Fayat Dynapac CC900G User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812274432.pdf
Vibratory rollerVibratory roller
CC900GCC900G
EngineEngine
Honda GX630RHonda GX630R
Serial numberSerial number
10000303x0C003469 - 0C005137
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in China
4812274432.pdf
Printed in China
10000303x0C005138 (Improved Frame) -

2000h-Maintenance
4812274432.pdf2017-07-10
Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Warning symbols......................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
Safety - General instructions.................................................................................................... 3
Safety - when operating ........................................................................................................... 5
Slopes ......................................................................................................... 5
Driving near edges ...................................................................................... 6
Sitting position............................................................................................. 7
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 ................................................................................................. 9
Roll Over Protective Structure (ROPS) ..................................................... 10
Battery handling ........................................................................................ 10
Jump starting............................................................................................. 11
Technical specifications - Noise/Vibrations/Electrical ............................................................ 13
Vibrations - Operator station ..................................................................... 13
Noise level................................................................................................. 13
Technical specifications - Dimensions ................................................................................... 15
Dimensions, side view............................................................................... 15
Dimensions, top view ................................................................................ 16
Weights and volumes................................................................................ 17
Working capacity....................................................................................... 17
General ..................................................................................................... 18

2000h-Maintenance
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Hydraulic system....................................................................................... 18
Tightening torque ...................................................................................... 18
ROPS - bolts ............................................................................................. 19
Identification ............................................................................................................ 19
Machine plate............................................................................................ 19
Product identification number on the frame .............................................. 20
Engine plates ............................................................................................ 21
Machine description- Decals.................................................................................................. 23
Location - decals ....................................................................................... 23
Safety decals............................................................................................. 24
Info decals................................................................................................. 25
Instruments/Controls ............................................................................................... 26
Locations - Instruments and controls ........................................................ 26
Function description .................................................................................. 27
Electrical system...................................................................................................... 28
Relays and fuses on the machine ............................................................. 28
Operation ............................................................................................................................... 29
Before starting ......................................................................................................... 29
Operator’s seat - Adjusting....................................................................... 29
Sprinkler - Check ...................................................................................... 29
Parking brake ............................................................................................ 30
Operator position....................................................................................... 30
Starting .................................................................................................................... 31
Starting the engine .................................................................................... 31
Driving ..................................................................................................................... 32
Operating the roller ................................................................................... 32
Vibration .................................................................................................................. 33
Manual vibration - Switching on ................................................................ 33
Operating - Stopping.............................................................................................................. 35
Braking .................................................................................................................... 35
Emergency stop......................................................................................... 30

2000h-Maintenance
Normal braking.......................................................................................... 35
Reserve brake........................................................................................... 36
Switching off.............................................................................................. 36
Parking .................................................................................................................... 37
Chocking the drums .................................................................................. 37
Long-term parking.................................................................................................................. 38
Engine ....................................................................................................... 40
Battery....................................................................................................... 38
Air cleaner, exhaust pipe........................................................................... 38
Sprinkler system........................................................................................ 38
Fuel tank ................................................................................................... 38
Hydraulic reservoir .................................................................................... 39
Steering cylinder, hinges, etc. ................................................................... 39
Hoods, tarpaulin ........................................................................................ 39
Miscellaneous ........................................................................................................................ 41
Locking the articulation ............................................................................. 41
Lifting the roller.......................................................................................... 41
Unlocking the articulation .......................................................................... 41
Securing CC900G for loading ................................................................... 42
Towing ..................................................................................................................... 43
Releasing the brake .................................................................................. 43
Towing the roller........................................................................................ 45
Operating instructions - Summary ......................................................................................... 47
Preventive maintenance ........................................................................................................ 49
Acceptance and delivery inspection.......................................................... 49
Warranty.................................................................................................... 49
Maintenance - Lubricants and symbols ................................................................................. 51
Maintenance symbols ............................................................................... 53
Maintenance - Maintenance schedule ................................................................................... 55
Service and maintenance points ............................................................... 55
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2000h-Maintenance
General ..................................................................................................... 56
Every 10 hours of operation (Daily)........................................................... 56
After the first 20 hours of operation........................................................... 56
After the FIRST 50 hours of operation ...................................................... 57
Every 50 hours of operation ...................................................................... 57
Every 100 hours of operation .................................................................... 57
Every 200 / 400 / 600 / 800 hours of operation ......................................... 58
Every 500 hours of operation .................................................................... 58
Every 1000 hours of operation .................................................................. 59
Every 2000 hours of operation .................................................................. 60
Maintenance - Maintenance measures, before use............................................................... 61
Static drum - Filling with water .................................................................. 61
Maintenance, 10h .................................................................................................................. 63
Engine - Checking the oil level.................................................................. 63
Hydraulic reservoir, Level check - Filling................................................... 63
Refueling ................................................................................................... 64
Water tank - Filling .................................................................................... 64
Sprinkler system - Check, cleaning........................................................... 64
Air circulation - Check ............................................................................... 65
Scrapers - Check, adjustment................................................................... 65
Warning lamps - Check............................................................................. 65
Air cleaner - check .................................................................................... 66
Maintenance - 20h ................................................................................................................. 67
Engine oil and oil filter - Change ............................................................... 67
Maintenance - 50h ................................................................................................................. 69
Brakes - Check.......................................................................................... 69
Air cleaner - cleaning ................................................................................ 70
Rubber elements and fastening screws - Check....................................... 70
Maintenance - 100h ............................................................................................................... 71
Spark plug - Check and adjustment .......................................................... 71
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Drum bearing seat - Check and lubrication .............................................. 70

2000h-Maintenance
Maintenance - 200 / 400 / 600 / 800 h ................................................................................... 73
Spark plug - Replace................................................................................. 73
Engine's fuel filter - Check......................................................................... 74
Engine oil and oil filter - Change ............................................................... 75
Forward/Reverse controls and joints - Check and lubrication................... 76
Maintenance - 500h ............................................................................................................... 77
Front drum - Checking the oil level ........................................................... 77
Hydraulic reservoir - Check/venting .......................................................... 78
Steering joint - Check................................................................................ 78
Air cleaner - replace insert ........................................................................ 79
Maintenance - 1000h ............................................................................................................. 81
Spark plug - Replace................................................................................. 81
Forward/Reverse controls and joints - Check and lubrication................... 83
Front drum - Checking the oil level ........................................................... 84
Hydraulic reservoir - Check/venting .......................................................... 84
Steering joint - Check................................................................................ 85
Air cleaner - replace insert ........................................................................ 85
Hydraulic fluid filter - Change .................................................................... 86
Engine oil and oil filter - Change ............................................................... 86
Engine's fuel filter - Check......................................................................... 87
Maintenance - 2000h ............................................................................................................. 89
Spark plug - Replace................................................................................. 89
Engine's fuel filter - Replace...................................................................... 90
Forward/Reverse controls and joints - Check and lubrication................... 91
Hydraulic reservoir - Check/venting .......................................................... 91
Steering joint - Check................................................................................ 92
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Engine's fuel filter - Replace...................................................................... 82
Hydraulic fluid cooler - Cleaning (Option).................................................. 90
Hydraulic fluid cooler - Cleaning (Option).................................................. 82

2000h-Maintenance
Air cleaner - replace insert ........................................................................ 92
Hydraulic fluid filter - Change .................................................................... 93
Engine oil and oil filter - Change ............................................................... 93
Hydraulic reservoir - fluid change.............................................................. 95
Front drum - Changing the oil ................................................................... 96
Water tank - Cleaning ............................................................................... 96
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Introduction
Replace immediately the instruction manuals if
lost, damaged or unreadable.
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Introduction
The machine
Dynapac CC900G is a self-propelled vibratory tandem
roller in the 1,6 metric tonnes class featuring 900 mm
wide drums. The machine is equipped with drive,
brakes, and vibration on both drums.
Intended use
CC900G is primarily used for smaller compaction
works, such as minor roads, sidewalks, cycle ways
and minor parking places.
Warning symbols
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
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.
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.
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.

Introduction
Additional instructions for the engine can be
found in the manufactuer's engine manual.
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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.
CALIFORNIA
Proposition 65 Warning
Gasolin 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.
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.
Additional instructions for the engine can be
found in the manufactuer's engine manual.

Safety - General instructions
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
(Also read the safety manual)
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.

Safety - General instructions
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
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
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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.
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 the ROPS (Roll Over
Protective Structure) is always used when
driving on slopes or unsafe ground.
It is recommended that the ROPS (Roll Over
Protective Structure) is always used when
driving on slopes or unsafe ground.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.

Safety - when operating
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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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.

Safety - when operating
ROPS should always be in the raised position
when machines with foldable ROPS are operated
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Sitting position
Figure. Seat position
1. ROPS
2. Seat belt
2
1
Remain seated at all times when operating the roller.
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

Safety - when operating
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Special instructions
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.
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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).
Higher ambient temperatures, above +40°C
(104°F)
For operation of the machine at higher ambient
temperatures, although maximum +50°C (122°F), the
following recommendations apply:
The petrol 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
equivalent.
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.
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. This is particularly important when using a
high-pressure cleaner.

Special instructions
Do not use a quick-charger for charging the
battery. This may shorten battery life.
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Roll Over Protective Structure (ROPS)
Never carry out any welding or drilling
operations of any kind on the Roll Over
Protective Structure (ROPS).
Never carry out any welding or drilling
operations of any kind on the Roll Over
Protective Structure (ROPS).
Never attempt to repair a damaged ROPS
structure. This must be replaced with new ROPS
structure.
Never attempt to repair a damaged ROPS
structure. This must be replaced with new ROPS
structure.
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.

Special instructions
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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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

Special instructions
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