................................................................................................63
Air Cleaner Main Filter ..................................................................................................63
Cleaning the Filter Element...........................................................................................64
Air Circulation................................................................................................................64
Hose and Clamps.................................................................................................64
Engine..................................................................................................................65
Batteries...............................................................................................................65
Check Electrolyte Level.................................................................................................66

Table of Contents
Fuel Tank.............................................................................................................66
Coolant system....................................................................................................................67
Water Tank ..........................................................................................................................67
Fixed scrapper .....................................................................................................................67
Brakes..................................................................................................................68
Sprinkler System..................................................................................................68
7.6 Lubrication and Filters..................................................................................... 69
Hydraulic Reservoir..............................................................................................69
Check Hydraulic Oil Level .............................................................................................69
Steering Cylinder and Steering Joint ....................................................................70
Drum - Oil Level ...................................................................................................70
Check Drum Gear Oil Level..................................................................................71
Controls .........................................................................................................................71
Housekeeping......................................................................................................71

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1
Introduction
Section 1: Introduction
1.1 General Information
This manual contains basic safety information, basic operation instructions, and preventive
maintenance information of the Dynapac CC425 roller.
The purpose of this manual is to provide the knowledge of the fundamental rules and criteria to be
followed for on-site use and maintenance of the CC425 roller for the operator and site maintenance
personnel.
The operator and site maintenance personnel must read and fully understand this instruction manual
before operating or servicing the roller. This manual has been organized to present the safety
precautions, operation requirements, and appropriate information needed to:
• Safely operate the CC425 roller while achieving optimum production.
• Understand the operating principal of each system associated with the CC425 roller.
• React effectively and safely to emergency and alarm conditions.
• Perform the necessary pre-operational and post-operational checks on the roller.
If any part of this manual cannot be understood, contact the supervisor or local Dynapac distributor.
This is an essential condition for working safely with the roller. The correct roller operation, use, and
regular maintenance are also essential elements to provide the highest performance and safety.
N o t e Always keep the Safety and Instruction manuals on the roller and available to the
operator and the helper. Always provide the model and serial number of the roller when
contacting the local Dynapac service or parts office.

Introduction
2
Instruction Manual Location
The instruction manuals are located behind the
operator seat within easy access.
Figure 1-1: Instruction manual Location
A Manual location
Receiving the Roller
The roller has been tested, accurately checked,
and prepared for shipment. Every part of the roller
is accurately checked before being shipped from
the factory.
When receiving the roller and before unpacking
the equipment, check if damage has occurred
during transport and if any parts are missing.
Check the equipment by consulting the shipment
documents.
If the goods are damaged or if parts are missing,
inform the freight agent and raise a complaint
against it.
Identification Data
An exact description of the model type and the
serial number of the roller facilitates fast and
efficient response from our parts and service
support operations.
Provide the model type and serial number while
contacting the local Dynapac service or parts
office.
Enter the roller data on the following lines to
maintain the roller and engine information
necessary to facilitate fast and efficient response
from our parts and service support operations:
Model:
Roller Serial
Number:
Chassis VIN
Number:
Year of
Manufacture:
Engine (Mfg. and Type of
Engine):
Engine Serial
Number:
A

3
Introduction
Roller Identification
The roller product identification number (PIN) plate is located on left hand side of the engine frame. The
PIN number is a 17 digit number which provides information about manufacturer, family model, check
letter, no coding, production unit, and serial number.
Figure 1-2: Location PIN
A Serial number
The pin number is punched on top-right side of the side plate
Figure 1-3: Location PIN
A Pin number
A
A Manufacturer
B Family/Model
C Check letter
D No coding
E Production unit
F Serial number

Introduction
4
Engine Identification
Figure 1-4: Identification Plate
A Engine identification plate
The engine identification plate is affixed to the right side of the engine. The engine identification plate
provides model identification and other important data about the engine. Refer to the engine operation
and maintenance manual for further information on the identification information. Have the following
engine data available when communicating with an authorized repair location or engine dealer. The
data on the engine identification plate is mandatory when sourcing service parts:
• Engine serial number
• Model
A

5
Introduction
1.2 Roller Description
The roller is a two self-propelled vibratory tandem rollers in the nine-metric tonnes class featuring
1690-mm wide drums. The roller is equipped with drive, brakes, and vibration on both drums.
To permit optimum performance on a wide range of applications and site requirements, the roller is
equipped with:
• Diesel engine
• Electrical system
• Propulsion system/transmission
• Brake system
• Secondary/parking brake
• Steering system
• Canopy
Identification of Major Components
Figure 1-5: Major Components Right Side
A Rear light
E
Mirror
J
Vibration motor
B Water tank
F
Steering console
K
ROC
C Hydraulic tank
G
Fuel tank
M
Drum
D Canopy
H
Head Light
Q
Drive motor

Introduction
6
Figure 1-6: Major Components Left Side
A
Rear light
J
Rear light
N
Cylinder
B
Water tank
K
Scraper
P
Drum
D
Seat
L
Vibration motor
Q
Propulsion motor
E
Platform
M
Steering hitch
R
Sprinkler pump
F
Fuel tank
Diesel Engine
The roller is equipped with the water-cooled, straight four-cylinder BS IV diesel engine.
R

7
Introduction
Electrical System
The roller is equipped with 12V DC electrical
system and 90A alternator.
Figure 1-7: Electric System
Figure 1-8: Fuses-View A
A 10A -Fuse D and E 40A - Main and Light
fuse
B 30A - Mini Relay F Battery Disconnector
Switch
C 100A -Starter Relay
G 30A- Engine ECU fuse
A Battery disconnector
Main and Light Fuses
The main fuse and light fuse are placed near to a
100A starter relay on battery disconnector
bracket.
Table 1-1:Placement of Fuses
F10
Main fuse
40 A
F11
Light fuse
40 A
F13
Engine ECU fuse
30 A
Component
Rating
Battery
12V, 150AH
Alternator
12V, 90amps
Starter
12V, 2.7kw

Introduction
8
Figure 1-9: Fuses- View B Figure 1-10: Fuse Boxes in Switch Box
A
Fuse box
C
Fuse for Driving Lights
B
Fuse
The flat pin, type C (medium) fuses and 20A
fuse are used for driving lights.
Table 1-2: Fuse Function and Amperage
Table 1-3: Driving light Fuse
A and B
Main and light
fuse
E
10A- fuse for back up
alarm
C
Engine ECU
F
Starter Relay
D
Battery
disconnector
switch
G
Mini Relay
H
Mini Relay
I
Mini Relay
Sl.
No
Function
Amperage
1
Main fuse
(Ignition/emergency/
Parking brake/vibration
Drum selection)
15 A
2
Working light
relay/Dyn@link/Ignition
terminal
15 A
3
Sprinkler pump/USB
charger
10 A
4
Rotating beacon relay
10 A
5
Drum Speed & Back up
alarm switch
15 A
6
Engine Diagnostic tool
10 A
7
ECU battery +ve & flasher
relay
20 A
8
ECU battery supply before
ignition
30 A
Sl.
No
Function
Amperage
1
Driving lights
20 A
2
Spare
10 A

9
Introduction
Propulsion system/
Transmission
The propulsion system is a hydrostatic system
with a hydraulic pump supplying two motors with
gear box connected in parallel. The motors drive
the front and rear drums.
The speed of the roller is proportional to the
deflection of the control lever from neutral.
Brake system
The brake system consists of a service brake,
secondary brake and parking brake. The service
brake is hydrostatic and is activated by moving the
control lever to neutral.
Secondary/Parking Brake
The secondary and parking brake system
consists of spring multiple disc brakes in the drive
gear box. The brakes are released with hydraulic
pressure and are operated with a switch on the
instrument panel.
Steering System
The steering system is a hydrostatic system.The
control valve on the steering column distributes
the flow to the control cylinder, which actuates the
articulation.
The steering angle is proportional to the deflection
of the steering wheel.
Roller Applications
The roller is built in accordance with international
standards and recognized safety rules.
Nevertheless, misuse may constitute a risk to the life
and limb of the user or third parties, and may cause
damage to the roller or other material property.
The roller must be used in accordance with its
designated use as described in this manual. The
roller must only be operated by trained, safety-
conscious persons who are fully aware of risks
involved in operating the roller. Any functional
disorders, especially those affecting the safety ofthe
roller, must be corrected immediately.
Designated Applications
The roller is designed primarily to compact thin
and thick asphalt layers with respect to dual
vibration amplitudes optimized for this purpose.
Non-Designated Applications
The roller is not designed to use as a ladder,
support, or a work surface. it is not used to carry
or transport passengers or equipment. The
manufacturer/supplier cannot be held liable for
any damage resulting from such use. The risk of
such use lies entirely with the user.
Operating the roller within the limits of its
designated use also involves compliance with the
inspection and maintenance directives contained
in the operating manual.

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11
SafetyFirst
Section 2:Safety First
2.1 General Information
This information is intended as a guide for trained and qualified personnel who are aware of the dangers
involved in handling potentially hazardous equipment. It is not intended to contain a complete list of all
safety precautions which should be observed by personnel using this equipment.
Before you operate, maintain, work around, or in any other way use this equipment:
N o t e Read and study the Safety Manual, and this Instruction Manual.
N o t e Ensure that all instructions in the maintenance section are followed. Failure to obey
instructions or warnings could result in injury or death.
• Those who operate, maintain, and work on roller must be competent.
• The maintenance and service of this roller involves risks both to personnel and roller and must be
performed only by qualified personnel exercising caution.
• Personnel engaged in the operation, maintenance, or servicing of this roller are urged to become
familiar with First Aid theory and practices.
• During operation of this roller, local safety, and fire protection standards must be observed.
• Do not use the roller in need of adjustment or repair. 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 roller. Do not jump on or off
a moving roller.
• Drive slowly and carefully during the sharp bends or during the uneven ground.
• Avoid driving across slopes. Drive straight up or straight down the slope.
• Fasten the seat belt while driving.
• Replace all the lost and damaged safety labels.
• Keep the roller in good working condition.
• Safety measures during refueling:
• Make sure to stop the engine.
• Do not smoke.
• Do not use naked flames in the vicinity.
• Ground the nozzle of the filling device against the tank to prevent sparks.
This safety summary includes general safety precautions and instructions that must be understood and
applied during operationand maintenanceto make sure personnel safety and protection of equipment.
Before performing any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be
reviewed and understood.

Safety First
12
Warnings and Cautions
Throughout the manual, Warnings, Cautions, and
Notes symbols are used to designate instructions
of particular importance. Look for these symbols
which point out items of extreme importance to
you and your co-workers’ safety. Read and
understand thoroughly. Heed the warning and
follow the associated instructions. In this manual,
these terms have the following significance:
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 roller or property if the warning is
ignored.
N o t e Note is used for supplementary
information not directly effecting
safety or damage to equipment. Note
can also refer to special information
on the efficient use of the roller.
Modifications
The roller is designed for safe operation. Do not
do anything that may hamper the safety features
or structural integrity of the roller.
Do not make any unauthorized modifications to
this roller. Dynapac cannot be held responsible for
any accidents, incidents, or damage to persons or
property that are related to the use of modified
roller.
Personnel Protective
Equipment
Anyone working around the roller must wear
approved safety equipment (safety shoes or
protective footwear, safety glasses, hearing
protection, hard hat, gloves, respirator, and the
like) when operating or maintaining the roller.
Wear close fitting clothing and confine long hair.
Operating requires full attention of the operator.
Do not wear radio or music headphones while
operating.
Tools and Equipment
Tools, lifting gear, fastening devices,
jacks, and other working equipment must
be in safe operational working
conditions.
Equipment or components which are
being fitted or removed or where their
installation position is being changed,
must be secured against unintentional
movement, slipping, or falling over. Use
suitable lifting gear or suspension/
support devices.
Systems and units (tensioning units)
must be depressurized in an appropriate
manner before opening.
Damaged hydraulic or mechanical pre-
tensioned spring elements must be
exchanged as a completed unit. Further
information can be found in the
respective component descriptions and/
or fitting and removal instructions.
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