Fayat Group Dynapac CC800 User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812160801_G.pdf4812160801_G.pdf
Vibratory rollerVibratory roller
CC800/900/1000CC800/900/1000
EngineEngine
Kubota D1105-E4BKubota D1105-E4B
Kubota D1105-E4B T4F / Stage VKubota D1105-E4B T4F / Stage V
Serial numberSerial number
10000357xxA012892 -10000357xxA012892 -
10000358xxA012889 - xA02334610000358xxA012889 - xA023346
10000360xxA012890 - xA02334410000360xxA012890 - xA023344
10000440xxA023605 -10000440xxA023605 -
10000441xxA023347 -10000441xxA023347 -
10000443xxA023345 -10000443xxA023345 -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in SwedenPrinted in Sweden

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Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Signal symbols and meaning ...................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
CE marking and Declaration of conformity.................................................. 3
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Sitting position............................................................................................. 7
Work driving ................................................................................................ 7
Driving near edges ...................................................................................... 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
Electrical system ....................................................................................... 13
Slopes ....................................................................................................... 13
Dimensions, side view............................................................................... 14
Dimensions, top view ................................................................................ 15
Weights and volumes................................................................................ 16

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Working capacity....................................................................................... 16
General ..................................................................................................... 17
CO2-emission............................................................................................ 17
Tightening torque ...................................................................................... 18
ROPS - bolts ............................................................................................. 19
Hydraulic system....................................................................................... 19
Machine description ............................................................................................................... 21
Diesel engine ............................................................................................ 21
Electrical system ....................................................................................... 21
Propulsion system/Transmission .............................................................. 21
Brake system ............................................................................................ 21
Steering system ........................................................................................ 21
ROPS ........................................................................................................ 21
Identification ............................................................................................................ 22
Product identification number on the frame .............................................. 22
Machine plate............................................................................................ 23
Explanation of 17PIN serial number.......................................................... 23
Engine plates ............................................................................................ 24
Decals...................................................................................................................... 25
Location - decals ....................................................................................... 25
Location - decals, CALIFORNIA ............................................................... 27
Safety decals............................................................................................. 27
Info decals................................................................................................. 30
Fuel ........................................................................................................... 31
Instruments/Controls ............................................................................................... 32
Locations - Instruments and controls ........................................................ 32
Locations - Control panel and controls...................................................... 33
Function description .................................................................................. 34
Electrical system...................................................................................................... 36
Fuses ........................................................................................................ 36

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Fuses in engine compartment................................................................... 37
Relays ....................................................................................................... 37
Operation ............................................................................................................................... 39
Before starting ......................................................................................................... 39
Battery isolation switch - On - Optional ..................................................... 39
PLUS version.............................................................................. 39
CC version .................................................................................. 39
Driver seat (CC version) - Adjustment ...................................................... 39
Driver seat (Plus version) - Adjustment..................................................... 40
Instruments and lamps - Checking............................................................ 40
Interlock..................................................................................................... 41
Operator position....................................................................................... 42
Starting .................................................................................................................... 43
Starting the engine .................................................................................... 43
Driving ..................................................................................................................... 45
Operating the roller ................................................................................... 45
Interlock/Emergency stop/Parking brake - Check ..................................... 46
Vibration .................................................................................................................. 46
Manual/Automatic vibration....................................................................... 46
Manual vibration - Switching on ................................................................ 47
Braking .................................................................................................................... 47
Normal braking.......................................................................................... 47
Emergency braking ................................................................................... 48
Switching off.............................................................................................. 48
Parking .................................................................................................................... 49
Chocking the drums .................................................................................. 49
Master switch - Optional............................................................................ 49
PLUS version.............................................................................. 49
CC version .................................................................................. 49
Long-term parking.................................................................................................................. 51

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Engine ....................................................................................................... 51
Battery....................................................................................................... 51
Air cleaner, exhaust pipe........................................................................... 51
Sprinkler system........................................................................................ 51
Fuel tank ................................................................................................... 51
Hydraulic reservoir .................................................................................... 52
Steering cylinder, hinges, etc. ................................................................... 52
Hoods, tarpaulin ........................................................................................ 52
Miscellaneous ........................................................................................................................ 53
Lifting ....................................................................................................................... 53
Locking the articulation ............................................................................. 53
Lifting the roller.......................................................................................... 53
Unlocking the articulation .......................................................................... 54
Transport ................................................................................................................. 54
Securing CC800/900/1000 for loading ...................................................... 55
Towing/Recovering.................................................................................................. 56
Releasing the brake .................................................................................. 57
Towing the roller........................................................................................ 58
Operating instructions - Summary ......................................................................................... 59
Preventive maintenance ........................................................................................................ 61
Acceptance and delivery inspection.......................................................... 61
Warranty.................................................................................................... 61
Maintenance - Lubricants and symbols ................................................................................. 63
Maintenance symbols ............................................................................... 65
Maintenance - Maintenance schedule ................................................................................... 67
Service and maintenance points ............................................................... 67
General ..................................................................................................... 68
Every 10 hours of operation (Daily)........................................................... 68
After the FIRST 50 hours of operation ...................................................... 69
Every 50 hours of operation (Weekly)....................................................... 69

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Every 250 / 750 / 1250 / 1750 hours of operation ..................................... 69
Every 500 / 1500 hours of operation ......................................................... 70
Every 1000 hours of operation .................................................................. 71
Every 2000 hours of operation .................................................................. 72
Service - Checklist................................................................................................... 73
Maintenance, 10h .................................................................................................................. 75
Diesel engine Check oil level ................................................................... 75
Hydraulic reservoir, Level check - Filling................................................... 76
Check - Coolant system ............................................................................ 76
Refueling ................................................................................................... 77
Water tank - Filling .................................................................................... 77
Sprinkler system/Drum
Cleaning of sprinkler nozzle ...................................................................... 78
Sprinkler system - Check, cleaning........................................................... 78
Air circulation - Check ............................................................................... 79
Scrapers - Check, adjustment................................................................... 79
Warning lamps - Check............................................................................. 80
Air cleaner indicator .................................................................................. 80
Brakes - Check.......................................................................................... 81
Maintenance - 50h ................................................................................................................. 83
Air cleaner - emptying ............................................................................... 83
Rubber elements and fastening screws - Check....................................... 84
Belt tension on the hydraulic vibration and steering pump drive belt -
Check ........................................................................................................ 84
Maintenance measures - 250 h ............................................................................................. 85
Air cleaner - Cleaning - Change................................................................ 85
Hydraulic fluid cooler - Cleaning ............................................................... 86
Forward/Reverse controls and joints - Check and lubrication................... 86
Maintenance measures - 500 h ............................................................................................. 87
Hydraulic fluid cooler - Cleaning ............................................................... 87

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Forward/Reverse controls and joints - Check and lubrication................... 88
Air cleaner - Cleaning - Change................................................................ 89
Engine oil and oil filter - Change ............................................................... 90
Check - Coolant system ............................................................................ 91
Drum - Checking the oil level .................................................................... 91
Hydraulic reservoir - Check/venting .......................................................... 92
Belt tension on the hydraulic vibration and steering pump drive belt -
Check ........................................................................................................ 92
Maintenance - 1000h ............................................................................................................. 93
Hydraulic fluid cooler - Cleaning ............................................................... 93
Forward/Reverse controls and joints - Check and lubrication................... 94
Air cleaner - Cleaning - Change................................................................ 95
Engine oil and oil filter - Change ............................................................... 96
Check - Coolant system ............................................................................ 97
Drum - Checking the oil level .................................................................... 97
Hydraulic reservoir - Check/venting .......................................................... 98
Hydraulic fluid filter - Change .................................................................... 99
Alternator belt - Checking tension - Change ............................................. 99
Belt tension on the hydraulic vibration and steering pump drive belt -
Check ...................................................................................................... 100
Maintenance - 2000h ........................................................................................................... 101
Hydraulic fluid cooler - Cleaning ............................................................. 101
Forward/Reverse controls and joints - Check and lubrication................. 102
Air cleaner - Cleaning - Change.............................................................. 103
Engine oil and oil filter - Change ............................................................. 104
Check - Coolant system .......................................................................... 105
Drum - Checking the oil level .................................................................. 105
Hydraulic reservoir - Check/venting ........................................................ 106
Hydraulic fluid filter - Change .................................................................. 107
Hydraulic reservoir - fluid change............................................................ 108

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Alternator belt - Checking tension - Change ........................................... 109
Water tank - Cleaning ............................................................................. 109
Drum - Changing the oil .......................................................................... 110
Fuel tank - Cleaning ................................................................................ 110
Steering joint - Check.............................................................................. 111
Belt tension on the hydraulic vibration and steering pump drive belt -
Check ...................................................................................................... 111

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Introduction
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Introduction
The machine
Dynapac CC800/900/1000 are self-propelled vibratory
tandem rollers in the 1,6 metric tonnes class featuring
800/900/1000 mm wide drums. The machine is
equipped with drive, brakes, and vibration on both
drums.
Intended use
CC800/900/1000 are primarily used for smaller
compaction works, such as minor roads, sidewalks,
cycle ways and minor parking places.
Signal symbols and meaning
WARNING ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in death or serious injury.
WARNING ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in death or serious injury.
CAUTION ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in minor or moderate injury, damage to
the machine or property.
CAUTION ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in minor or moderate injury, damage to
the machine or property.
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.
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.
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Introduction
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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.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Prevent persons from entering or remaining in
the risk zone, 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 risk zone, 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 risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
The operator may allow a person to remain in
the risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
CALIFORNIA
Decal and location of decal shown in section
Machine description.
Proposition 65
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.
Inspect the machine every day, before starting.
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Introduction
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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, where maintenance after every 10 and
50 hours of operation can be performed by the
machine operator. Other maintenance intervals must
be carried out by accredited (Dynapac) service
personnel.
Additional instructions for the engine can be
found in the manufacturer's engine manual.
Additional instructions for the engine can be
found in the manufacturer's engine manual.
Specific maintenance and checks on diesel
engines must be performed by engine supplier
authorized personnel.
Specific maintenance and checks on diesel
engines must be performed by engine supplier
authorized personnel.
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 regulations and directives
applicable for this machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable regulations
and directives with supplements, as well as the
harmonized standards and other regulations that are
applied and according to the regulations must be
declared in writing.
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Introduction
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Safety - General instructions
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Safety - General instructions
(Also read the safety manual)
•The operator must be familiar with the contents of the OPERATION section
before starting the roller.
•The operator must be familiar with the contents of the OPERATION section
before starting the roller.
•Ensure that all instructions in the MAINTENANCE section are followed. •Ensure that all instructions in the MAINTENANCE section are followed.
•Only the operator is allowed to be on the roller. Remain seated at all times
when operating the roller.
•Only the operator is allowed to be on the roller. Remain seated at all times
when operating the roller.
•Never use the roller if it is in need of adjustment or repair. •Never use the roller if it is in need of adjustment or repair.
•Only ascend and descend the roller when it is stationary. Use the intended
footsteps, grips and rails. Always use the three-point grip (both feet and one
hand, or one foot and both hands) when ascending or descending the
machine. Never jump down from the machine.
•Only ascend and descend the roller when it is stationary. Use the intended
footsteps, grips and rails. Always use the three-point grip (both feet and one
hand, or one foot and both hands) when ascending or descending the
machine. Never jump down from the machine.
•Dynapac always recommends mounted ROPS (Roll Over Protective
Structure), or a ROPS-approved cab and seat belt usage.
•Dynapac always recommends mounted ROPS (Roll Over Protective
Structure), or a ROPS-approved cab and seat belt usage.
•Drive slowly in sharp bends. •Drive slowly in sharp bends.
•Avoid driving across slopes. Drive straight up or straight down the slope. •Avoid driving across slopes. Drive straight up or straight down the slope.
•Never operate with the drum outside the edge, the substrate might not have
full bearing strength or the edge is close to a slope. Avoid operating close to
edges and ditches and the like as well as on poor ground conditions that
jeopardizes the bearing strength and capacity to support the roller.
•Never operate with the drum outside the edge, the substrate might not have
full bearing strength or the edge is close to a slope. Avoid operating close to
edges and ditches and the like as well as on poor ground conditions that
jeopardizes the bearing strength and capacity to support the roller.
•Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
•Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
•Drive particularly carefully on uneven ground. •Drive particularly carefully on uneven ground.
•Keep the roller clean. Clean any dirt or grease that accumulates on the
footsteps or operator platform to avoid slipping risk. Keep all signs and
decals clean and legible.
•Keep the roller clean. Clean any dirt or grease that accumulates on the
footsteps or operator platform to avoid slipping risk. Keep all signs and
decals clean and legible.
•Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle by keeping it in contact to the tank
opening to avoid sparks.
•Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle by keeping it in contact to the tank
opening to avoid sparks.
•Before repairs or service:
- Chock the drums/wheels.
- Lock the articulation if necessary.
- Place blocks under overhanging equipment, such as strike-off blade, edge
cutter/compactor and chip spreader.
•Before repairs or service:
- Chock the drums/wheels.
- Lock the articulation if necessary.
- Place blocks under overhanging equipment, such as strike-off blade, edge
cutter/compactor and chip spreader.
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Safety - General instructions
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•Hearing protection is recommended if the noise level exceeds 80 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
•Hearing protection is recommended if the noise level exceeds 80 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
•Modifications to the roller, including the use of any attachment/equipment,
not approved by Dynapac that might compromise safety (including visibility)
are not allowed. Any modifications are only to be made after written approval
has been given by Dynapac.
•Modifications to the roller, including the use of any attachment/equipment,
not approved by Dynapac that might compromise safety (including visibility)
are not allowed. Any modifications are only to be made after written approval
has been given by Dynapac.
•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.
•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.
•For your own protection always wear:
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
Also wear:
- helmet if no cab or FOPS, or if required by worksite management
- working gloves if no cab and for work outside operator´s platform.
•For your own protection always wear:
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
Also wear:
- helmet if no cab or FOPS, or if required by worksite management
- working gloves if no cab and for work outside operator´s platform.
•If the machine seems to be responding abnormally during travel, stop and
check it.
•If the machine seems to be responding abnormally during travel, stop and
check it.
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Safety - when operating
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Safety - when operating
Prevent persons from entering or remaining in
the risk zone, 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 risk zone, 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 risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
The operator may allow a person to remain in
the risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
Avoid driving across a slope. Drive straight up
and down sloping ground.
Avoid driving across a slope. Drive straight up
and down sloping ground.
Sitting position
Fig. Seat position
1. ROPS
2. Seat belt
2
1
Remain seated at all times when operating the roller. If
the operator stands up during operation, a buzzer
sounds. After 4 seconds the brakes are activated and
the engine stops. Brace yourself for a sudden stop.
Always use the seat belt where fitted. Where the
seat belt is not used, there is a great risk that the
operator will be thrown off and land under the
machine if the machine topples over.
Always use the seat belt where fitted. Where the
seat belt is not used, there is a great risk that the
operator will be thrown off and land under the
machine if the machine topples over.
The seat belt is standard equipment on rollers fitted
with Roll Over Protective Structure (ROPS) (1).
ROPS should always be in the raised position
when machines with foldable ROPS are operated
ROPS should always be in the raised position
when machines with foldable ROPS are operated
Work driving
Dynapac always recommends mounted ROPS
(Roll Over Protective Structure) and seat belt
usage.
Dynapac always recommends mounted ROPS
(Roll Over Protective Structure) and seat belt
usage.
On machines with foldable ROPS, make sure that
the ROPS is correctly mounted in the upright
position during all operation.
On machines with foldable ROPS, make sure that
the ROPS is correctly mounted in the upright
position during all operation.
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Safety - when operating
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Avoid operating close to edges and ditches and the
like as well as on poor ground conditions that
jeopardizes the bearing strength and capacity to
support the roller. Pay attention to potential obstacles
above the machine, such as overhead cables and the
branches of trees etc.
Pay particular attention to the stability of the substrate
when compacting close to edges and holes. Do not
compact with a large overlap from the previous track in
order to maintain roller stability. Consider other
compaction methods such as remote-control or a
walk-behind roller close to steep slopes or where the
bearing strength of the substrate is unknown.
Driving near edges
Never operate with the drum outside the edge, the
substrate might not have full bearing strength or
the edge is close to a slope.
Never operate with the drum outside the edge, the
substrate might not have full bearing strength or
the edge is close to a slope.
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.
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Special instructions
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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 ambient temperature for
biological hydraulic fluid is +35°C (95°F).
The maximum ambient 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 S2V100 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.
Never aim the water jet directly at the fuel tank
cap, or into exhaust pipe. This is particularly
important when using a high-pressure cleaner.
Never aim the water jet directly at the fuel tank
cap, or into exhaust pipe. This is particularly
important when using a high-pressure cleaner.
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Special instructions
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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)
Never carry out any welding or drilling in the
Roll Over Protective Structure (ROPS).
Never carry out any welding or drilling in the
Roll Over Protective Structure (ROPS).
Never repair a damaged ROPS structure, it must
be replaced with a new one.
Never repair a damaged ROPS structure, it must
be replaced with a new one.
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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