Dynapac Static Three-drum Roller CS1400 VI Operating & Maintenance Manual 4812164401_B PDF DOWNLOAD

Instruction manual Operating & Maintenance 4812164401_B.pdf Static Three-drum Roller CS1400 VI Engine Deutz TD 3.6 L04 (Stage IIIA) Deutz TD 3.6 L04 (Stage V) Serial number 10000519xxA032198 10000518xxA026818 -

Translation of original instruction Reservation for changes Printed in Sweden

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Table of Contents Introduction .............................................................................................................................. 3 The machine ............................................................................................... 3 Intended use ............................................................................................... 3 Training ....................................................................................................... 3 Signal symbols and meaning ...................................................................... 3 Safety information ....................................................................................... 3 General ....................................................................................................... 4 (Only Stage V)............................................................................................. 5 CE marking and Declaration of conformity.................................................. 5 Safety - General instructions.................................................................................................... 7 Safety - when operating ........................................................................................................... 9 Driving near edges ...................................................................................... 9 Work driving .............................................................................................. 10 Safety (Optional) .................................................................................................................... 11 Automatic climate control .......................................................................... 11 Edge cutter/compactor .............................................................................. 11 Special instructions ................................................................................................................ 13 Standard lubricants and other recommended oils and fluids .................... 13 Higher ambient temperatures, above +40°C (104°F)................................ 13 Lower ambient temperature - Freeze risk ................................................. 13 Temperatures............................................................................................ 13 High pressure cleaning ............................................................................. 14 Fire fighting ............................................................................................... 14 Fire extinguisher........................................................................................ 14 Roll Over Protective Structure (ROPS), ROPS approved cab .................. 15 Battery handling ........................................................................................ 15 Jump starting (24V)................................................................................... 16 Technical specifications ......................................................................................................... 17 Noise level................................................................................................. 17 (Only Stage V)........................................................................................... 17

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Vibrations - Operator station ..................................................................... 17 Slopes ....................................................................................................... 17 Dimensions, side view............................................................................... 18 Dimensions, top view ................................................................................ 19 Weights and volumes................................................................................ 20 Working capacity....................................................................................... 21 General ..................................................................................................... 21 CO2-emission (Stage V only) .................................................................... 22 Air Conditioning / Automatic Climate Control (ACC) (Optional) ................ 22 Tightening torque ...................................................................................... 23 Hydraulic system....................................................................................... 24 Machine description ............................................................................................................... 25 Diesel engine ............................................................................................ 25 Stage IIIA .................................................................................................. 25 Stage V ..................................................................................................... 25 Electrical system ....................................................................................... 25 Propulsion system/Transmission .............................................................. 25 Brake system ............................................................................................ 25 Steering system ........................................................................................ 25 Cab............................................................................................................ 26 Emergency exit ......................................................................................... 26 Seat........................................................................................................... 26 FOPS and ROPS ...................................................................................... 26 Identification ............................................................................................................ 27 Product and component plates ................................................................. 27 Product identification number on the frame .............................................. 27 Machine plate............................................................................................ 28 Explanation of 17PIN serial number.......................................................... 28 Engine plates ............................................................................................ 29 Decals...................................................................................................................... 30

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Location - decals ....................................................................................... 30 Location - decals, CALIFORNIA ............................................................... 31 Safety decals............................................................................................. 31 Info decals................................................................................................. 34 Instruments/Controls ............................................................................................... 36 Control panel and controls ........................................................................ 36 Forward & Reverse lever .......................................................................... 38 Function descriptions ................................................................................ 38 Display, key............................................................................................... 40 "MAIN MENU" ........................................................................................... 42 "USER SETTINGS"................................................................................... 43 Manuals (WIP) .......................................................................................... 43 "MAIN MENU" ........................................................................................... 44 "USER SETTINGS"................................................................................... 44 Manuals (WIP) .......................................................................................... 44 Settings menu ("SETTINGS MENU")........................................................ 45 "SERVICE MENU" .................................................................................... 47 "ABOUT" ................................................................................................... 49 Machine alarm........................................................................................... 49 Instruments and controls, cab ................................................................... 50 Function description of instruments and controls in the cab ..................... 51 Using the cab controls............................................................................... 52 Defroster ..................................................................................... 52 Heat ............................................................................................ 52 ACC ............................................................................................ 52 Heater panel.............................................................................................. 52 ACC - Control panel .................................................................................. 53 Main display screen .................................................................................. 53 ACC - Operation menus............................................................................ 53 Electrical system...................................................................................................... 55

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Distribution box ......................................................................................... 55 Circuit board in main switch ...................................................................... 56 Fuses in cab.............................................................................................. 57 Main and Engine ECU............................................................................... 57 Operation ............................................................................................................................... 59 Before starting ......................................................................................................... 59 Battery isolation switch - Switching on ...................................................... 59 Control panel, adjustments ....................................................................... 59 Operator's seat - Adjustment..................................................................... 60 Operator's seat, comfort - Adjustments..................................................... 60 Belt reminder............................................................................................. 61 Display - Control........................................................................................ 61 Parking brake ............................................................................................ 62 Interlock..................................................................................................... 62 Operator position....................................................................................... 63 View .......................................................................................................... 64 Rear view mirrors - Adjustment................................................................. 64 Working lights - Adjustment ...................................................................... 64 Cab windows - de-icing ............................................................................. 64 Wiper blade - Replacement....................................................................... 65 Washer fluid - Checking and filling............................................................ 65 Foldable rotating beacon (Accessory)....................................................... 66 Starting .................................................................................................................... 67 Starting the engine .................................................................................... 67 Parking brake test ..................................................................................... 69 Display when activating choice via the button set..................................... 70 Alarm descriptions..................................................................................... 72 Driving ..................................................................................................................... 73 Operating the roller ................................................................................... 73 Alarm - Regeneration ................................................................................ 75

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Sub-menu - Regeneration......................................................................... 76 Soot........................................................................................................... 77 Tampering of DPF..................................................................................... 80 Ash.............................................................................................. 81 Interlock/Emergency stop/Parking brake - Check ..................................... 82 Joint cutter (Accessory)............................................................................. 82 Braking .................................................................................................................... 83 Service brake ............................................................................................ 83 Emergency brake ...................................................................................... 84 Emergency stop ........................................................................................ 84 Switching off.............................................................................................. 85 Parking .................................................................................................................... 85 Chocking the drums .................................................................................. 85 Battery disconnector ................................................................................. 86 Long-term parking.................................................................................................................. 87 Engine ....................................................................................................... 87 Battery....................................................................................................... 87 Air cleaner, exhaust pipe........................................................................... 87 Sprinkler system........................................................................................ 87 Fuel tank ................................................................................................... 87 Hydraulic reservoir .................................................................................... 88 Steering cylinder, hinges, etc. ................................................................... 88 Engine coolant .......................................................................................... 88 Hoods, tarpaulin ........................................................................................ 88 Miscellaneous ........................................................................................................................ 89 Lifting ....................................................................................................................... 89 Locking the articulation ............................................................................. 89 Lifting the roller.......................................................................................... 90 Lifting the roller with jack:.......................................................................... 91 Unlocking the articulation .......................................................................... 91

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Load securing CS1400 VI ......................................................................... 92 Towing/Recovering.................................................................................................. 95 Brake release pump.................................................................... 96 Short distance towing with the diesel engine switched off/not running ..... 97 Towing....................................................................................................... 97 Operating instructions - Summary ......................................................................................... 99 Preventive maintenance ...................................................................................................... 101 Acceptance and delivery inspection........................................................ 101 Warranty.................................................................................................. 101 Maintenance - Lubricants and symbols ............................................................................... 103 Maintenance symbols ............................................................................. 104 Maintenance - Maintenance schedule ................................................................................. 105 Service and maintenance points ............................................................. 105 General ................................................................................................... 106 Every 10 hours of operation (Daily)......................................................... 106 After the FIRST 50 hours of operation .................................................... 106 Every 50 hours of operation (Weekly)..................................................... 107 Every 250 / 750 / 1250 / 1750 hours of operation ................................... 107 Every 500 / 1500 hours of operation ....................................................... 107 Every 1000 hours of operation ................................................................ 108 Every 2000 hours of operation ................................................................ 109 Service - Checklist................................................................................................. 110 Maintenance, 10h ................................................................................................................ 111 Diesel engine Check oil level ................................................................. 111 Hydraulic reservoir, Level check - Filling................................................. 112 Coolant, Level check - filling ................................................................... 112 Fuel tank - Refueling ............................................................................... 114 Water tank - Filling .................................................................................. 115 Sprinkler system/Drum Check ...................................................................................................... 116

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Cleaning the coarse filter ........................................................................ 117 Sprinkler system/Drum Cleaning of sprinkler nozzle .................................................................... 118 Scrapers - Check/Cleaning ..................................................................... 118 Draining the diesel engine's fuel prefilter ................................................ 119 Diesel engine Check oil level ................................................................. 120 Maintenance - 50h ............................................................................................................... 121 Air cleaner Checking - Change the main air filter...................................................... 121 Backup filter - Change............................................................................. 122 Air cleaner - Cleaning................................................................................................ 123 Articulation steering and steering cylinder bushings - Lubrication .......... 123 Tightening the drum nuts - Check ........................................................... 124 Maintenance measures - 250 h ........................................................................................... 125 Radiator - Check/Cleaning ...................................................................... 125 Battery - Check condition .................................................................................... 126 Automatic Climate Control (Optional) - Inspection .................................. 126 Air conditioning (Optional) - Cleaning................................................................................................ 127 Air conditioning (Optional) - Inspection.............................................................................................. 127 Edge cutter (Optional) - Lubrication ............................................................................................ 127 Maintenance measures - 500 h ........................................................................................... 129 Radiator - Check/Cleaning ...................................................................... 129 Hinges, controls - Lubrication.................................................................. 130 Seat bearing - Lubrication ....................................................................... 130 Diesel engine - Oil change ...................................................................... 131 Edge cutter (Optional) - Lubrication ............................................................................................ 132 Hydraulic reservoir cap - Check .............................................................. 133

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Maintenance - 1000h ........................................................................................................... 135 Radiator - Check/Cleaning ...................................................................... 135 Hinges, controls - Lubrication.................................................................. 136 Seat bearing - Lubrication ....................................................................... 136 Diesel engine - Oil change ...................................................................... 137 Edge cutter (Optional) - Lubrication ............................................................................................ 138 Hydraulic reservoir cap - Check .............................................................. 139 Replacing the fuel filter / fuel prefilter...................................................... 140 Hydraulic fluid filter - Replacement ......................................................... 141 Fuel tank - Draining off water .................................................................. 142 Air conditioning (Optional) Fresh air filter - Change .......................................................................... 142 Hydraulic reservoir - Draining.................................................................. 143 Maintenance - 2000h ........................................................................................................... 145 Radiator - Check/Cleaning ...................................................................... 145 Hinges, controls - Lubrication.................................................................. 146 Seat bearing - Lubrication ....................................................................... 146 Diesel engine - Oil change ...................................................................... 147 Edge cutter (Optional) - Lubrication ............................................................................................ 148 Hydraulic reservoir - Draining.................................................................. 149 Replacing the fuel filter / fuel prefilter...................................................... 150 Hydraulic fluid filter - Replacement ......................................................... 151 Fuel tank - Draining off water .................................................................. 152 Fuel tank - Cleaning............................................................................................... 152 Hydraulic reservoir cap - Check .............................................................. 153 Water tank - Cleaning ............................................................................. 154 Steering joint - Check.............................................................................. 154 Watering system - Draining................................................................................................ 155

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Hydraulic reservoir Fluid change............................................................................................ 156 Air conditioning (Optional) - Overhaul ............................................................................................... 157 Drying filter - Check................................................................................. 158

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Introduction Introduction The machine Dynapac CS1400 VI is a static 3-drum roller in the 11-ton class (12.8 tons ballasted), with a compaction width of 2100 mm (83 in.) and the same static linear load on all drums.

It features articulated steering and is equipped with drive and brakes on all drums.

Intended use The area of application for CS1400 VI is the compaction of asphalt for layers up to 50 mm. It is ideal for surfaces where the substrate should not be vibrated, for example, close to vibration sensitive areas, next to buildings and bridges.

Training The purpose of operator training is to impart the operator the knowledge and skills necessary for proper operation and routine maintenance of the roller according to this manual.

Note to trainer: Further information on operator training can be found in ISO 7130.

Signal symbols and meaning 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.

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.

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.

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Introduction Read the entire manual before starting the machine and before carrying out any maintenance.

Replace immediately the instruction manuals if lost, damaged or unreadable.

Only the operator is allowed to be on the roller.

Ensure good ventilation (extraction of air by fan) where the engine is run indoors.

CALIFORNIA Proposition 65 Decal and location of decal shown in section Machine description.

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 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.

If faults or suspected damage are detected on the roller, contact the responsible supervisor for any action.

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.

Specific maintenance and checks on diesel engines must be performed by engine supplier authorized personnel.

(Only Stage V)

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 Safety - General instructions (Also read the safety manual) •

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.

•

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.

•

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.

•

Drive slowly in sharp bends.

•

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.

•

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.

•

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.

•

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.

•

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.

•

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.

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Safety - when operating 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.

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.

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.

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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Safety - when operating Work driving To exit the cab in an emergency, release the hammer on the rear right post and break the rear window.

Dynapac always recommends mounted ROPS (Roll Over Protective Structure), or a ROPS-approved cab and seat belt usage.

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.

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Safety (Optional) Safety (Optional) Automatic climate control The system described in this manual is an ACC type (Automatic climate control) The system contains pressurized refrigerant. It is forbidden to release refrigerants into the atmosphere.

The cooling system is pressurized. Incorrect handling can result in serious personal injury. Do not disconnect or undo the hose couplings.

Fig. Cab

The system must be recharged with approved refrigerant as required by authorized personnel.

The refrigerant contains a tracing agent, enabling leak-tracing to be performed using UV light.

The condenser is located together with other radiators, and the drying filter is located on the right-hand side of the radiator stand.

Edge cutter/compactor The operator must make sure that nobody is in the area of operation while the machine is in use.

The edge cutter consists of rotating components and there is a risk of being crushed.

3 1

2

Fig. Edge cutter/compactor 1. Transport position 2. Operating position 3. Holder for cutter/compactor wheel.

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The tool must be returned to the transport position (raised position) (1) every time it has been used.

If the edge cutter and its parts are dismantled, make sure that it is set in a relieved position and resting on the ground.

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Safety (Optional)

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Special instructions 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 biodegradable hydraulic oil 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.

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Special instructions 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.

When working with compressed air, use the following protective equipment: Protective goggles Protective gloves Ear protectors

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.

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.

Fire extinguisher A fire extinguisher can be ordered as an option.

Though, different standards are used around the world.

If not using the original fire extinguisher, place your extinguisher as in the picture. A 4 kg extinguisher is recommended.

Follow the installation instructions supplied with the fire extinguisher and make sure that the location does not create any risks.

1 Fig. Cab 1. Fire extinguisher

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Special instructions Roll Over Protective Structure (ROPS), ROPS approved cab If the machine is fitted with a Roll Over Protective Structure (ROPS, or ROPS approved cab) never carry out any welding or drilling in the structure or cab.

Never attempt to repair a damaged ROPS structure or ROPS structure in cab. These must be replaced with new ROPS structure or new cab.

Battery handling When removing batteries, always disconnect the negative cable first.

When fitting batteries, always connect the positive cable first.

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.

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Special instructions Jump starting (24V) 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.

1

2

Turn the ignition and all power consuming equipment off. Switch off the engine on the machine which is providing jump start power.

12V

Jump leads must have 24V.

3 24V

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 lifjting eye on the machine with the flat battery.

4

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.

12V

Fig. Jump starting

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Technical specifications Technical specifications Noise level Sound levels have been measured according to the operational cycle described in the EU directive 2000/14/EC on machines equipped for the EU market with operator seat in transport position.

Guaranteed sound power level, LwA

101 dB (A)

Sound pressure level at the operator's ear (cab), LpA

72 ±3 dB (A)

(Only Stage V)

Vibrations - Operator station (ISO 2631) Vibration levels have been measured according to the operational cycle described in the EU directive 2000/14/EC on machines equipped for the EU market with operator seat in transport position.

Measured whole-body vibrations are below the action value of 0.5 m/s² as specified in Directive 2002/44/EC. (Limit is 1.15 m/s²) Measured hand/arm vibrations also were below the action level of 2.5 m/s² specified in the same directive. (Limit is 5 m/s²)

Slopes The recommended max slope angle is for a machine that runs straight on hard, flat surface.

Max 20° or 36%

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Unstable ground, vibration on, speed and steering the machine can all cause the machine to topple at smaller angles than specified here.

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Technical specifications Dimensions, side view

Dimensions

mm

in

A

Wheel base

2900

114.2

D

Diameter, drum

1500

59

H

Height, with cab / ROPS

2990

117.7

K

Ground clearance

310

12.2

L

Length

4850

190.9

S

Thickness, drum amplitude, Nominal

22

0.87

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Technical specifications Dimensions, top view

CAB

ROPS

Dimensions

mm

in

B1

Cab

2370

93.3

B1

ROPS

2100

82.7

B2

1635

64.4

W1

1060

41.7

W2

570

22.4

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Technical specifications

Weights and volumes Weights Gross machinery mass (EN474) - including Cab with ballast

13200 kg

29,100 lbs

- including Edge cutter with ballast

13530

kg

29,830 lbs

- including Cab with ballast

12500 kg

27,560 lbs

- including Cab and Edge cutter with ballast

12830 kg

28,285 lbs

- including Cab without ballast

10450 kg

23,040 lbs

- including Cab and Edge cutter without ballast

10780 kg

23,765 lbs

- Maximum front, including cab, edge cutter and with ballast

7100 kg

15,655 lbs

- Maximum front, including cab and with ballast

6770 kg

14,925 lbs

- Maximum rear, including cab, edge cutter and with ballast

6100 kg

13,450 lbs

- Maximum rear, including cab and with ballast

5770 kg

12,720 lbs

- Front, including cab, edge cutter and with ballast

6980 kg

15,390 lbs

- Front, including cab and with ballast

6650 kg

14,660 lbs

- Rear, including edge cutter and cab with ballast

6180 kg

13,625 lbs

- Rear, including cab with ballast

5850 kg

12,895 lbs

Operating mass

Drum module mass

Fluid volumes Fuel tank

110 liters

29 gal

Water tank

525 liters

139 gal

Washer fluid reservoir

2.1 liters

2.2 qts

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Technical specifications Working capacity Compaction data Static linear load - Front

50 kg/cm

280 pli

- Rear

44,7 kg/cm

250.3 pli

- Front, with ballast

58,2 kg/cm

325.9 pli

- Rear, with ballast

55,3 kg/cm

309.7 pli

- Front

61.9 kg/cm

346.6 pli

- Rear

57.2 kg/cm

320.3 pli

Static linear load with maximum working weight

Propulsion Speed range Climbing capacity (theoretical)

0-15 km/h

0-9 mph

45 %

General Engine Manufacturer/Model

Deutz TD3.6 L04 (Stage IIIA)

Water-cooled turbo diesel

Deutz TD3.6 L04 (Stage V)

Water-cooled turbo diesel

Power output (SAE J1995), 2200 rpm 55 kW

74 hp

Engine speed - idling

900 rpm

- loading/unloading (ECO/intermediate speed)

1800 rpm

- work/transport

2200 rpm

The Stage V engine requires the use of Ultra Low Sulphur Diesel (ULSD) fuel, which has a sulfur content of 15 ppm (parts per million) or less. A higher sulfur content causes operating problems and puts the useful life of components at risk, which can lead to engine trouble.

In order to satisfy emissions requirements on regulated markets, the sulfur content at most may be 15 ppm.

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Technical specifications CO2-emission (Stage V only) CO2-emissions measured according to applicable test cycle in Regulation (EU) 2016/1628.

Manufacturer/Model Deutz TD 3.6 L04

Test-cycle Stage V

NRTC

CO2-emission (g/kWh) 848,7

NRTC: Non-road transient test cycles

Electrical system Battery

24V (2x12V 74Ah)

Alternator

24V 70A

Fuses

See the Electrical system section - fuses

Bulbs (if mounted)

Watt

Socket

Drive lights, front

75/70

P43t (H4)

Direction lights, front

21

BA15s

Side lights

5

SV8,5

Brake-Position lights

21/5

BAY15d

Direction lights, rear

21

BA15s

License plate light

5

SV8,5

Cab lights

10

SV8,5

Air Conditioning / Automatic Climate Control (ACC) (Optional) The system described in this manual is an AC/ACC type (Automatic Climate Control). ACC is a system that maintains the set temperature in the cab, provided windows and doors are kept closed.

The system contains fluorinated greenhouse gases.

Coolant designation: HFC-134a Coolant weight when full: 1,600 kg CO2-equivalent: 2,288 ton GWP:1430

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Technical specifications Tightening torque Tightening torque in Nm for oiled or dry bolts tightened with a torque wrench.

Metric coarse screw thread, bright galvanized (fzb): STRENGTH CLASS: Mthread

8.8, Oiled

8.8, Dry

10.9, Oiled

10.9, Dry

12.9, Oiled

12.9, Dry

M6

8,4

9,4

12

13,4

14,6

16,3

M8

21

23

28

32

34

38

M10

40

45

56

62

68

76

M12

70

78

98

110

117

131

M14

110

123

156

174

187

208

M16

169

190

240

270

290

320

M20

330

370

470

520

560

620

M22

446

497

626

699

752

839

M24

570

640

800

900

960

1080

M30

1130

1260

1580

1770

1900

2100

Metric coarse thread, zinc-treated (Dacromet/GEOMET): STRENGTH CLASS: M - thread

10.9, Oiled

10.9, Dry

12.9, Oiled

12.9, Dry

M6

12,0

15,0

14,6

18,3

M8

28

36

34

43

M10

56

70

68

86

M12

98

124

117

147

M14

156

196

187

234

M16

240

304

290

360

M20

470

585

560

698

M22

626

786

752

944

M24

800

1010

960

1215

M30

1580

1990

1900

2360

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Technical specifications Hydraulic system Opening pressure (Absolute pressure) Drive system (MPa)

42.0

Supply system (MPa)

2.5

Control systems (MPa)

20.0

Brake release (MPa)

1.5

Type of fluid

Mineral or Saturated ester based

Working flow-rate range (l/min) - Propulsion

Up to 274

- Steering

Up to 56,8

24

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Machine description Machine description Diesel engine The machine is equipped with a water-cooled, in-line four-cylinder turbocharged, four-stroke diesel engine.

Stage IIIA The engine is equipped with cooled exhaust gas recirculation and closed crankcase ventilation.

• ceEGR - External Cooled EGR-electronically controlled

Stage V The engine is equipped with external cooled EGR-electronically controlled (ceEGR) and a diesel particle filter (DPF) system for exhaust after-treatment.

In this design the engine is also equipped with closed crankcase ventilation.

• ceEGR - External Cooled EGR-electronically controlled

DPF - Diesel particulate filter

Electrical system • Main ECU (for the machine) • Engine-ECU (for DEUTZ 3.6 L4 (Stage V (55 kW)))

Propulsion system/Transmission The propulsion system is a hydrostatic system with a hydraulic pump supplying oil to three driver motors connected in parallel. Each motor drives one drum.

The speed of the machine is proportional to the deflection/angle 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 hydrostatisc and is activated by moving the control lever to neutral.

Secondary/Parking brake The secondary and parking brake system consists of sprung multiple disc brakes in the motors. 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 value on the steering column distributes 2022-02-02

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25

Machine description the flow to the control cylinder, which actuates the articulation.

The steering angle is proportional to the deflection of the steering wheel.

Cab Different types of cabs are available; Asymmetrical and Symmetrical.

These variants are available as follows: - Standard cab – has a heating and ventilation system, with defrosters for all windows.

Meets the requirements of ISO 10263.

- Comfort cab – has a heating and ventilation system, with defrosters for all windows.

It is also equipped with AC and complies with ISO 10263.

Emergency exit The cab has one emergency exit: the right-opening windows, which can be broken with the emergency hammer located in the cab.

Seat Different kind of seats are available. The seat always comply with at least the applicable requirements on the market where the machine is originally placed.

Seat is tested and comply with seat dimension ISO 11112, SIP ISO 5353, suspension ISO7096, seat belt ISO 6683.

FOPS and ROPS FOPS is the abbreviation for "Falling Object Protective Structure" (roof protection (ISO 3449)) and ROPS is the abbreviation for "Roll Over Protective Structure" (ISO 3471).

If any part of the protective construction on the cab or FOPS/ROPS structure reveals plastic deformation or cracking, the FOPS/ROPS structure must be replaced immediately.

Never perform any modifications on the cab or FOPS/ROPS structure without first having discussed the modification with Dynapac's production unit.

Dynapac determines whether the modification could result in the approval according to the FOPS/ROPS standards becoming invalid.

If the roller is equipped with a cab, it is FOPS level I and ROPS approved.

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Machine description If equipped with ROPS roof, there is no FOPS approval.

Identification Product and component plates

3 2

1

4

1.

Product plate - Product Identification Number (PIN), model/type designation

2.

Engine plate - Type description, product and serial numbers

3.

Cab/ROPS plate - Certification, product and serial numbers

4.

Component plate, drum - Product and serial numbers

Product identification number on the frame The machine PIN (product identification number) (1) is punched on the right side of the front frame.

1

Fig. Front frame 1. PIN

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Machine description Machine plate The machine plate (1) is affixed to the left side of the platform.

The plate specifies the manufacturers name and address, the type of machine, the PIN, Product Identification Number (serial number), operating weight, engine power and year of manufacture. (On machines supplied to outside the EU, there are no CE markings and in some cases no year of manufacture.)

Operating mass and Max. axle load front / rear is the value as the roller is equipped when delivered from the factory.

1 Fig. Machine plate, Platform 1. Machine plate

Please state the machine's PIN when ordering spares.

Explanation of 17PIN serial number 100

00123

V

x

A

B

C

F

A

123456

A= Manufacturer B= Family/Model C= Check letter F= Serial number

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Machine description Engine plates The engine's type plate (1) is located on top of the cylinder head cover.

The plate specifies the type of engine, its serial number and the engine specification.

Please specify the engine serial number when ordering spares. Refer also to the engine manual.

1 Fig. Engine (Stage IIIA) 1. Type plate

1 Fig. Engine (Stage V) 1. Type plate

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Machine description Decals Location - decals

16

14

22 24

12 4 9 20 8

4

8

15

1

6

13

23

18 14

5

17 21

11 10

24

16

19

4 15

4 8

8 1 1.

Warning, crush zone

4700903422

13.

4.

5.

6.

8.

Lifting point Warning, instructions manual Warning, brake release Fixing point

4700357587 4700903459 4700904895 4700382751

9.

10.

Master switch Diesel fuel

4700904835 4700991658 * 4811000345 **

14.

15.

16.

17.

18.

19.

20.

21.

11.

Fuel with low sulphur content 4811000344

22.

12.

Hoisting plate *) Stage IIIA

23.

24

**) Stage V

30

4700904870

25.

Hydraulic fluid/ Biological hydraulic fluid Handbook compartment Warning, locking Water Sound effect level Hydraulic fluid level Coolant Battery voltage Warning, locking during transportation Emergency exit (asymetric cab) Warning, Joint cutter Emergency exit (symetric cab) Washer fluid

4812164401_B.pdf

4700272372/ 4700792772 4700903425 4700908229 4700991657 4700791271 4700272373 4700388449 4700393959 4812125363 4700903590 4700904083 4812131981 4812132929

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Machine description Location - decals, CALIFORNIA Proposition 65

1.

1

Warning, CALIFORNIA Proposition 65

4812129673

Fig. Location

Safety decals Always make sure that all safety decals are completely legible, and remove dirt or order new decals if they have become illegible. Use the part number specified on each decal.

If a part is replaced and this part have a decal, make sure to also order the decal.

4700903422 Warning - Crush zone, articulation/drum.

Maintain a safe distance from the crush zone.

(Two crush zones on machines fitted with pivotal steering)

4700904895 Warning - Brake disengagement Study the towing chapter before disengaging the brakes.

Danger of being crushed.

4700903459 Warning - Instruction manual The operator must read the safety, operation and maintenance instructions before operating the machine.

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Machine description 4700908229 Warning - Risk of crushing The articulation must be locked when lifting.

Read the instruction manual.

4812125363 Warning - Locking The articulation must be locked during transport and lifting, but be open during operation.

Read the instruction manual.

4700904083 Warning - Edge cutter (optional) Warning of rotating parts.

Maintain a safe distance from the crush zone.

32

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Machine description 4812129673 Warning CALIFORNIA - Proposition 65

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Machine description Info decals 4. Lifting point

8. Fixing point

9. Master switch

4700357587

4700382751

4700904835

10. Diesel fuel (Stage IIIA)

11. Fuel with low sulfur content (Stage V)

12. Hoisting plate

4700991658

4811000344

4700904870

13. Hydraulic fluid

13. Biological hydraulic fluid 14. Handbook compartment PANOLIN

4700272372

4700792772

4700903425

16. Water

17. Noise power level

18. Hydraulic fluid level

4700991657

4700791271

4700272373

19. Coolant

20. Battery voltage

22. Emergency exit (asymetric cab)

470038849

4700393959

4700903590

24. Emergency exit (symetric cab)

25. Washer fluid

34

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Machine description

4812132981

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Machine description Instruments/Controls Control panel and controls 16

14

11 33 13

20

6

5

30 10

15

9

17

25 2 29

18

27

4

28

22

24

31

21

23

8

7

19

1

Fig. Control panel 1 2

Ignition switch Forward & Reverse lever

3 4 5

* Offset left/right

6 7 8 9 10 11

13 14

15 No available on this model 16 Full flow ("full on"), edge cutter, 17 sprinkling (blue) Button set/Keypad 18 Start-stop button 19 Menu button 20 Main menu, return button 21 No available on this model 22 No available on this model 23 24

No available on this model Work mode (soft start and stop activated and joint cutter if fitted)) No available on this model Watering, manual/automatic Display knob, select button

25

Parking brake

27 28 29

* Rotating beacon/Flashlight

Return button, previous Settings menu knob Working light Horn Emergency stop Speed limiter Speed selector and ECO Mode, diesel engine

30 31

Gear position switch Activation of joint cutter

33

Display

No available on this model * Edge cutter, up/down (green)

* Optional

36

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Machine description

1.

Hazard indicators

Activate the hazard indicators with the switch.

1

Fig. Steering column

1.

2.

3.

4.

5.

Functions Direction indicators Driving lights Full/Dipped beam Parking lights Horn

Figure. Steering column switch (optional)

4

5

1

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2

3

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Machine description Forward & Reverse lever 1 2 3

3

Full flow ("full on")

* Edge cutter down * Edge cutter up * Optional

2

1

Fig. Forward & Reverse lever

Function descriptions No

Designation

1

Ignition key

Symbol

Function The electric circuit is broken.

All instruments and electric controls are supplied with power.

2

Forward/Reverse lever

NOTE: The lever must be in neutral to start the machine. The engine will not start if the lever is in any other position.

The direction and speed are controlled with the forward/reverse lever. Moving the lever forward moves the roller forward, and moving it back moves the roller back.

The speed of the roller is proportional to the distance of the lever from neutral. The further the lever is from neutral, the higher the speed.

5

Full flow

“Acute sprinkling" of drums and sprinkling of joint cutter/edge press if fitted on the machine. Press on the button to engage full sprinkling flow.

6

Button set/Keypad

7

Start-stop button

Start or stop the diesel engine.

8

Menu button

Menu selector

9

Main menu, return

Return button to the main menu, "Home."

14

Work mode (soft start and stop activated and joint cutter if fitted)

Activates work mode, as well as soft start and stop. The roller always starts in transport mode. Work mode must be activated for the sprinkler system and joint cutter, if fitted, to be used.

16

Sprinkler

Left LED lit indicates manual sprinkling. Gives continuous sprinkling of the drums. Activation of the right LED gives automatic sprinkling (auto active). Sprinkling is activated when the Forward/Reverse lever is outside of neutral.

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Machine description No

Designation

Symbol

Function

17

Display knob, selection button

Scroll using the knob to the desired selection, select by pressing the knob in the middle.

18

Return button, previous

Return to last selection/display.

19

Settings menu button

20

Working lights

By activating the working lights will turn ON.

21

Horn

Press to sound the horn.

22

Emergency stop

Brakes the roller and switches off the engine. The power supply goes off.

NOTE: The emergency stop must be deactivated when starting the machine.

23

Speed limiter

Limitation of the machine's max. speed (max.speed is obtained with full deflection of the F/R lever). Set the knob to the required position and read the speed on the display (30).

24

Rpm switch, diesel engine

Speed adjustment, increases with each press. Selection illuminated in the top of the button, idling (-), intermediate speed / ECO (- -) and work speed (- - -).

NOTE! When starting the machine, the control must be in the idling position (-). The engine also runs at low speed when stationary for more than about 10 seconds if the F&R lever is in neutral.

If the F&R lever is moved out of neutral, the speed will increase to the set speed again.

25

Parking brake

To activate the brakes, press the top of the switch to change the position of the lever.

To release the brakes, press down the red part at the same time as the switch and change the position of the lever.

NOTE: When starting the machine, the parking brake must be activated.

27

Rotating beacon

Activation of the rotating beacon/flashlight

29

Edge press/cutter, UP/DOWN

The edge cutter can be moved up and down when the machine is in Work mode. The edge cutter can only be moved up when the machine is in Transport mode.

Pressing on the bottom button moves the edge cutter down.

Pressing on the top button moves the edge cutter up.

30

Gear position switch

Activates the two different gear positions: (1), (2). The current gear position is shown in the display by means of the following figures.

Position 1: Normal working gear, gives maximum hill-climbing capacity during compaction Position 2: Used for maximum transport speed or for high speed during smooth rolling

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Machine description No

Designation

Symbol

Function

31

Joint cutter

Activates joint cutter

32

Low beam lights

When this symbol lights green in the lower left corner of the display, low beam lighting is enabled.

Display, key When the ignition key is activated, a start screen becoms visible on the display. This screen is visible while the system is prepared for start.

Fig. Start screen

The Home screen shows multiple information images.

Fig. Display screen - Home 1

13

2

3

4 5 6

6

9 8

1. Machine working hours 2. Gear indicator (2 gears) 3. Diesel engine rpm 4. Time watch 5. Fuel level

40

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Machine description 6. Speedometer 7. Sprinkler tank level 8. Warning lamps (Yellow is warning and red is high alert) 9. Asphalt temperature meter (two sensors shifting from front and back depending on the direction of travel) 13. Driving direction

In the machine image, middle is shown even if front and back are selected.

The display is of "touch screen type" but can also be worked from the display controller.

Fig. Display controller

The touch screen allows you to activate, adjust different functions etc. directly on the display. If you prefer you can use the display controller instead.

Sprinkler

Pointing to the right of the display, brings up a quick selection menu.

Warning Compacting

Selections in quick-choice menu:

Brake test

Sprinkler • Opens Sprinkler settings in the Settings menu.

Main menu

Fig. Quick menus

Alarm • Opens the alarms with logs and error codes.

Compacting • Opens Compaction settings in the Settings menu (Asphalt temperature)

Brake test • Must be performed daily according to procedure in separate section in Start chapter.

Main menu • Opens the start page in the Main menu.

An image for the asphalt temperature can be shown when the asphalt temperature meter is installed on the machine.

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Machine description Asphalt temperature meter Asphalt temperatures are shown either in degrees Celsius or Fahrenheit. (selected in User settings) Dual temperature sensors, one front and one rear.

Fig. Asphalt temperature image

The sensor that sits foremost in the current direction of travel is highlighted and it is this one that is read to avoid the disruption of moisture from the drum’s sprinklers. The sensor that is rearmost in the current direction of travel is shaded/dimmed.

Min

Max

Setting of max. and min values by plus or minus on the display image, the temperature area will be green if the temperature keeps within the desired values and turns yellow if the temperature is higher than the maximum value.

Fig. Temperature settings

"MAIN MENU" In the main menu it is also possible to change some user and machine settings, access the service menu and return to Home screen.

42

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Machine description "USER SETTINGS" Users can change the light settings, choose between the Metric or Imperial system, and set time and date.

User settings

Display light Home screen

Measure unit Clock

Return Date

Main menu

Manuals (WIP) Manuals (WIP)

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Machine description "MAIN MENU" In the main menu it is also possible to change some user and machine settings, access the service menu and return to Home screen.

"USER SETTINGS" Users can change the light settings, choose between the Metric or Imperial system, and set time and date.

User settings

Display light Home screen

Measure unit Clock

Return Date

Main menu

Manuals (WIP) Manuals (WIP)

This menu shows information about software installed on the ECU and which version of software on the display.

If the machine is not equipped with an edge cutter, the green buttons (1) are deactivated.

The symbols appear for the green buttons (1) even

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Machine description when this menu is opened on the screen.

1

Fig. Forward / reverse control 1. Buttons (Green) for operating edge cutter

Settings menu ("SETTINGS MENU") Settings

Different selections in the settings menu will bring up areas where settings can be altered for Sprinkler, Motor, Compacting

SPRINKLER Sprinkler

Selection of pump 1/2 or both are active.

Adjustment of the pause time (seconds) between sprinklers for automatic sprinkling. (AWC)

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Machine description

ENGINE Engine

Activation of Parked regeneration.

COMPACTION Compaction

Limit setting for asphalt temperature measurement.

46

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Machine description

"SERVICE MENU" Service

The service menu is accessible via the main menu for adjustments.

"ALARMS" system logs and error codes Alarms

"MACHINE STATUS" - Summary of levels, loads and temperatures.

Machine status

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Machine description

Spd Limit Calibrations

"SPD LIMIT CALIBRATIONS"

"RAMP SETTINGS" This section is protected by Pin Code Ramp settings

There are 3 different modes that can be seleted in the machine's workmode. (Soft, Medium, Hard).

The machine alerts at startup when the setting is in Soft Mode.

"JOYSTICK CALIBRATIONS" Joystick calibrations

48

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Machine description

"TEST MODE" - Installation personnel only, requires pin code.

Test mode

"ABOUT" It is also possible to see the version of the installed software.

Machine alarm Symbol

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Designation

Function

Warning symbol, hydraulic fluid filter

If the symbol is shown when the diesel engine is running at full speed, the hydraulic fluid filter must be changed.

Warning symbol, clogged air filter

If this symbol is shown when the engine is running at full speed, the air filter must be checked/replaced.

Warning symbol, battery charging

If the symbol is shown when the engine is running, then the alternator is not charging.

Switch off the engine and locate the fault.

Warning symbol, engine temperature

If this symbol is shown, the engine is too hot. Stop the engine immediately and locate the fault.

Refer also to the engine manual.

Warning symbol, hydraulic fluid temperature

If this symbol is shown, the hydraulic fluid is too hot.

Do not drive the roller; allow the fluid to cool by running the engine on idle, and then locate the fault.

Warning symbol, low fuel level

Less than 10% of the fuel is left if this symbol is shown.

Warning symbol, low sprinkler water level

If this symbol is shown, there is less than 10% of the sprinkler water left in the main tank.

Warning symbol, low oil pressure, diesel engine

If this symbol is shown, the engine's oil pressure is too low.

Switch off the engine immediately.

Warning symbol, low coolant level

If this symbol is shown, fill with coolant/glycol and search for leaks.

Warning symbol, water in the fuel

If this symbol is shown, the engine must be stopped and the fuel pre-filter drained of water.

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Machine description Instruments and controls, cab Radio/CD

Fig. Cab roof, front

14

1

ACC

Heater

8

10

11

2

3

4 5

6

7

15

Fig. Right rear cab post 15. Hammer for emergency exit

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Machine description Function description of instruments and controls in the cab No

Designation

Symbol

Function

1

Fuse box

Contains fuses for the electrical system in the cab.

2

Front wiper, switch

Press to operate the front screen wiper.

3

Front and rear window screen washers, switch

Press the upper edge to activate the front screen washers Press the lower edge to activate the rear screen washers.

4

Rear wiper, switch

Press to activate the rear wiper.

5

Front side wiper, switch

Press to activate the front side wiper.

6

Front and rear side window screen washers, switch

Press the upper edge to activate the front side screen washer.

Press the lower edge to activate the rear side screen washer.

7

Rear side wiper, switch

Press to activate the rear side wiper.

8

Heater

Cab heater.

10

Automatic Climate Control (ACC) (micro ECC)

Automatic control of the air conditioning.

11

Front wiper, intermittent

Intermittent function for front wiper.

14

Defroster nozzle

Turn the nozzle to direct the flow of air.

15

Hammer for emergency exit

To escape from the cab in an emergency, release the hammer and break the opening windows on the right-hand side.

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Machine description Using the cab controls.

Defroster To quickly remove ice or mist, make sure that only the front and rear air nozzles are open.

Turn the heater and fan dial to max.

Adjust the nozzle so that it blows on the window to be de-iced, or to remove mist.

Heat If the cab is cold, open the lower nozzle on the front columns and the middle nozzles just over the controls for the heater and fan.

Turn to max heat and max fan speed.

When the required temperature has been reached, open the other nozzles and if necessary turn down the heat and fan speed.

ACC NOTE: When using ACC all the windows must be closed for the system to work efficiently.

Heater panel

1.

4

2.

3.

4.

1

52

2

3

5

5.

The display shows figures from 0 to 7. Seven steps for heating and seven steps for fan speed, where 7 is max.

Arrows for up and down steps on fan speed or heat.

Fan.When diode is lit it is possible to set the fan speed with the setting arrows (up and down)(2).

Heater.When diode is lit by the thermometer it is possible to set the heat with the setting arrows (up and down)(2).

Fan on or off. Diode is lit when fan is activated.

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Machine description ACC - Control panel 1. LCD Display During normal operation, the set-point temperature, blower speed, operation mode and fresh/re-circulated air selection are displayed.

2. SET / SELECT Button Under normal operation button is used for selecting between modes.

(Also used in Test/diagnostics mode for different options) 3. Power Button Device ON/OFF.

Main display screen 1. Air mix control The air mix can be set to full fresh air or full re-circulated air.

2. Mode Displays the mode, "Automatic", "Heat", "Cool" and "Defrost" 3. Temperature Set-point Displays current inside set-point temperature.

4. Blower speed Displays current blower speed setting.

ACC - Operation menus Main screen When the unit is turned on, the main screen will appear. Current set-point temperature, climat control mode, air-circulation and blower speed are displayed.

A small warning icon appears if there is something wrong with the system.

Blower speed settings: Press SET / SELECT button until the blower icon appears, then turn clockwise to increase blower speed and counterclockwise to decrease blower speed with 5% increments.

The blower speed can not be adjusted in defrost mode (Defrost).

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Machine description

Climate Control mode settings: Press SET / SELECT button until the climate control mode icon appears, and then turn the button until the required mode is displayed.

AUTO

The system runs automatically to keep the temperature that is selected (set-point temperature).

Cool

A / C compressor is running to cool the interior temperature.

Heating valve is turned off while cooling off ("Cool") is selected.

Heat

Interior temperature warms up with the electronic heater valve.

A / C compressor is turned off while warming ("Heat") is selected When defrosting ("Defrost") is activated, the A / C compressor is turned on, the blower is turned on full speed and the heater valve is fully open.

Defrost

Air circulation setting: Press the SET button until the air circulation mode icon appears.

Turn the knob clockwise to fully recirculated air or counterclockwise full fresh air.

Display settings: To adjust the display settings and the temperature scale, press the SET button until the display settings screen appears, then turn the SET button clockwise or counterclockwise to adjust the settings.

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Machine description Turning HVAC system OFF: In the main screen, press the Power button to turn off the HVAC system. When the system is turned off, the backlight will turn off and the interior temperature will be displayed on the screen.

To turn off the HVAC system from Defrost mode, press the Power button until the HVAC system returns to the AUTO mode, then press the Power button again to turn off the HVAC unit.

Diesel heating mode (if a diesel heater is installed): When a Diesel heating mode signal is received, the backlight will be switched off, the fan will run at 15%, the heater valve is fully open and the air circulation changes to fresh air until the coil’s temperature is above 20 ºC (78 ºF). When the temperature of the coil is above 20 ºC (78 ºF), the fan will run at a preset speed. No other function is permitted.

Electrical system Distribution box The distribution box is located in the middle, under the rear of the cab. There is a cover over the distribution box and fuses.

1 Fig. Distribution box 1. Circuit card (A6)

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Machine description

Circuit board in main switch The figure shows the position of the fuses and the relays.

The table below gives fuse amperage and function.

All fuses are flat pin fuses, type C (medium).

The table also shows the relay functions.

Fig. Circuit board A6.

Fuse card (A6) Fuses F1

Display, Display control, Key pad,

10A

F8

Sprinkler pump

7.5A

F2

Fuel pump

15A

F9

Sprinkler pump 2

7.5A

F3

ECU

10A

F10

Spare

F4

Aspfalt temp.sensor, Speed sensor

5A

F11

Dyn@lyzer

7.5A

F5

Parking brake switch, Back-up alarm, Dyn@link, Seat belt, Seat switch, Displacement switch

5A

F12

Dyn@link, Ignition switch, Power supply (CPU)

5A

F6

Working lights, 24/12V power converter

15A

F13

Hazard light, Direction lights

7.5A

F7

Working lights, 24V Supply

15A

F14

Driving lights

10A

K9

Flash relay (Hazard light, Directions indicators)

Relays K2

Fuseboard, Main relay

K6.1 Working lights left, ROPS/Cab

K12.1 Sprinkler pump

K6.2 Working lights right, ROPS/Cab

K12.2 Back-up pump

K8

56

Driving lights

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Machine description Fuses in cab The electrical system in the cab has a separate fuse box located behind the cover plate on the front right side of the cab roof.

Fig. Cab roof fuse box (F7)

The figure shows fuse amperage and function.

1.

2.

3.

4.

5.

6.

7.

8.

Interior light Wiper motor/washer front/rear AC/ACC Heater blower Front/rear side washer pump Front/rear side wiper motor, Pressure guard AC Dyn@lyzer Reserve

10A 10A 15A 20A 10A 15A

All fuses are flat pin fuses.

7.5A

Main and Engine ECU The ECU units for the machine and the engine are located to the left of the engine compartment.

1

2

Fig. Engine compartment (IIIA) 1. Engine ECU 2. Main ECU

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1

2

Fig. Engine compartment (Stage V) 1. Engine ECU 2. Main ECU

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Machine description

58

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Operation Operation Before starting Battery isolation switch - Switching on Remember to carry out daily maintenance. Refer to the maintenance instructions.

The battery disconnector is located in the front beam.

Turn the key (3) to the On position. The roller is now supplied with power.

2

The machine can be equipped with a pull-out wire in the engine compartment. This permits the battery disconnector to be switched on without the need of opening the engine hood.

1

The engine cover must be unlocked when operating, so that the battery can be quickly disconnected if necessary.

3 Fig. Battery bay in front beam 1. Battery disconnector 2. Power socket, 12V 3. Key

Control panel, adjustments 2

The control unit has three adjustment options, transverse travel, rotation and steering column angle.

Pull the lever (1) forward (A) to release the transverse travel catch for transverse travel.

Pull the lever (1) backwards to perform rotation. (B) Ensure that the control unit locks in position before operating the machine.

Release locking lever (2) to adjust the steering column angle. Lock the steering column in the new position.

See the basic/comfort seat section for the seat adjustment options.

1 Fig. Operator's station 1. Lever - transverse travel/rotation 2. Locking lever - steering column angle

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Adjust all settings when the machine is stationary.

Always ensure that the seat is in locked position before operating the roller.

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Operation

Operator's seat - Adjustment Adjust the operator’s seat so that the position is comfortable and so that the controls are within easy reach.

2

1

The seat can be adjusted as follows.

4 3

- Length adjustment (1) - Weight adjustment (2)

Fig. Operator's seat 1. Lock pack- Length adjustment 2. Weight adjustment 3. Back support angle 4. Seat belt

- Back support angle (3) Always make sure that the seat is secure before beginning operation.

Do not forget to use the seatbelt (4).

Operator's seat, comfort - Adjustments 6

Adjust the operator's seat so that the position is comfortable and so that the controls are within easy reach.

3 5

2

4 1 Fig. Operator’s seat 1. Lever - length adjustment 2. Wheel - height adjustment 3. Wheel - seat cushion inclination 4. Wheel - backrest inclination 5. Wheel - armrest inclination 6. Wheel - lumbar support adjustment

60

The seat can be adjusted as follows: - Length adjustment (1) - Height adjustment (2) - Seat-cushion inclination (3) - Backrest inclination (4) - Armrest inclination (5) - Lumbar support adjustment (6) Always ensure that the seat is locked in position before operating the roller.

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Operation Belt reminder The machine can be equipped with seat belt with belt reminder.

Unless the seat belt is used, a warning image in the display will flash until the driver becomes aware of using the seat belt.

Display - Control 2

Sit down for all operations.

Turn the ignition key (1) to the right so that a start image is shown on the display. Wait until the start image (2) goes out and the status image is shown on the display.

1 Fig. Instrument panel 1. Ignition key 2. Status image

3 4 5

Check that the gauges (3, 4) show readings and the charge shows at least 24V. The hourmeter (5) registers and shows the total number of hours the engine has run.

Fig. Status image 3. Fuel level 4. Water level 5. Hourmeter

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Operation Parking brake 1

Ensure that the parking brake (1) is definitely switched on.

The brakes are always activated in Neutral. (automatically switched on after 2 seconds) Fig. Control panel 1. Parking brake

The parking brake must be activated to start the machine!

Interlock The roller is equipped with Interlock.

The diesel engine with switch off after 7 seconds if the operator gets off the seat when going forwards/backwards.

If the control is in neutral when the operator stands up a buzzer will go on until the parking brake is activated.

If the parking brake is activated, the diesel engine will not stop if the forward/reverse lever is moved out of neutral.

The diesel engine will switch off immediately if for any reason the forward/reverse lever is moved out of neutral when the operator is not sitting down and the parking brake has not been activated.

Sit down for all operations!

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Operation Operator position If a ROPS (Roll Over Protective Structure) or a cab is fitted to the roller, always wear the seat belt (1) provided and wear a protective helmet.

3

2

2

3

Replace the seat belt (1) if it shows signs of wear or has been subjected to high levels of force.

1 5 Fig. Operator position 1. Seat belt 2. Safety railing 3. Locking knob 4. Rubber element 5. Anti-slip

4

The safety rails (2) around the cab are adjustable in the inner and the outer positions. Pull in the rails when driving close to walls or other obstacles, and when transporting the machine.

Inspect the ROPS/Cab for damages. Contact your supervisor for further actions if damages are detected.

Release the locking knob (3), set the the railings in the required position and relock in position.

Check that the rubber elements (4) on the platform are intact. Worn elements will reduce comfort.

Ensure that the anti-slip (5) on the platform is in good condition. Replace where anti-slip friction is poor.

If the machine is fitted with a cab, make sure that the door is closed when in motion.

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Operation View Before starting, make sure that the view forwards and backwards is unobstructed.

All cab windows should be clean and the rear view mirrors should be clean and correctly adjusted.

Fig. View

Rear view mirrors - Adjustment The rear view mirror adjustment is accessible from the ground.

The arm of the rear-view mirror has a stop in the maximum extended position. The mirror may then be adjusted for a good rear view.

The visibility requirement is fulfilled as per standard ISO 14401.

All rear view mirrors must be clean and adjusted for good backward visibility.

1 Fig. Rear view mirrors

Working lights - Adjustment Use a ladder for easier access to adjust the working lights.

Cab windows - de-icing To de-ice the cab windows, stand steadily on the cab step, or the water tank filling step.

Use a telescopic ice scraper and de-ice the windows as far as you can reach.

Adjust the seat to the left position for the best view through the de-iced section of the window.

Turn on the defroster fully, and the remaining part of the windows will be de-iced within a few minutes.

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Operation Wiper blade - Replacement Ensure that the wiper blades are in good condition.

Replace the blades when they no longer wipe the cab windows clean.

Use a ladder for easier access for wiper blade replacement.

Washer fluid - Checking and filling

Place the roller on a level surface.

1

Top up the washer fluid when if necessary, in the reservoir (1) located behind the operator’s seat.

The reservoir holds 2.1 liters (2.2 qts)

Fig. Operator’s platform 1. Washer fluid reservoir

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Operation Foldable rotating beacon (Accessory) Stand firmly with both feet on the top step (1).

On a machine equipped with ROPS, hold a firm grip with one hand, on the left rear side rail (2) on the operator platform.

2

On a machine equipped with a cab, make sure that the door (3) or the rear side window (4) on the door is open. Take a firm grip with one hand, on the handle (5) located on the left-hand rear cab pillar.

Now loosen the knob (6) with the other hand and fold down the lamp holder (7).

Undo and remove any warning light (8) from the lamp holder.

1 Fig. ROPS equipped roller 1. Step 2. Handrail

To raise the rotating beacon, perform the above procedure in reverse.

The rotating beacon should always be folded down before transport, where the total height of the trailer is less than three meters.

Prior to starting work, make sure that the rotating beacon is not damaged and in working order. If not, replace immediately.

5 7

8

3

1

4 6

Fig. Cab equipped roller 1. Step 3. Cab door 4. Side window 5. Handle bar

66

Fig. Rotating beacon 6. Knob 7. Lamp holder 8. Warning light

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Operation Starting Starting the engine Make sure that the emergency stop is not activated, but the parking brake is switched on.

Set the forward/reverse lever (1) in neutral position.

1

The diesel engine cannot be started in any other position of the controls.

3

2 Fig. Control panel 1. F/R lever 2. Ignition key 3. Start-stop button

Turn the ignition key (2) to the right and a start screen appears on the display. Wait until the start screen turns off.

Activate start by pressing the start-stop button (3). The status image appears on the display.

Fig. Display - Start screen

The system will automatically take care of essential measures such as preheating and activation of the starter motor.

At the start of the diesel engine when the ambient temperature is below +10 ° C (50 ° F), it must be warmed up at idle (low speed) until the hydraulic oil temperature exceeds +10 ° C (50 ° F).

Ensue that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Fig. Display - Status image

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Operation When starting and driving a machine that is cold, remember that the hydraulic fluid is also cold and that braking distances can be longer than normal until the machine reaches the working temperature.

The machine always starts in Transport mode, without it being possible to use sprinkling.

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Operation Parking brake test To be sure that the parking brake works and is in good condition, perform following procedure daily.

Put the machine on flat ground.

2

Make sure that there are no obstacles in the direction of travel, on the ground, in front of or behind the roller, or overhead.

1 3 4

Activate the parking brake with the parking brake button (2). Turn on the quick selection menu on the display, the brake test button (5) is now visible in the menu bar on the touch screen.

Fig. Control panel 1. Rpm switch 2. Parking brake 3. Forward/Reverse lever 4. Speed limiter

Set the engine speed (1) to medium or high speed and set the propulsion speed limiter to max., i.e. no limitation

Push the brake test button (5) in the touch screen and keep it pushed, a pop-up symbol (6) shows on the screen when the button is activated.

Fig. Display view 5. Brake test button

5

Move the forward/reverse lever (3) slowly forward and slowly back to neutral again and then release the brake test button (5).Be prepared for the machine to move during this operation. Stop the machine by immediately pulling the lever to neutral If the machine does not move the parking brake effect is approved.

6 Fig. Display view 6. Pop-up symbol (parking brake test)

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If the machine moves the parking brake is not approved and the brake discs are worn and need to be replaced.

The machine must be immediately taken out of operation and must not be used until the brakes are repaired and approved.

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Operation Display when activating choice via the button set.

Working mode, offset and vibration possible.

6

3

Watering, manual/automatic Automatic water control (auto active), watering is activated when the Forward/Reverse lever is outside of neutral.

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Operation Display when activating choice via the button set.

Working mode, offset and vibration possible.

Watering, manual/automatic Automatic water control (auto active), watering is activated when the Forward/Reverse lever is outside of neutral.

Warning alarm display, see the table for details.

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Operation Alarm descriptions Pos Symbol

Designation

Function

1.

Warning lamp, hydraulic filter

If the lamp comes on while the engine is running at full speed, the hydraulic filter must be changed.

2.

Warning lamp, air filter

If the lamp comes on while the engine is running at full speed, the air filter must be cleaned or replaced.

3.

Warning lamp, battery charging

If the lamp comes on while the engine is running, the alternator is not charging.

Stop the engine and locate the fault.

4.

Warning light, engine temperature

If the lamp comes on, the engine is too hot. Stop the engine immediately and locate the fault.

Refer also to the engine manual.

5.

Warning lamp, hydraulic fluid temperature

If the lamp comes on, the hydraulic fluid is too hot.

Do not drive the roller. Cool the fluid by allowing the engine to idle and locate the fault.

6.

Warning light, parking brake

If the lamp comes on, the parking brake is activated.

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Operation Driving Operating the roller 2

Under no circumstances is the machine to be operated from the ground. The operator must be seated inside the machine during all operation.

1 3 Activate working speed (1) = HI or ECO if available.

In ECO, the machine automatically regulates the engine speed according to requirements.

Fig. Control panel 1. Rpm switch 2. Parking brake 3. Forward/Reverse lever

If the machine is only to be transported, MID or ECO should be selected instead.

Check that the steering is working correctly by turning the steering wheel once to the right and once to the left while the roller is stationary.

5

4

When compacting asphalt, remember to turn on the sprinkler system (4) or (5).

Make sure that the area in front of and behind the roller is clear.

Release the parking brake (2).

4. Manual/automatic watering 5. Panic watering

Gear position switch

2

1

Switch (1) is a spring-return gear position switch, where gear changing take place by stepping through the two different gear positions: Position 1 and Position 2.

• Position 1: Used for maximum hill-climbing capacity.

• Position 2: Used for maximum transport speed or for high speed for static passes during smooth rolling.

Fig. Control panel 1. Gear position switch 2. Forward/Reverse lever

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Operation The machine's gear position is shown in the center of the speedometer; select the gear/speed for the task.

The forward/reverse lever must be in neutral in order to change gear.

Fig. The display shows the selection (position 1 or 2)

= Position 1

Max. speed 6 km/h

3.8 mph

= Position 2

12 km/h

7.5 mph

Carefully move the forward/reverse lever (2) forwards or backwards, depending on which direction of travel is required.

The speed increases as the lever is moved away from the neutral position.

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Operation Alarm - Regeneration The following symbols can be shown at the bottom of the display: 1

2

3

4

5

6

7

Comment: To initialize and complete regeneration, the engine coolant temperature must be > 70° C.

8

Fig. Display, regeneration - Symbols

No Symbol Designation and Function 1.

Warning lamp (Yellow) Less serious fault: Rectify as soon as possible.

2.

Warning lamp (Red) Serious fault: Switch off engine immediately!

3.

Regeneration in progress (Yellow) Leave the machine running until the symbol disappears.

While regeneration is in progress, the symbol flashes and a percentage indicates how much of the procedure has been performed.

4.

Engine tampering The symbol is displayed if the operator has tried to make changes to the engine.

5.

Parked regeneration required (Yellow) Park the machine, put the FNR lever in neutral and apply the parking brake.

Open the regeneration menu and start a parked regeneration.

3.

Regeneration not possible (Yellow) This symbol is displayed when regeneration is not possible for some reason.

6.

Engine power reduction (Yellow) This symbol is displayed when the soot level is above 125% and the engine power is reduced.

7.

Motor error (Yellow)

8.

This symbol is shown in the middle of the display, when the engine temperature is below 70 ºC and when regeneration is not possible.

DPF filter washing This symbol appears in the middle of the display when the ash level exceeds 99%.

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Operation

Sub-menu - Regeneration To access the regeneration page, proceed as follows: - In home mode, select the main menu icon (2) in the lower right corner.

- On the main menu, select the Settings icon (3) in the upper right corner.

1

2

Fig. Home mode 1. Reset button 2. Main menu

The system automatically switches from home to the engine menu if the following conditions are met: - Soot level is above 125% - The machine is running and wants to perform regeneration

Parked regeneration requires the following conditions to be met: - FNR/selector lever in neutral position - Parking brake activated - Engine temp >70 °C (Stage V engine) - Engine speed in mode LOW 3 Fig. Main menu 3. Settings

A parked regeneration lasts between 22 and 25 minutes.

4 Fig. Settings 4. Engine menu

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Operation In the engine menu, there is a bar (1) on the left that is filled with grey the higher the soot-level increases.

At the bottom center, the soot/ash levels (6) are shown in %.

Warning levels (7) are shown at the top. The warning is marked with a grey box. The higher up the box the more serious the error.

1

6

7

8

9

10

Fig. Engine menu, Parked Regeneration 5. Stack 6. Soot/Ash levels (%) 7. Warning levels 8. Activation of parked regeneration when this is possible 9. Interruption of ongoing regeneration 10. Reset button

At the bottom right, the buttons for activating Parked regeneration (8) and cancelling ongoing regeneration (9) are shown.

On the right side of the display, there is a reset button (10). This button switches the menu to the settings menu (3).

Soot Level 1 - 2 At these levels, no warnings are displayed and no action needs to be taken.

11

Level 3 Soot level is 100% or more - If the yellow symbol (8) in the display flashes (0.5 Hz), a Parked regeneration is required.

- If the yellow symbol (13) in the display flashes (0.5 Hz), a Parked regeneration cannot be performed.

- If the symbol (11) flashes in the display, a Parked regeneration cannot be performed when the engine temperature is below 70 ºC. Satisfy the conditions for Parked regeneration and perform this immediately.

8

13

To access the engine menu with the warnings, select the reset button (10) and then the settings button (3).

Fig. Level 3 - DPF Full 8. Parked regeneration (Yellow) 11. Low engine temperature 13. Regeneration not possible (Yellow)

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Operation DPF full is the lowest warning level.

7

6

Fig. Level 3 - Engine menu, DPF full 6. Soot/Ash levels (%) 7. Warning level

Level 4 Soot level is 115% or higher.

The inhibit symbol (yellow) (13) in the display flashes (0.5 Hz).

The warning symbol (yellow) (1) lights continuously.

Engine power begins to be reduced.

To access the engine menu with the warnings, select the reset button (10) and then the settings button (3).

13

1

Fig. Level 4 - Warning 1. Warning symbol (Yellow) 13. Regeneration not possible (Yellow)

6

7

Fig. Level 4 - Engine menu, Warning 6. Soot/Ash levels (%) 7. Warning level

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Operation Level 5 The soot level is 125% or higher.

The inhibit symbol (yellow) (13) in the display flashes (3 Hz), the Warning symbol (yellow) (1) lights continuously, the Warning symbol (red) flashes (0.5 Hz) and the Power reduction symbol lights continuously.

Engine power continues to be reduced.

1

2

13 7

To access the engine menu with the warnings, select the reset button (10) and then the settings button (3).

Fig. Level 5 - Warning 1. Warning symbol (Yellow) 2. Warning symbol (Red) 7. Power reduction (Yellow) 13. Regeneration not possible (Yellow)

When the filter is full, a full DPF filter service is required. This can only be done by an authorized Deutz representative using service tools.

6

7

Fig. Level 5 - Engine menu, Warning 6. Soot/Ash levels (%) 7. Warning level

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Operation Level 6 The soot level is 144% or higher.

The inhibit symbol (yellow) (13) in the display flashes (3 Hz). The DPF is full and needs emptying. A Parked regeneration cannot be performed.

The Warning symbol (yellow) (1) lights continuously, the Warning symbol (red) flashes (0.5 Hz) and 1

13 7

2

Fig. Level 6 - Service 1. Warning symbol (Yellow) 2. Warning symbol (Red) 7. Power reduction (Yellow) 13. Regeneration not possible (Yellow)

the Power reduction symbol illuminates continuously and engine power continues to be reduced.

To access the engine menu with the warnings, select the reset button (10) and then the settings button (3).

Service is the highest warning level.

At this level the DPF needs to be replaced.

This can only be done by an authorized Deutz representative using service tools.

6

7

Fig. Level 6 - Engine menu, Service 6. Soot/Ash levels (%) 7. Warning level

Tampering of DPF Manipulations to the injection and control system can affect the engine’s performance and the exhaust characteristics.

In this case compliance with environmental regulations will no longer be guaranteed.

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Operation 12 Ash If the ash level exceeds 99% (regardless of soot or warning level), a symbol (DPF filter washing) (12) starts flashing in the middle of the display.

The DPF then needs to be emptied of ash. This can only be done by Deutz service technicians using service tools.

To access the engine menu, select the reset button (10) and then the setting button (3).

Fig. Ash level 12. DPF filter washing symbol

The engine menu shows the ash level (6) in %.

6 Fig. Level 3 - Engine menu 6. Ash level (%)

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Operation Interlock/Emergency stop/Parking brake Check

The interlock, emergency stop and parking brake must be checked daily before operating. A function check of the interlock and emergency stop requires a restart.

The interlock function is checked by the operator standing up from the seat when the roller is moving very slowly forwards/backwards. (Check in both directions). Hold the steering wheel firmly and brace yourself for a sudden stop. A buzzer goes on and after 7 seconds the engine switches off and the brakes are activated.

Check the function of the emergency stop by pressing the emergency stop button when the roller is moving slowly forwards/backwards. (Check in both directions). Hold the steering wheel firmly and brace yourself for a sudden stop. The engine switches off and the brakes are activated.

If a function error is detected when testing the emergency stop, this should be replaced immediately.

Check the function of the parking brake by activating the parking brake when the roller is moving very slowly forwards/backwards. (Check in both directions). Hold the steering wheel and brace yourself for a sudden stop when the brakes are activated. The engine does not switch off.

Joint cutter (Accessory) The machine must be running to activate the edge cutter/compactor.

2

1

Select with button (1) to activate the joint cutter and sprinkler valve for the joint cutter.

Water sprinkling of the joint cutter is carried by activating the drums’ regular sprinkler system and then running in auto mode at the set interval.

Sprinkling of the joint cutter can also be carried out by pressing and holding the blue button on the control lever.

Fig. Switches 1. Joint cutter, activation 2. Joint cutter/edge press, Up/Down

When the machine is in Working mode and if the lower left button on the lever (2) is pressed, the edge cutter/compactor is lowered to the asphalt surface by means of a hydraulic cylinder. To return the edge cutter/compactor to its original position, press on the upper left button on the lever to lift the edge cutter/compactor.

Note that the joint cutter/edge press can also be lifted

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Operation if the machine is in Transport mode.

A bypass valve prevents the hydraulic system being overloaded.

The standard sprinkler system should be activated first to avoid asphalt sticking to the joint cutter/edge press.

Now press and hold blue button on the front/reverse lever in order to spray water on the joint cutter/edge press.

There are two tools to choose between: a cutter wheel for joint cutting and a conical compaction wheel for edge pressing. In the figure the joint cutter (1) is mounted for work. The joint cutter (2) can easily be replaced with the edge press by loosening the bolted joint (3).

4 2

3

1

3

Fig. Replacing the tool 1. Edge press 2. Joint cutter 3. Bolted joints 4. Holder for cutter/press wheel

Braking Service brake 1 2

Move the forward/reverse lever (2) to the neutral position to stop the roller.

Always press down the parking brake (1), before leaving the operator platform.

Fig. Control panel 1. Parking brake 2. Forward/reverse lever

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Operation If the forward/reverse lever is moved quickly (forwards or backwards) toward/past neutral, the system switches to a rapid braking Mode and the machine stops.

Activate normal driving Mode again by moving the forward/reverse lever back to neutral.

Emergency brake 2 1

Braking is normally activated using the forward/reverse lever. The hydrostatic transmission retards and slows the roller when the lever is moved towards the neutral position.

There is a disc brake in the drums’ drive motors that acts as a secondary brake when operating, and as a parking brake when stationary (then activated with the parking brake button (2)).

Fig. Control panel 1. Emergency stop 2. Parking brake

For reverse braking, press the parking break button (2), hold the steering wheel firmly and be prepared for a sudden stop. The engine stops.

The Diesel engine will stop and must be restarted.

Emergency stop The emergency stop is activated by pressing the button (1).

1

Hold the steering wheel firmly and brace yourself for a sudden stop.

The brake is applied and the engine stops.

Fig. Control panel 1. Emergency stop

84

After an emergency stop, return the forward/reverse lever to neutral and deactivate the emergency stop by pulling up the button (1).

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Operation Switching off Set the speed control in idling position and allow the engine to idle for a few minutes to cool down.

1

Do not allow the engine to idle for more than 10 minutes. During prolonged idling, a lot of soot is formed, which results in a need for more frequent regeneration and thus shortens the DPF’s service life.

3

2

Check the display to see if any faults are indicated.

Switch off all lights and other electrical functions.

Activate the parking brake (3) and then turn the ignition lock (2) to the left to the off position.

Fig. Control panel 1. Display 2. Ignition lock 3. Parking brake

Fit the instrument cover on the display and top of the control box (on rollers without cab), and lock it.

Parking Chocking the drums Never get off the roller when the diesel engine is running, without first activating the parking brake.

Make sure that the roller is parked in a safe place with respect to other road users. Chock the drums if the roller is parked on sloping ground.

1 Fig. Positioning 1. Chocks

1

Remember that there is a risk of freezing during the winter. Empty the water tanks, water pipes and ballast water from the drums. Fill antifreeze in the engeine cooling system and the washer fluid reservoir in the cab. Also see maintenance instructions.

Before using the roller again, make sure that the engine is switched off and the parking brake is activated. The brake chocks can then be removed.

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Operation Battery disconnector Before leaving the roller at the end of the shift, switch off the battery disconnector (1) and remove the key (3).

2

1

3

This will prevent battery discharge and will also make it difficult for any unauthorized person to start and drive the machine. Also lock the hood to the engine compartment.

The machine can be equipped with a pull-out wire in the engine compartment. This permits the battery disconnector to be switched off without the need of opening the engine hood.

Fig. Battery bay in front beam 1. Battery disconnector 2. Power socket, 12V 3. Key

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Long-term parking Long-term parking The following instructions should be followed when long term parking (more than one month).

These measures apply when parking for a period of up to 6 months.

Before re-commissioning the roller, the points marked with an asterisk * must be returned to the pre-storage state.

Fig. Roller weather protection

Wash the machine and touch up the paint finish to avoid rusting.

Treat exposed parts with anti-rust agent, lubricate the machine thoroughly and apply grease to unpainted surfaces.

Engine * Refer to the manufacturer’s instructions in the engine manual that is supplied with the roller.

Battery * Remove the battery from the machine, clean the outside, check that the electrolyte level is correct (see under the heading "Every 250 hours of operation") and trickle charge the battery once a month.

Air cleaner, exhaust pipe * Cover the air cleaner (see under the heading 'Every 50 hours of operation' or 'Every 1000 hours of operation') or its opening with plastic or tape. Also cover the exhaust pipe opening. This is to avoid moisture entering the engine.

Sprinkler system * Drain the water tank completely (see under the heading ‘Every 2000 hours of operation’). Drain all hoses, filter housings and the water pump. Remove all sprinkler nozzles (see under the heading ‘Every 10 hours of operation’).

Fuel tank Fill the fuel tank completely full to prevent condensation.

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Long-term parking Hydraulic reservoir Fill the hydraulic reservoir to the uppermost level mark (see under the heading ‘Every 10 hours of operation.’)

Steering cylinder, hinges, etc.

Lubricate the steering joint bearings and both bearings on the steering cylinder with grease (see under the heading 'Every 50 hours of operation').

Grease the steering cylinder piston with conservation grease.

Grease the hinges on the doors to the engine compartment and the cab. Grease both ends of the forward/reverse control (bright parts) (see under the heading 'Every 500 hours of operation').

Engine coolant Check that the coolant mix are within recommended levels and have a freezing temperature lower than expected lowest temperature during the storage period.

Hoods, tarpaulin * Lower the instrument cover over the instrument panel. * Cover the entire roller with a tarpaulin. A gap must be left between the tarpaulin and the ground. * If possible, store the roller indoors and ideally in a building where the temperature is constant.

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Miscellaneous Miscellaneous Lifting Locking the articulation 2

Articulation must be locked to prevent inadvertent turning before lifting the roller.

Turn the steering wheel to the straight ahead position.

Activate the parking brake.

3

4 Pull up the locking pin (2), provided with wire.

Fig. Articulation in interlocked mode 2. Locking pin 3. Locking arm 4. Locking lug

Fold out the locking arm (3) and secure it to the upper locking lug (4) on the front machine frame.

Insert the locking pin through the holes in the locking arm and locking lug.

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Miscellaneous Lifting the roller

The machine’s gross weight (3) is specified on the machine plate (2).

Lifting equipment such as chains, steel wires, straps and lifting hooks must be dimensioned in accordance with the relevant safety regulations for the lifting equipment.

1 Weight: refer to the machine plate on the roller

Max. 600 2 3

Stand well clear of the hoisted machine! Make sure that the lifting hooks are properly secured.

1 Fig. Roller prepared for lifting 1. Lifting point 2. Machine plate

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Miscellaneous Lifting the roller with jack: The machine’s gross weight (4) is specified on the machine plate (1).

Weight: refer to the machine plate on the roller

The lifting device such as a jack (2), or equivalent, must be dimensioned according to the safety regulations for lifting devices.

1

4

Figure. Roller lifted with jack 1. Machine plate 2. Jack 3. Marking

Do not go under a lifted load! Make sure that the lifting device is secure in its position, and on a level and stable suface.

The machine must only be lifted with a jack, or the like, positioned as per the markings (3). The frame is reinforced at these points to withstand the tension.

Lifting at any other place can result in damage to the machine or personal injury.

Unlocking the articulation Remember to unlock the articulation before operating.

Pull out the lowermost locking pin (1), which has a a wire attached. Pull up the locking dowel (2) which also has a wire attached.

3

4

2

Fig. Articulation in the locked position 2. Locking dowel 3. Locking arm 4. Locking lug

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Fold the locking arm (3) back and secure it in the locking lug (4) with the locking dowel (2).

The locking lug is located on the front frame of the machine.

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Miscellaneous Load securing CS1400 VI Securing of a triple drum static roller of model CS1400 VI from Dynapac loaded in backward direction on a trailer for transport on road and in the Baltic Sea (Sea area A).

Roller loaded in backward direction

Direct of travel

1 - 3 = double lashings, i.e. one lashing with two parts secured to two different lashing mounts, symmetrically located on the right and left sides.

4 = rubber friction pads

The lashings' permitted distance interval in meters (1 - 3: Double lashings, LC at least 1.6 tonnes (1 600 daN) Double L1

Double L2

Double L3

0.1 - 2.5

0.4 - 2.5

0.3 - 2.5

L1 - L3 are the longitudinal distances between the lashing points on the roller and lashing points on the platform.

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Miscellaneous Load carrier - The static three-drum roller is loaded centered laterally on the platform (± 5 cm) and in the backward direction.

- The parking brake is applied and in good working condition.

- The drums are placed on rubber friction pads (4) to achieve the static friction 0.6 between the surfaces.

- The contact surfaces must be clean, wet or dry, and free from frost, ice and snow. If there is a risk of frost, ice and/or snow the platform has to be salted.

- The lashing mounts on the load carrier have MSL/LC/SWL at least 2 tonnes.

Lashings - The maximum securing load (MSL/LC/SWL) of the lashings (strap or chain) is at least 1.6 tonnes (1,600 daN) and the lashings are well pre-tensioned during the entire transport.

- Each of lashings 1-3 is either one double or two single lashings. The double lashing is the same lashing in a sling through a lashing eye or round a machinery part down in two different lashing points on the platform.

- Lashings in the same direction are placed in different lashing mounts on the trailer. Lashings that are pulled in opposite directions may be placed in the same lashing mount, however.

- The lashings are as short as possible.

- The lashing hooks must not lose grip if the lashings become slack.

- The lashings are protected against sharp edges and corners.

- The lashings are located symmetrically in pairs on the right and left sides.

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Miscellaneous Load securing CS1400 VI Securing of a triple drum static roller of model CS1400 VI from Dynapac loaded in backward direction on a trailer for transport on road and in the North Sea (Sea area B).

Roller loaded in backward direction

Direct of travel

1 - 3 = double lashings, i.e. one lashing with two parts secured to two different lashing mounts, symmetrically located on the right and left sides.

4 = rubber friction pads

The lashings' permitted distance interval in meters (1 - 3: Double lashings, LC at least 1.6 tonnes (1 600 daN) Double L1

Double L2

Double L3

0.1 - 1.8

0.4 - 2.0

0.3 - 2.0

L1 - L3 are the longitudinal distances between the lashing points on the roller and lashing points on the platform.

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Miscellaneous Load carrier - The static three-drum roller is loaded centered laterally on the platform (± 5 cm) and in the backward direction.

- The parking brake is applied and in good working condition.

- The drums are placed on rubber friction pads (4) to achieve the static friction 0.6 between the surfaces.

- The contact surfaces must be clean, wet or dry, and free from frost, ice and snow. If there is a risk of frost, ice and/or snow the platform has to be salted.

- The lashing mounts on the load carrier have MSL/LC/SWL at least 2 tonnes.

Lashings - The maximum securing load (MSL/LC/SWL) of the lashings (strap or chain) is at least 1.6 tonnes (1,600 daN) and the lashings are well pre-tensioned during the entire transport.

- Each of lashings 1-3 is either one double or two single lashings. The double lashing is the same lashing in a sling through a lashing eye or round a machinery part down in two different lashing points on the platform.

- Lashings in the same direction are placed in different lashing mounts on the trailer. Lashings that are pulled in opposite directions may be placed in the same lashing mount, however.

- The lashings are as short as possible.

- The lashing hooks must not lose grip if the lashings become slack.

- The lashings are protected against sharp edges and corners.

- The lashings are located symmetrically in pairs on the right and left sides.

Towing/Recovering The roller can be moved up to 300 meters (330 yards) using the instructions below.

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Miscellaneous Brake release pump Chock the drums to prevent the roller from moving when the brakes are hydraulically disengaged.

1 The release pump for the brakes is located on the right-hand side of the front frame, under the cab.

Fig. Engine compartment 1. Brake release pump

2

3

For towing: Press in the brake release button (3).

Pump with the arm (2) until the brakes are released.

The roller can now be towed.

After towing, pull the brake release button (3) out, whereby the brakes are reactivated.

If the diesel engine is once again in working order and starts, the brakes are reactivated if the supply pressure is reached.

Fig. Brake disengagement pump 2. Pump arm 3. Brake release button

The machine must not be moved at a speed higher than 3 km/h (2 mph), and no more than 300 meters (330 yards). Otherwise there is a risk of damaging the drives.

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Miscellaneous Short distance towing with the diesel engine switched off/not running Chock the drums to prevent the roller from moving when the brakes are hydraulically disengaged.

1 Fig. Propulsion pump 1. By-pass valve

Open the hood and make sure that the propulsion pump is accessible.

There are two bypass valves (1) on the pump, which should be opened counterclockwise to set the system in bypass mode.

This function enables a machine to be moved without the drive shaft on the propulsion pump rotating.

The bypass valves (1) are reset by tightening clockwise. (200 Nm)

Towing A towing bar must be used when towing, as the roller has no brakes and can only be slowed and stopped by the vehicle towing the roller.

1

2 Fig. Towing the roller 1. Drawbar 2. Lashing eye

The roller must be towed slowly, max. 3 km/h (2 mph) and for short distances only, max. 300 m (330 yards).

When towing/retrieving a machine, the drawbar (1) must be connected to the lower of the lashing eyes (2). Pulling forces must act longitudinally on the machine as illustrated. Maximum total pulling force per lifting hole is 92 kN.

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Operating instructions - Summary

98

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Operating instructions - Summary Operating instructions - Summary 1.

Follow the SAFETY INSTRUCTIONS specified in the Safety Manual.

2.

Make sure that all instructions in the MAINTENANCE section are followed.

3.

Turn the master switch to the ON position.

4.

Set the emergency stop in the pulled out position.

5.

Move the forward/reverse lever to the NEUTRAL position.

6.

Start the engine and allow it to warm up.

7.

Drive the roller. Operate the forward/reverse lever with care.

8.

Test the brakes. Remember that the braking distance will be longer if the roller is cold.

9.

Check that the drums are thoroughly watered when watering is required.

10. IN AN EMERGENCY: - Push in the EMERGENCY STOP - Hold the steering wheel firmly.

- Brace yourself for a sudden stop.

11. When parking: - Activate the parking brake - Stop the engine and chock the drums.

12. When lifting: - Refer to the relevant section in the Instruction Manual.

13. When towing: - Refer to the relevant section in the Instruction Manual.

14. When transporting: - Refer to the relevant section in the Instruction Manual.

15. When recovering - Refer to the relevant section in the Instruction Manual.

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Operating instructions - Summary

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Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost.

The Maintenance section includes the periodic maintenance that must be carried out on the machine.

The recommended maintenance intervals assume that the machine is used in a normal environment and working conditions.

Acceptance and delivery inspection The machine is tested and adjusted before it leaves the factory.

On arrival, before delivery to the customer, delivery inspection must be conducted as per the check list in the warranty document.

Any transport damage must be reported immediately to the transport company, as this is not covered by the product warranty.

Warranty The warranty is only valid if the stipulated delivery inspection and the separate service inspection have been completed as per the warranty document, and when the machine has been registered for starting under the warranty.

The warranty is not valid if damage has been caused by inadequate service, incorrect use of the machine, the use of lubricants and hydraulic fluids other than those specified in the manual, or if any other adjustments have been made without the requisite authorization.

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Preventive maintenance CALIFORNIA Proposition 65 Decal and location of decal shown in section Machine description.

102

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Maintenance - Lubricants and symbols Maintenance - Lubricants and symbols Always use high-quality lubricants and the amounts recommended. Too much grease or oil can cause overheating, resulting in rapid wear.

Other fuel and lubricants are required when operating in areas with extremely high or extremely low ambient temperatures. See the ‘Special instructions’ chapter, or consult Dynapac.

ENGINE OIL

Air temperature -15°C - +50°C (5°F-122°F)

Dynapac Engine oil 200 P/N 4812161855 (5 liters) P/N 4812161856 (20 liters) P/N 4812161857 (209 liters)

HYDRAULIC FLUID

Air temperature -15°C - +50°C (5°F-122°F)

Dynapac Hydraulic 300

Air temperature over +50°C (122°F)

Shell Tellus S2 V100

When it leaves the factory, the machine may be filled with biologically degradable fluid.

The same type of fluid must be used when changing or topping up.

PANOLIN HLP Synth 46 (www.panolin.com)

BIOLOGICAL HYDRAULIC FLUID, PANOLIN

GREASE

for the articulated joint.

P/N 4812161868 (20 liters), P/N 4812161869 (209 liters)

Dynapac Roller Grease (0.4kg), P/N 4812030096

Shell Retinax LX2 for other grease points.

FUEL

See engine manual.

-

-

COOLANT

Anti-freeze protection down to about -37°C (-34.6°F)

Dynapac Coolant 100 P/N 4812161854 (20 liters) (mixed 50/50 with water).

WASHER FLUID

Use alcohol-based washer fluid with the concentration recommended by the manufacturer for the lowest expected ambient temperature.

Fluid volumes Hydraulic reservoir

40.5 liters

10.7 gal

- Lubricating oil incl. replacement of oil filter

7.5 liters

7.9 qts

- Coolant

19 liter

5 gal

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Maintenance - Lubricants and symbols Fluid volumes - Ballast front

2x470 liters

2x124 gal

- Ballast rear

1130 liter

298.3 gal

Maintenance symbols Engine, oil level

Air filter

Engine, oil filter

Battery

Hydraulic reservoir, level

Sprinkler

Hydraulic fluid, filter

Sprinkler water

Lubricating oil

Fuel filter

Fuel gauge

Recycling

Coolant level

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Maintenance - Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points

7

6

17

5 2

6

1 9

12

15

14

6 20

6

18

6

6 8 19

16

6

6

4 11

3

10

Fig. Service and maintenance points

1.

2.

3.

4.

5.

6.

7.

Engine oil Radiator Drum nuts Refueling Air cleaner Scrapers Water tank, filling

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8.

9.

10.

11.

12.

13.

14.

Sprinkler system Battery Articulation joint Steering cylinder Hydraulic filter Hydraulic fluid level Hydraulic fluid, filling

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15. Hydraulic reservoir 16. Diesel engine 17. Hinge 18. Fuel tank 19. Fresh air filter 20. Joint cutter

105

Maintenance - Maintenance schedule General Periodic maintenance should be carried out after the number of hours specified. Use the daily, weekly etc. periods where number of hours cannot be used.

Remove all dirt before filling, when checking oils and fuel and when lubricating using oil or grease.

The manufacturer’s instructions found in the engine manual also apply.

Specific maintenance and checks on diesel engines must be carried out by the engine supplier’s certified personnel.

Every 10 hours of operation (Daily) Refer to the contents to find the page number of the sections referred to !

Pos. in fig

Action

Comment

Before starting up for the first time on that day 1

Check the engine oil level

Refer to the engine manual

13

Check the hydraulic reservoir level

2

Check the coolant level

4

Refuel

7

Fill the water tank

8

Check the sprinkler system Test the brakes

6

Check the scraper setting Drain the diesel engine's fuel prefilter

After the FIRST 50 hours of operation Refer to the contents to find the page number of the sections referred to !

Action 12

106

Comment

Change the hydraulic fluid filter

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Maintenance - Maintenance schedule Every 50 hours of operation (Weekly) Refer to the contents to find the page number of the sections referred to !

Action

Comment

5

Check/clean the filter element in the air cleaner.

10

Lubricate the articulation

11

Lubricate the steering cylinder mounts

15

Check tightening of drum nuts.

Every 250 / 750 / 1250 / 1750 hours of operation Refer to the contents to find the page number of the sections referred to !

Pos. in fig

Action

Comment

2

Clean the cooler element

If necessary

Checking the battery Checking/Cleaning the air conditioning

Accessory

Lubrication of edge cutter

Accessory

Every 500 / 1500 hours of operation Refer to the contents to find the page number of the sections referred to !

Pos. in fig

Action

Comment

2

Clean the cooler element

If necessary

Lubricate hinges and controls Lubrication of the seat bearing 1

Change the engine oil and oil filter

Refer to the engine manual *) 500 h or once every six months

Lubrication of edge cutter 14

Check the cap/breather filter on the hydraulic reservoir

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Maintenance - Maintenance schedule Every 1000 hours of operation Refer to the contents to find the page number of the sections referred to !

Pos. in fig

Action

Comment

2

Clean the cooler element

If necessary

Lubricate hinges and controls Lubrication of the seat bearing 1

Change the engine oil and oil filter

Refer to the engine manual *) 500 h or once every six months

Lubrication of edge cutter 14

Check the cap/breather filter on the hydraulic reservoir

16

Change the engine fuel filter

Refer to the engine manual

Change the engine pre-filter

Refer to the engine manual

16

Check the engine V belt tension

Refer to the engine manual

16

Check engine valve clearances

Refer to the engine manual

12

Change the hydraulic fluid filter

19

Drain the fuel tank

20

Replace the air cleaner filter in the cab

15

Drain the condensation water from the hydraulic reservoir

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Maintenance - Maintenance schedule Every 2000 hours of operation Refer to the contents to find the page number of the sections referred to !

Pos. in fig

Action

Comment

2

Clean the cooler element

If necessary

Lubricate hinges and controls Lubrication of the seat bearing 1

Change the engine oil and oil filter

Refer to the engine manual *) 500 h or once every six months

Lubrication of edge cutter 14

Check the cap/breather filter on the hydraulic reservoir

16

Change the engine fuel filter

Refer to the engine manual

Change the engine pre-filter

Refer to the engine manual

16

Check the engine V belt tension

Refer to the engine manual

16

Check engine valve clearances

Refer to the engine manual

12

Change the hydraulic fluid filter

19

Drain the fuel tank

9

Drain and clean the fuel tank

15

Drain the condensation water from the hydraulic reservoir

5

Drain and clean the water tanks

10

Check the condition of the articulation

15

Change the hydraulic fluid Overhaul the air conditioning

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Maintenance - Maintenance schedule Service - Checklist

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Maintenance, 10h Maintenance, 10h Every 10 hours of operation (Daily) Park the roller on a level surface.

The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Diesel engine Check oil level Take care not to touch any hot parts of the engine or the radiator when removing the dipstick. Risk for burns.

The dipstick is located on the engine's right side.

1

Pull up the dipstick (1) and check that the oil level is between the upper and lower marks. For further details, refer to the engine's instruction manual.

Fig. Engine (Stage IIIA) 1. Dipstick

1 Fig. Engine compartment (Stage V) 1. Dipstick

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Maintenance, 10h

Hydraulic reservoir, Level check - Filling

2

1

The hydraulic tank is located on the right side of the machine. Wipe the sight glass (1) and check that the oil level is between the upper and lower marks.

If necessary, fill with hydraulic fluid by unscrewing the filler cap (2). See under the "Lubricants" heading for the correct oil grade.

Fig. Hydraulic reservoir 1. Sight glass 2. Filler cap

Coolant, Level check - filling If the coolant tank (3) cannot be reached from the ground, use a ladder.

3 2 Place the roller on a level surface.

Stand firmly with both feet on a non-slip surface, on the front cross beam (1).

1 Fig. Engine compartment 1. Cross beam 2. Plate 3. Coolant tank

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Maintenance, 10h Check that the coolant level is between max./min. in the sight glass (5) and (6).

5 6 7 4 Fig. Expansion tank 4. Filler cap 5. Max level 6. Min level 7. Level sensor

Top up with coolant if the level is too low.

For filling, loosen the filler cap (4) and make sure that the coolant level is between max/min in the sight glasses (5) and (6).

Now screw on the filler cap (4) again.

Use the following protective equipment: Eye protection Protective gloves.

Do not open the radiator cap while the engine is warm, as the radiator may contain fluid and/or steam under pressure, which may cause skin and eye damage.

Fill with a mixture of 50% water and 50% anti freeze.

See the lubrication specifications in these instructions and in the engine manual.

Flush the system every other year and change the coolant. Make sure also that the air flow through the cooler is unobstructed.

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Maintenance, 10h

Fuel tank - Refueling Never refuel while the engine is running, do not smoke, and avoid spilling fluid.

1

Fig. Fuel tank 1. Filler cap

The fuel tank is located on the left-hand side of the machine. Refuel every day before commencing work.

Unscrew the lockable tank cap (1) fill with diesel up to the lower edge of the filler pipe. Refit and lock the tank cap after refueling.

See the engine handbook for the grade of diesel fuel.

The fuel tank holds 110 liters (29 gal).

When refueling, it is important to ground the filling nozzle of the device to avoid static electricity with the risk of sparking and ignition.

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Maintenance, 10h

Water tank - Filling

1

Before filling: Make sure that the step (2) is in the fully lowered position.

Unscrew the filler cap (1) and fill with clean water. Do not remove the strainer.

Fig. Water tank 1. Tank cap

The water tank is located at the rear of the machine.

Fill the water tank via one of the tank caps (1). The tank holds 525 liters (139 gal).

If there is a risk of frost. If the system is not drained completely, mix in the recommended amount of environmentally friendly antifreeze.

Make sure that the mixture reaches the nozzles before parking the machine.

After filling: Make sure that the step (2) is locked in the raised position.

3 2 Fig. Rear frame 2. Step 3. Handle bar

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Maintenance, 10h

Sprinkler system/Drum Check Start the sprinkler system and make sure that no nozzles (1) are clogged. If necessary, clean blocked nozzles which are located under the cover (2), and the coarse filter placed by the water pump (see the next section).

2 1

Fig. Front drum 1. Nozzle 2. Cover

1

Fig. Rear drum 1. Nozzle

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Maintenance, 10h Cleaning the coarse filter 3

1

3

The pump system is located behind the cover on the right side of the rear frame.

To clean the coarse filter (1) open the drain tap (2) on the filter and allow any dirt to run out.

If necessary, clean the filter and filter housing. Check that the rubber gasket in the filter housing is intact.

After inspecting and cleaning, reset and start the system to check that it works.

There is a drain tap (4) in the space for the pump system. This can be used to drain the tank and the pump system.

4

2

Fig. Pump system, rear frame right side 1. Coarse filter 2. Drainage tap, filter 3. Water pump 4. Drain tap

To drain the complete sprinkler system, see section for Watering system - Draining, 2,000 h.

Inspect the intake water filters of the pumps every day.

The water filter housing (2) can be removed.

Flush the housing and the filter clean with water and then put them back into place.

Only use clean water in the water tank.

1

2

Fig. Water system (basic setting) 1. Water pump 2. Water filter housing

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1

The water system must be completely drained if the roller is to be left unused for a longer period or if temperatures below zero can be expected. Top up the tank if necessary by removing the bottom plug.

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Maintenance, 10h Sprinkler system/Drum Cleaning of sprinkler nozzle Dismantle the blocked nozzle by hand.

1 2 3

Figure. Nozzle 1. Nozzle 2. Gasket 3. Filter

Blow the nozzle (1) and fine filter (3) clean using compressed air. Alternatively, fit replacement parts and clean the blocked parts later on.

Nozzle Colour l/min (at 2.0 gal/min (at bar) 40 psi) Standard

yellow

0.63

0.20

Option

blue

0.98

0.30

Option

red

1.31

0.40

Option

brown

1.63

0.50

After inspecting and carrying out any necessary cleaning, start the system and check that it works.

When working with compressed air.

Use the following protective equipment: Eye protection Protective gloves Ear protectors

Scrapers - Check/Cleaning Make sure that the scrapers are undamaged. The spring-action scrapers require no adjustment because the spring force provides the correct contact force.

Asphalt remnants can accumulate on the scraper and influence the contact force. Clean as necessary.

Make sure the scrapers are retracted from the drum when transporting.

1 Fig. Spring-action scrapers, front 1. Drum scraper

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Maintenance, 10h

1 Fig. Spring-action scrapers, rear 1. Drum scraper

Draining the diesel engine's fuel prefilter

The fuel prefilter (1) is located in front or the cooler in the engine compartment.

Unscrew the lower part (2) of the prefilter and drain off any water, and then replace the filter unit if necessary.

1 2 Fig. Engine compartment (Stage IIIA) 1. Pre-filter

1 2 Fig. Engine compartment (Stage V) 1. Pre-filter

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Maintenance, 10h

Diesel engine Check oil level Take care not to touch any hot parts of the engine or the radiator when removing the dipstick. Risk for burns.

The dipstick is located on the engine's right side.

Pull up the dipstick (1) and check that the oil level is between the upper and lower marks. For further details, refer to the engine's instruction manual.

1 Fig. Engine (Stage IIIA) 1. Dipstick

2

3

Fig. Engine compartment (Stage V) 1. Dipstick

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Maintenance - 50h Maintenance - 50h Every 50 hours of operation (Weekly) Park the roller on a level surface.

The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Air cleaner Checking - Change the main air filter Change the air cleaner's main filter when the warning lamp on the display lights when the diesel engine is operating at full speed.

Use a step ladder to reach the air filter (3).

3 2

Place the roller on a level surface.

Stand firmly with both feet on a non-slip surface, on the front cross beam (1).

1

Hold the plate in front of the air filter (3).

Fig. Engine compartment 1. Cross beam 2. Plate 3. Air filter

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Maintenance - 50h 2

3

Release the clips (1), pull off the cover (2), and pull out the main filter (3).

Do not remove the backup filter (4).

Clean the air cleaner if necessary, see section Air cleaner - Cleaning.

6

1

Fig. Air cleaner 1. Clips 2. Cover 3. Main filter 4. Backup filter 5. Filter housing 6. Dust valve

4

5

When replacing the main filter (3), insert a new filter and refit the air cleaner in the reverse order.

Check the condition of the dust valve (6); replace if necessary.

When refitting the cover, make sure that the dust valve is positioned downwards.

Backup filter - Change

1

Change the backup filter with a new filter after every third replacement of the main filter.

To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.

Clean the air cleaner if necessary, see section Air cleaner - Cleaning.

Fig. Air filter 1. Backup filter

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Maintenance - 50h

Air cleaner - Cleaning Wipe clean the inside of the cover (2) and the filter housing (5). See the previous illustration.

Wipe clean on both sides of the outlet pipe.

Inner edge of outlet pipe.

Wipe also both surfaces for the outlet pipe; see adjacent figure.

Check that the hose clamps between the filter housing and the suction hose are tight and that the hoses are intact. Inspect the entire hose system, all the way to the engine.

Outer edge of outlet pipe.

Articulation steering and steering cylinder bushings - Lubrication 1

2

1 2 1 Fig. Lubricant nipples 1. Lubricant nipples, articulation 2. Bearings, steering cylinder

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Nobody must be allowed near the steering joint when the engine is running. Danger of being crushed when steering is operated. Push the reserve/parking brake knob before lubricating.

Turn the steering wheel fully to gain access to all seven grease nipples (1 and 2) from the right side of the machine.

Wipe the grease nipples. Lubricate the articulation nipples (1) with five strokes of the hand grease gun, and the steering cylinder bearings (2) with three strokes in each bearing. Make sure that grease penetrates the bearings. If grease does not penetrate the bearings, it may be necessary to relieve the articulation joint with a jack while repeating the greasing process.

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Maintenance - 50h

Turn the machine back for driving straight ahead. This makes the rear bearing (1) of the left steering cylinder accessible from the left side of the machine.

1

Wipe the lubricant nipple and grease with three strokes of the hand grease gun.

Fig. Lubricant nipple 1. Lubricant nipple, steering cylinder

Tightening the drum nuts - Check This only applies to a new machine or newly fitted drums.

1 Fig. Drum 1. Drum nut

124

Ensure that all nuts on all three drums are properly tightened. Tightening torque: 500 Nm.

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Maintenance measures - 250 h Maintenance measures - 250 h Every 250/750/1250/1750..... hours of operation (every 3 months) Park the roller on a level surface.

The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1) and (2).

Clean a dirty radiator using compressed air or a high-pressure water jet.

Blow air or direct water through the cooler in the opposite direction to that of the cooling air.

Be careful when using a high-pressure washer do not place the nozzle too close to the radiator.

1 Fig. Engine compartment 1. Water cooler 2. Hydraulic oil cooler

2 When working with compressed air or a high-pressure washer, use the following protective equipment: Safety glasses Protective gloves Ear protectors

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Maintenance measures - 250 h

Battery - Check condition The batteries are sealed and maintenance-free.

Make sure there is no open flame in the vicinity when checking the electrolyte level. Explosive gas is formed when the alternator charges the battery.

Figure. Batteries

When disconnecting the battery, always disconnect the negative cable first. When connecting the battery, always connect the positive cable first.

The cable shoes should be clean and tightened.

Corroded cable shoes should be cleaned and greased with acid-proof Vaseline.

Wipe the top of the battery.

Automatic Climate Control (Optional) Inspection Park the roller on a level surface, chock the drums and activate the parking brake.

1 Open the engine hood with the unit in operation and check using the sight glass (1) that bubbles are not visible on the drying filter.

Fig. Drying filter 1. Sight glass

126

The filter is located on the left side of the engine compartment. If bubbles are visible through the sight glass, this is a sign that the refrigerant level is too low.

If so, stop the unit. The unit may be damaged if it is run with insufficient refrigerant.

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Maintenance measures - 250 h

Air conditioning (Optional) - Cleaning If there is a significant loss of cooling capacity, clean the condenser element (1) located in the engine compartment.

1

Fig. Cab 1. Condensor element

Air conditioning (Optional) - Inspection Inspect refrigerant hoses and connections and make sure that there are no signs of an oil film that can indicate a refrigerant leakage.

The refrigerant contains tracing liquid, which makes it possible to detect leaks with the aid of a UV lamp. If the areas around the connections are strongly coloured, this is an indication of a leak.

Edge cutter (Optional) - Lubrication Refer to the operation section for information on how to operate the edge cutter.

2

1

Grease the two points as shown in the figure.

Grease should always be used for lubrication, see the lubricant specifications.

Figure. Two grease points for lubricating the edge cutter

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Grease all bearing points with five strokes of a hand-operated grease gun.

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Maintenance measures - 250 h

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Maintenance measures - 500 h Maintenance measures - 500 h Every 500/1500..... hours of operation (every six months) Park the roller on a level surface.

The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1) and (2).

Clean a dirty radiator using compressed air or a high-pressure water jet.

Blow air or direct water through the cooler in the opposite direction to that of the cooling air.

Be careful when using a high-pressure washer do not place the nozzle too close to the radiator.

1 Fig. Engine compartment 1. Water cooler 2. Hydraulic oil cooler

2 When working with compressed air or a high-pressure washer, use the following protective equipment: Safety glasses Protective gloves Ear protectors

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Maintenance measures - 500 h

Hinges, controls - Lubrication

Lubricate both hinges (1) on the engine compartment doors until grease penetrates through.

Grease the hinges of the cab door in the same way.

Lubricate the hinges of the front and rear spotlight covers with a few drops of oil.

1 Lubricate the forward/reverse control wires by the control arm of the hydraulic pump. Apply a few drops of oil to the mouth of the control sleeve.

Fig. Engine compartment 1. Hinge

Seat bearing - Lubrication Keep in mind that the chain is a vital part of the steering mechanism.

5 6

Remove the covers (5) to access the lubrication nipple (1). Lubricate the driver seat slew bearing with three strokes of a hand-operated grease gun.

2

3

Clean and grease the chain (3) between the seat and the steering column.

Also grease the seat slide rails (6).

4 1 7 Figure. Seat bearing 1. Grease nipple 2. Gearwheel 3. Steering chain 4. Adjusting screw 5. Covers 6. Slide rails 7. Marking

130

If the chain is slack on the sprocket (2), loosen the screws (4) and move the steering column forward.

Tighten the screws and check chain tension.

No not tension the chain too tightly. It should be possible to move the chain about 10 mm (0.4 in) to the side with a forefinger/thumb at the marking (7) in seat frame. Fit the chain lock at the bottom.

If the seat starts to be stiff when adjusting, it should be lubricated more often than specified here.

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Maintenance measures - 500 h

Diesel engine - Oil change

Run the engine warm before draining the oil.

2

Make sure that ventilation (extraction) is adequate if the engine is run indoors. (Risk of carbon monoxide poisoning).

Switch off the engine and activate the parking brake.

1 3 Fig. Oil filter (Stage IIIA) 1. Oil filter 2. Engine dipstick 3. Drain plug

Place a receptacle that is capable of holding at least 19 liters (5 gallons) under the drain plug.

Hand in the drained oil and filter to an environment-friendly waste disposal station.

Observe care when draining hot engine oil. Use the following protective equipment: Protective gloves

2

Safety glasses

1 3 Fig. Oil filter (Stage V) 1. Oil filter 2. Engine dipstick 3. Drain plug

Remove the drain plug (3). Allow all of the oil to drain off and refit the plug.

Change the engine oil filter (1). See engine instruction manual.

Fill with fresh engine oil; see Lubricant specification for the correct grade of oil.

Check the dipstick (2) to ensure that the engine oil level is correct; for details see the engine manual.

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Maintenance measures - 500 h On the Stage V engine is the oil filter, easily accessible, placed on the under side of the engine compartment.

The oil filter can easily be replaced by loosening the screws (3) on the protection plate (2).

3 2 1 Fig. Engine compartment, under side 1. Oil filter 2. Protection plate 3. Screw

Edge cutter (Optional) - Lubrication Refer to the operation section for information on how to operate the edge cutter.

2

1

Grease the two points as shown in the figure.

Grease should always be used for lubrication, see the lubricant specifications.

Figure. Two grease points for lubricating the edge cutter

132

Grease all bearing points with five strokes of a hand-operated grease gun.

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Maintenance measures - 500 h

Hydraulic reservoir cap - Check

Screw off the tank cap and check that it is not clogged.

Air must have unobstructed passage through the cap in both directions.

1

If clogged in either direction, clean with a little diesel oil and blow with compressed air until free passage is assured or replace the cap with a new one.

When working with compressed air, use the following protective equipment:

Fig. Hydraulic reservoir 1. Tank cap

Safety glasses Protective gloves Ear protectors

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Maintenance measures - 500 h

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Maintenance - 1000h Maintenance - 1000h Performed after 1000 operating hours (each year) Park the roller on a level surface.

The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1) and (2).

Clean a dirty radiator using compressed air or a high-pressure water jet.

Blow air or direct water through the cooler in the opposite direction to that of the cooling air.

Be careful when using a high-pressure washer do not place the nozzle too close to the radiator.

1 Fig. Engine compartment 1. Water cooler 2. Hydraulic oil cooler

2 When working with compressed air or a high-pressure washer, use the following protective equipment: Safety glasses Protective gloves Ear protectors

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135

Maintenance - 1000h

Hinges, controls - Lubrication

Lubricate both hinges (1) on the engine compartment doors until grease penetrates through.

Grease the hinges of the cab door in the same way.

1 Lubricate the hinges of the front and rear spotlight covers with a few drops of oil.

Fig. Engine compartment 1. Hinge

Lubricate the forward/reverse control wires by the control arm of the hydraulic pump. Apply a few drops of oil to the mouth of the control sleeve.

Seat bearing - Lubrication Keep in mind that the chain is a vital part of the steering mechanism.

5 6

Remove the covers (5) to access the lubrication nipple (1). Lubricate the driver seat slew bearing with three strokes of a hand-operated grease gun.

2

3

Clean and grease the chain (3) between the seat and the steering column.

Also grease the seat slide rails (6).

4 1 7 Figure. Seat bearing 1. Grease nipple 2. Gearwheel 3. Steering chain 4. Adjusting screw 5. Covers 6. Slide rails 7. Marking

136

If the chain is slack on the sprocket (2), loosen the screws (4) and move the steering column forward.

Tighten the screws and check chain tension.

No not tension the chain too tightly. It should be possible to move the chain about 10 mm (0.4 in) to the side with a forefinger/thumb at the marking (7) in seat frame. Fit the chain lock at the bottom.

If the seat starts to be stiff when adjusting, it should be lubricated more often than specified here.

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Maintenance - 1000h

Diesel engine - Oil change

Run the engine warm before draining the oil.

2

Make sure that ventilation (extraction) is adequate if the engine is run indoors. (Risk of carbon monoxide poisoning).

Switch off the engine and activate the parking brake.

1 3 Fig. Oil filter (Stage IIIA) 1. Oil filter 2. Engine dipstick 3. Drain plug

Place a receptacle that is capable of holding at least 19 liters (5 gallons) under the drain plug.

Hand in the drained oil and filter to an environment-friendly waste disposal station.

Observe care when draining hot engine oil. Use the following protective equipment: Protective gloves

2

Safety glasses

1 3 Fig. Oil filter (Stage V) 1. Oil filter 2. Engine dipstick 3. Drain plug

Remove the drain plug (3). Allow all of the oil to drain off and refit the plug.

Change the engine oil filter (1). See engine instruction manual.

Fill with fresh engine oil; see Lubricant specification for the correct grade of oil.

Check the dipstick (2) to ensure that the engine oil level is correct; for details see the engine manual.

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Maintenance - 1000h On the Stage V engine is the oil filter, easily accessible, placed on the under side of the engine compartment.

The oil filter can easily be replaced by loosening the screws (3) on the protection plate (2).

3 2 1 Fig. Engine compartment, under side 1. Oil filter 2. Protection plate 3. Screw

Edge cutter (Optional) - Lubrication Refer to the operation section for information on how to operate the edge cutter.

2

1

Grease the two points as shown in the figure.

Grease should always be used for lubrication, see the lubricant specifications.

Figure. Two grease points for lubricating the edge cutter

138

Grease all bearing points with five strokes of a hand-operated grease gun.

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Maintenance - 1000h

Hydraulic reservoir cap - Check

Screw off the tank cap and check that it is not clogged.

Air must have unobstructed passage through the cap in both directions.

1

If clogged in either direction, clean with a little diesel oil and blow with compressed air until free passage is assured or replace the cap with a new one.

When working with compressed air, use the following protective equipment:

Fig. Hydraulic reservoir 1. Tank cap

Safety glasses Protective gloves Ear protectors

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Maintenance - 1000h

Replacing the fuel filter / fuel prefilter

Place a container underneath to collect fuel that runs out when the filter is released.

Loosen and unscrew the fuel filter (1).

Replace the filter unit.

Unscrew the lower part of the fuel filter (2) and drain off any water, and then replace the filter unit.

1 Fig. Engine compartment 1. Fuel filter 2. Fuel prefilter

2

The filters are of the disposable type and cannot be cleaned. Hand in to environment-friendly station.

The fuel should be taken to an environment-friendly waste disposal station.

Refer to the engine manual for detailed instructions when replacing the fuel filter.

Start the engine and check that the fuel filter is tight.

Ensure good ventilation (air extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning.

NOTE! The new fuel filters must not under any circumstances be pre-filled with fuel due to the purity requirements of the fuel system.

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Maintenance - 1000h

Hydraulic fluid filter - Replacement

The filter is located behind the plate (1), where the cover for the hydraulic oil sits, on the right side of the machine. To access the filter, the plate (1) must first be removed by unscrewing the screws (2).

Clean thoroughly around the oil filter.

Remove the oil filter and discard it in a safe manner. The filter is of the expendable type and cannot be cleaned.

1

2

4

Fig. Hydraulic reservoir 1. Plate 2. Screws 3. Cover 4. Sight glass, hydraulic fluid

3

Make sure that the old sealing ring is not left on the filter holder, as this could cause leakage between the new and old gaskets.

Thoroughly clean the sealing surface of the filter holder.

Apply a thin coat of fresh hydraulic fluid to the rubber gasket on the new filter. Screw tight the filter by hand.

Now refit the plate (1) by tightening the screws (2).

First screw on until the filter seal lies against the filter holder. Then screw a further half turn. Do not tighten the filter too hard as this could damage the gasket.

Start the engine and check that there is no leakage of hydraulic fluid from the filter. Check level of fluid in the sight glass (4) and top up as required.

Make sure that ventilation (extraction) is adequate if the engine is run indoors. Risk of carbon monoxide poisoning.

1 Fig. Hydraulic reservoir 1. Hydraulic oil filter

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Maintenance - 1000h

Fuel tank - Draining off water

Water can be drained via the drain plug at the bottom of the tank. Draining should be done when the roller has been standing still for some time, eg, overnight.

Unscrew the drain plug (1) and allow water and sediment to drain off until only pure fuel runs out.

Tighten the drain plug. If the tank is emptied completely then the fuel system must be vented. See engine service manual

1 Fig. Fuel tank 1. Drain plug

Air conditioning (Optional) Fresh air filter - Change 2

1

Use a step ladder to reach the filter (1).

There is a fresh air filter (1), located at the rear of the cab.

Loosen the quick lock (2) and open the protective cover.

Fig. Cab 1. Fresh air filter 2. Quick lock

Remove the filter insert and replace with a new filter insert.

The filter may need to be changed more often if the machine is operated in a dusty environment.

Do not drive in contaminated areas, as the air filter is not intended for air contaminated with, for example, gas, radioactive particles or similar.

The filter is of disposable type and cannot be cleaned. Dispose of the replaced filter in an environment-friendly manner.

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Maintenance - 1000h

Hydraulic reservoir - Draining

Drain condensation water via the drain plug (1) at the bottom of the tank. Draining should be done when the roller has been standing still for some time, eg, overnight.

Drain as follows:

Put a can underneath the drain plug (1).

1 Fig. Hydraulic reservoir 1. Drain plug

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Loosen the drain plug (1) and allow any condensation water to run out.

Tighten the drain plug.

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Maintenance - 1000h

144

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Maintenance - 2000h Maintenance - 2000h Performed after 2000 operating hours (every two years) Park the roller on a level surface.

The engine must be switched off and the parking brake activated when checking or adjusting the roller, unless otherwise specified.

Ensure that there is good ventilation (air extraction) if the engine is run indoors. Risk of carbon monoxide poisoning.

Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1) and (2).

Clean a dirty radiator using compressed air or a high-pressure water jet.

Blow air or direct water through the cooler in the opposite direction to that of the cooling air.

Be careful when using a high-pressure washer do not place the nozzle too close to the radiator.

1 Fig. Engine compartment 1. Water cooler 2. Hydraulic oil cooler

2 When working with compressed air or a high-pressure washer, use the following protective equipment: Safety glasses Protective gloves Ear protectors

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Maintenance - 2000h

Hinges, controls - Lubrication

Lubricate both hinges (1) on the engine compartment doors until grease penetrates through.

Grease the hinges of the cab door in the same way.

1 Lubricate the hinges of the front and rear spotlight covers with a few drops of oil.

Fig. Engine compartment 1. Hinge

Lubricate the forward/reverse control wires by the control arm of the hydraulic pump. Apply a few drops of oil to the mouth of the control sleeve.

Seat bearing - Lubrication Keep in mind that the chain is a vital part of the steering mechanism.

5 6

Remove the covers (5) to access the lubrication nipple (1). Lubricate the driver seat slew bearing with three strokes of a hand-operated grease gun.

2

3

Clean and grease the chain (3) between the seat and the steering column.

Also grease the seat slide rails (6).

4 1 7 Figure. Seat bearing 1. Grease nipple 2. Gearwheel 3. Steering chain 4. Adjusting screw 5. Covers 6. Slide rails 7. Marking

146

If the chain is slack on the sprocket (2), loosen the screws (4) and move the steering column forward.

Tighten the screws and check chain tension.

No not tension the chain too tightly. It should be possible to move the chain about 10 mm (0.4 in) to the side with a forefinger/thumb at the marking (7) in seat frame. Fit the chain lock at the bottom.

If the seat starts to be stiff when adjusting, it should be lubricated more often than specified here.

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Maintenance - 2000h

Diesel engine - Oil change

Run the engine warm before draining the oil.

2

Make sure that ventilation (extraction) is adequate if the engine is run indoors. (Risk of carbon monoxide poisoning).

Switch off the engine and activate the parking brake.

1 3 Fig. Oil filter (Stage IIIA) 1. Oil filter 2. Engine dipstick 3. Drain plug

Place a receptacle that is capable of holding at least 19 liters (5 gallons) under the drain plug.

Hand in the drained oil and filter to an environment-friendly waste disposal station.

Observe care when draining hot engine oil. Use the following protective equipment: Protective gloves

2

Safety glasses

1 3 Fig. Oil filter (Stage V) 1. Oil filter 2. Engine dipstick 3. Drain plug

Remove the drain plug (3). Allow all of the oil to drain off and refit the plug.

Change the engine oil filter (1). See engine instruction manual.

Fill with fresh engine oil; see Lubricant specification for the correct grade of oil.

Check the dipstick (2) to ensure that the engine oil level is correct; for details see the engine manual.

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Maintenance - 2000h On the Stage V engine is the oil filter, easily accessible, placed on the under side of the engine compartment.

The oil filter can easily be replaced by loosening the screws (3) on the protection plate (2).

3 2 1 Fig. Engine compartment, under side 1. Oil filter 2. Protection plate 3. Screw

Edge cutter (Optional) - Lubrication Refer to the operation section for information on how to operate the edge cutter.

2

1

Grease the two points as shown in the figure.

Grease should always be used for lubrication, see the lubricant specifications.

Figure. Two grease points for lubricating the edge cutter

148

Grease all bearing points with five strokes of a hand-operated grease gun.

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Maintenance - 2000h

Hydraulic reservoir - Draining

Drain condensation water via the drain plug (1) at the bottom of the tank. Draining should be done when the roller has been standing still for some time, eg, overnight.

Drain as follows:

Put a can underneath the drain plug (1).

1 Fig. Hydraulic reservoir 1. Drain plug

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Loosen the drain plug (1) and allow any condensation water to run out.

Tighten the drain plug.

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Maintenance - 2000h

Replacing the fuel filter / fuel prefilter

Place a container underneath to collect fuel that runs out when the filter is released.

Loosen and unscrew the fuel filter (1).

Replace the filter unit.

Unscrew the lower part of the fuel filter (2) and drain off any water, and then replace the filter unit.

1 Fig. Engine compartment 1. Fuel filter 2. Fuel prefilter

2

The filters are of the disposable type and cannot be cleaned. Hand in to environment-friendly station.

The fuel should be taken to an environment-friendly waste disposal station.

Refer to the engine manual for detailed instructions when replacing the fuel filter.

Start the engine and check that the fuel filter is tight.

Ensure good ventilation (air extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning.

NOTE! The new fuel filters must not under any circumstances be pre-filled with fuel due to the purity requirements of the fuel system.

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Maintenance - 2000h

Hydraulic fluid filter - Replacement

The filter is located behind the plate (1), where the cover for the hydraulic oil sits, on the right side of the machine. To access the filter, the plate (1) must first be removed by unscrewing the screws (2).

Clean thoroughly around the oil filter.

Remove the oil filter and discard it in a safe manner. The filter is of the expendable type and cannot be cleaned.

1

2

4

Fig. Hydraulic reservoir 1. Plate 2. Screws 3. Cover 4. Sight glass, hydraulic fluid

3

Make sure that the old sealing ring is not left on the filter holder, as this could cause leakage between the new and old gaskets.

Thoroughly clean the sealing surface of the filter holder.

Apply a thin coat of fresh hydraulic fluid to the rubber gasket on the new filter. Screw tight the filter by hand.

Now refit the plate (1) by tightening the screws (2).

First screw on until the filter seal lies against the filter holder. Then screw a further half turn. Do not tighten the filter too hard as this could damage the gasket.

Start the engine and check that there is no leakage of hydraulic fluid from the filter. Check level of fluid in the sight glass (4) and top up as required.

Make sure that ventilation (extraction) is adequate if the engine is run indoors. Risk of carbon monoxide poisoning.

1 Fig. Hydraulic reservoir 1. Hydraulic oil filter

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Maintenance - 2000h

Fuel tank - Draining off water

Water can be drained via the drain plug at the bottom of the tank. Draining should be done when the roller has been standing still for some time, eg, overnight.

Unscrew the drain plug (1) and allow water and sediment to drain off until only pure fuel runs out.

Tighten the drain plug. If the tank is emptied completely then the fuel system must be vented. See engine service manual

1 Fig. Fuel tank 1. Drain plug

Fuel tank - Cleaning It is easiest to clean the tank when it is almost empty.

A drain plug (1) is placed under the fuel tank on the left-hand side.

Alternatively drain the tank with a suitable pump, e.g. an oil drain pump, to bring up any bottom sediment.

Collect the fuel and sediment in a container and deliver to environmentally correct handling.

1 Keep in mind fire risk when handling fuel.

Fig. Fuel tank 1. Drain plug

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Maintenance - 2000h

Hydraulic reservoir cap - Check

Screw off the tank cap and check that it is not clogged.

Air must have unobstructed passage through the cap in both directions.

1

If clogged in either direction, clean with a little diesel oil and blow with compressed air until free passage is assured or replace the cap with a new one.

When working with compressed air, use the following protective equipment:

Fig. Hydraulic reservoir 1. Tank cap

Safety glasses Protective gloves Ear protectors

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Maintenance - 2000h

Water tank - Cleaning 1, 2 Clean the tank/tanks with water and a suitable detergent for plastic surfaces.

Close the drain cock (2), fill with water and check for leaks.

Fig. Water tank 1. Cover 2. Filter

The water tanks are made of plastic (polyethylene) and are recyclable.

2 Figure. Water tank 2. Drain plug

Steering joint - Check Inspect the steering joint to detect any damage or cracks.

Check and tighten any loose bolts.

Check also for any stiffness and play in the steering joint.

Fig. Articulation joint

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Maintenance - 2000h

Watering system - Draining Remember that there is a risk of freezing during the winter. Empty the tank, pump, filter and lines, or mix antifreeze in the water.

There is a drain tap (2) is located in the space for the pump system on the right-hand side of the machine.

This can be used to drain both the tank and parts of the pump system.

1

2

The water hoses are connected to the pump with quick couplings to simplify drainage.

Figure. Pump system 1. Filter housing 2. Drain cock 3. Stop cock 4. Quick couplings

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Maintenance - 2000h

Hydraulic reservoir Fluid change Take care when draining the hydraulic fluid. Use the following protective equipment: Protective gloves Safety glasses

1 Fig. Hydraulic reservoir 1. Drain plug

The drain plug (1) is located under the hydraulic reservoir.

Place a receptacle that holds at least x0 liters (xx gal) under the engine compartment.

Remove the oil drain plug (1) and connect a drain hose.

Allow all the oil to run out, reset by refitting the plug (1).

Deliver the drained fluid to environmentally correct handling.

Fill with fresh hydraulic fluid. Refer to the lubricants specification for grade information.

Replace the hydraulic filter. See section "Maintenance - 1000 hours".

Start the engine and operate the hydraulic functions.

Check the level in the reservoir and top off as required.

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Maintenance - 2000h

Air conditioning (Optional) - Overhaul Regular inspection and maintenance is necessary to ensure satisfactory long-term operation.

Clean all dust from the condenser element (1) using compressed air. Blow from above downwards.

The air jet can damage the element flanges if it is too powerful.

When working with compressed air, use the following protective equipment:

2

1

Figure. Cab 1. Condensor element 2. Drying filter

Safety glasses Protective gloves Ear protectors

Inspect the condenser element attachment.

Check the system hoses for chafing. Make sure that drainage from the cooling unit is unobstructed so that condensation does not accumulate inside the unit.

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Maintenance - 2000h Drying filter - Check Park on a level surface. Chock the drums and apply the parking brakes.

1

2

The compressor will be damaged if the unit is run with too little refrigerant.

Do not disconnect or undo the hose couplings.

Fig. Drying filter in engine compartment 1. Sight glass 2. Filter element

The cooling system is pressurized. Incorrect handling can result in serious personal injury.

The system contains pressurized refrigerant. It is forbidden to release refrigerants into the atmosphere. Work on the refrigerant circuit is only to be carriedd out by authorized companies.

With the unit in operation, open the engine hood and check using the sight glass (1) that bubbles are not visible on the drying filter. If bubbles are visible through the sight glass, it is a sign that the refrigerant level is too low. If so, stop the unit. The unit may be damaged if it is run with insufficient refrigerant.

Check that the color in the sight glass (1) is blue. If the color is beige, the drying cartridge must be replaced by an authorized service company.

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Dynapac Compaction Equipment AB Box 504, SE 371 23 Karlskrona, Sweden www.dynapac.com