Maintenance: Dynapac CC 422/422C/CC 422HF/422CHF CC 432 CC 522/522C/CC 522HF/522CHF
Maintenance: Dynapac CC 422/422C/CC 422HF/422CHF CC 432 CC 522/522C/CC 522HF/522CHF
Maintenance: Dynapac CC 422/422C/CC 422HF/422CHF CC 432 CC 522/522C/CC 522HF/522CHF
CC 422/422C/CC 422HF/422CHF
CC 432
CC 522/522C/CC 522HF/522CHF
MAINTENANCE
M422EN5
Maintenance
M422EN5, August 2003
R Diesel engine:
FO Cummins B 3.9 TAA
L E
UA C These instructions apply from:
N EN CC 422 PIN (S/N) *42520422*
A
M ER CC 422C PIN (S/N) *42620427*
IS EF CC 422HF PIN (S/N) *43520423*
TH R CC 422CHF PIN (S/N) *43620429*
P E
R
EE U
CC 432 PIN (S/N) *42720433*
K UT CC 522 PIN (S/N) *42920523*
F CC 522C PIN (S/N) *43020527*
CC 522HF PIN (S/N) *43720522*
CC 522CHF PIN (S/N) *43820526*
The Dynapac CC 422 is a vibratory roller in the 10-tonne class, with articulated
steering and with propulsion, brakes and vibration on both drums.
The above roller is also available in a so-called Combi version with model designation
CC 422C. It weighs about 9 tonnes and has a vibratory drum at the front and four
smooth rubber tyres at the rear; all with drive and braking functions.
CC 432 is a vibratory roller in the 11-ton class, with articulated steering and
vibration on both drums.
CC 522 is the designation of this model, the biggest roller in the series. It features wider
and larger diameter drums compared with the CC 422 and is in the 12 tonne class.
This roller is also available in a combi version, weighing about 11 tons and
with model designation CC 522C.
Reservation for changes.
Printed in Sweden.
CONTENTS
Page
Lubricants and symbols ................................................... 3
Technical specifications ............................................... 4-7
Maintenance schedule ..................................................... 8
Maintenance measures .............................................. 9, 10
Every 10 hours of operation (Daily) .......................... 11-16
Every 50 hours of operation (Weekly) ...................... 17-20
Every 250 hours of operation (Monthly) ................... 21, 22
Every 500 hours of operation (Every three months) . 23-27
Every 1000 hours of operation (Every six months) . 28, 29
Every 2000 hours of operation (Yearly) .................... 30-34
Long-term storage .......................................................... 35
Special instructions ........................................................ 36
Electrical system, fuses ............................................ 37-39
WARNING SYMBOLS
GENERAL
Read the entire manual before starting any
service work.
ENGINE OIL
ambient temperature Shell Rimula SAE 15W/40 or equivalent.
-10°C-+40°C (14°F-104°F) API CF-4/SG (CD/CE)
HYDRAULIC FLUID
ambient temperature
-10°C to +40°C (14°F-104°F) Shell Tellus TX68 or equivalent
above +40°C (above 104°F) Shell Tellus TX100 or equivalent
BIOLOGICAL Shell Naturelle HF-E46
HYDRAULIC FLUID 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 off.
DRUM OIL
ambient temperature
-15°C to +40°C (5°F-104°F) Mobil SHC 629 or equivalent
TRANSMISSION OIL
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
GREASE SKF LGHB2 (NLGI Class 2) or equivalent for the
articulated joint.
Shell Retinax LX2 or equivalent for other grease points.
FUEL See engine manual.
Other fuel and lubricants are required for operation in extremely high or extremely low
ambient temperature. See the “Special instructions” chapter, or consult Dynapac.
Operating mass with ROPS, EN500, kg (lbs) 10400 (22,932) 9950 (21,940) 11900 (26,240)
Operating mass without ROPS, kg (lbs) 10000 (22,050) 9550 (21,058) 11500 (25,358)
Operating mass with cab, kg (lbs) 10400 (22,932) 9950 (21,940) 11900 (26,240)
Length, standard equipped roller, mm (in) 4950 (195) 4950 (195) 4950 (195)
Width, standard equipped roller, mm (in) 1810 (71) 1810 (71) 1810 (71)
Width, with cab, mm (in) 2025 (80) 2025 (80) 2025 (80)
Height, without cab (Shipping height), mm (in) 2170 (85) 2170 (85) 2170 (85)
Height, with cab, mm (in) 2970 (117) 2970 (117) 2970 (117)
Height, with AC, mm (in) 2970 (117) 2970 (117) 2970 (117)
Height, with AC and hazard beacon, mm (in) 3295 (130) 3295 (130) 3295 (130)
Operating mass with ROPS, EN500, kg (lbs) 11850 (26,129) 11000 (24,255)
Operating mass without ROPS, kg (lbs) 11450 (25,247) 10600 (23,373)
Operating mass with cab, kg (lbs) 11850 (26,129) 11000 (24,255)
Length, standard equipped roller, mm (in) 5090 (200) 5090 (200)
Width, standard equipped roller, mm (in) 2090 (82) 2090 (82)
Width, with cab, mm (in) 2160 (85) 2160 (85)
Height, without cab (Shipping height), mm (in) 2240 (88) 2240 (88)
Height, with cab, mm (in) 3040 (120) 3040 (120)
Height, with AC, mm (in) 3040 (120) 3040 (120)
Height, with AC and hazard beacon, mm (in) 3365 (132) 3365 (132)
Electrical system
Battery 12 V 170 Ah
Alternator 12 V 95A
Fuses 5, 7,5, 15, 20 och 25 Ampére
Speed range, km/h (mph) 0-11 (0-7) 0-11 (0-7) 0-11 (0-7) 0-12 (0-7.5) 0-12 (0-7.5)
Climbing ability (theoretical) % 42 47 36 34 34
Tire dimension E20 (13/80 R20) Lisse E20 (13/80 R20) Lisse
Tire pressure(kPa) 200 (2,0 kp/cm²), (29 psi) 200 (2,0 kp/cm²), (29 psi)
M STRENGTH CLASS
thread 8.8 10.9 12.9
M6 8,4 12 14,6
M8 21 28 34
M10 40 56 68
M12 70 98 117
M16 169 240 290
M20 330 470 560
M24 570 800 960
M30 1130 1580 1900
M36 1960 2800 –
ROPS
ROPS bolts must always be tightened dry.
Air Condition (Optional) The system described in this manual is of the ACC
type (Automatic Climate Control), ie, a system that
maintains the set temperature in the cab, on condition
that windows and door are kept closed.
Vibration
The vibration levels are measured in conformance
(ISO 2631) with the operation cycle described in EU directive
2000/14/EC on EU equipped machines, on soft
polymer material with vibration switched ON and
operator’s seat in the transport mode.
Whole-body vibration is measured at less than the
action value of 0.5 m/s2 specified in EU directive
2002/44/EC. (The limit value is 1.15 m/s2.)
Hand/arm vibration is measured at less than the
action value of 2.5 m/s2 specified in the same
directive. (The limit value is 5 m/s2.)
Acoustic values
The acoustic values are measured in conformance with the operation
cycle described in EU directive 2000/14/EC on EU-equipped
machines, on soft polymer material with vibration switched ON and
operator's seat in the transport mode.
23 5 1 2 3 4 5
6
6
7
7
8
20
19
8
19 18 7 17 16 15 14 13 12 11 10 9 7
21, 22
23 24 25
After the first 50 hours of operation change only the drum oil and all the oil filters.
Diesel engine,
oil level – Check
Place the roller on a level surface. Switch
1 2 the engine off and push in the reserve/
parking brake knob for all checking and
adjustments on the roller, unless otherwise
specified.
Fig. 2 Engine compartment The dipstick is located on the short side of the engine
1. Oil dipstick above the hydraulic pumps.
2. Filler cap
Pull up the dipstick (1) and ensure that the oil level is
between the upper and lower mark. For further details,
see the engine manual.
Fig. 3 Radiator
1. Filler cap
2. Level/max. mark
3. Level/min. mark
4. Intercooler
5. Radiator
6. Hydraulic fluid cooler
Hydraulic reservoir,
level check – Filling
3 Place the roller on a level surface. Switch
the engine off and push in the reserve/
parking brake knob for all checking and
2 adjustments on the roller, unless otherwise
specified.
Sprinkler system/Drum
– Checking/Cleaning
Start the sprinkler system and make sure that no
nozzle (1) is clogged. If necessary, clean clogged
nozzles and the coarse filter located adjacent to the
3 water pump (2); see figures below.
2 1
Fig. 7 Rear drum
1. Nozzle
2. Pump system/cover
3. Quick-screws
Fig. 8 Nozzle
1. Sleeve
2. Nozzle
3. Seal
4. Fine filter
Clean the filter and filter housing, ensure that the rubber
gasket in the filter housing is intact.
Emergency watering
If one of the water pumps stops, the remaining pump
1 will be able to keep the sprinkler system operating -
however, at reduced capacity.
Scrapers, fixed
– Checking/Setting
Make sure that the scrapers are undamaged. Adjust the
3 3
scrapers so that they lie 1–2 mm (0.04-0.08 in) from the
drum. For special asphalt compounds, it may be better if
2 2 the scraper blades (1) lie lightly against the drums.
1 Clean as needed.
Sprinkler system/Wheels
– Checking/Cleaning
Fill the rear tank with emulsion fluid; for example, water
1 mixed with 2% cutting fluid. Make sure that the sprink-
ler nozzles (2) are not clogged. Clean them and the
filter if necessary. See under Sprinkler system/Drum –
Check/Cleaning, for detailed instructions.
Scrapers
– Checking/Setting
Make sure that the scrapers are undamaged. Adjust
2 3
the scrapers so that they lie 1–2 mm (0.04-0.08 in) from
the tires. For special asphalt compounds, it may be
better if the scraper blades (1) lie lightly against the
tires. Contact is adjusted with the screw at the back of
the scraper mount.
1 1-2 mm
Fig. 14 Tire scrapers
1. Scraper blade
2. Locking bracket
3. Adjusting screw
1
Fig. 15 Tire scrapers
1. Scraper blade
2. Locking bracket
Brake function
– Check
Check operation of the brakes as follows:
38 40
Steering joint
– Lubrication
Place the roller on a level surface. Switch the
1 engine off and push in the reserve/parking-
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Allow no one to get 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.
Wipe the nipples (1) and grease each one with three
strokes of the hand-operated grease gun.
1
Fig. 18 Left side of articulation
1. Grease nipples
Pivot cylinder
– Lubrication (Optional)
Allow no one near the rear drum while the
engine is running. Danger of being crus-
hed when the drum is operated.
Turn the rear drum for turning left to make the two
grease nipples (1) accessible from the right side of the
machine.
1 Wipe the nipples and lubricate in the same way as for
1
the steering cylinder above.
Fig. 19 Pivot cylinder
1. Grease nipples
Air cleaner
– Check/Cleaning
Replace or clean the main filter of the air
2 3 cleaner when the warning lamp on the instru-
ment panel lights at full engine revs.
Release the three locking braces (1) and pull off the
cover (2), pull out the main filter (3).
1 4 5
Wipe the inside of the cover (2) and the filter housing (5).
Fig. 21 Main filter Ensure that the hose clips between the filter
housing and the intake hose are tightened and
that the hoses are intact. Inspect the entire
hose system all the way to the engine.
To change the backup filter (4), pull the old filter out
from its holder, insert a new one and reassemble the air
cleaner in the reverse order.
Tires
– Tire pressure
Check the tire pressure with a pressure gauge.
1
Fig. 24 Inner wheel
1. Air valve
Air conditioning
– Inspection (Optional)
Never work under the roller with the engi-
ne running. Park on a level surface, chock
the wheels and press the parking brake
control.
Steer the roller fully to the right for easier access to the
dryer filter.
1
Always push the parking brake knob.
Fig. 27 Cab
1. Condenser element
Air conditioning
– Inspection (Optional)
Inspect refrigerant hoses and connections and make
1 2
sure that there are no signs of oil film that could indicate
leakage of refrigerant.
4
Use safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.
Engine
– Changing the oil
Place the roller on a level surface. Switch
the engine off and push in the reserve/parking-
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
The engine oil drain plug is located adjacent to the
battery behind the left door of the engine compartment.
Unscrew the oil drain plug (1). Allow all of the oil to
drain off, and refit the plug.
1
Fig. 34 Engine compartment, right side
1. Oil filter
Wipe clean around the level plug (2) - the small plug -
and unscrew it.
Make sure that the oil level reaches up to the lower
2 edge of the hole, top off with fresh oil as required. See
Lubricant specification.
When removing the filler plug, wipe it clean from any
metal on its magnet.
Make sure that plug seals are intact and replace with
new seals as required.
Fig. 35 Drum, vibration side
1. Filler plug Refit the plugs.
2. Level plug Check both drums.
Drive a distance and make sure that the plugs are tight.
CC 432
1
Position the roller with the filler plug (1) straight up.
Hinges, controls
– Lubrication
Lubricate both hinges (1) on the engine compartment
doors until grease penetrates through.
Seat bearing
– Lubrication
Remember that the chain is a vital part of the
5
steering mechanism.
lean and grease the chain (3) between the seat and
the steering column.
If the chain becomes slack on the cogwheel (2), loosen
4
the screws (4) and move the steering column forward,
tighten the screws and check the tension of the chain.
2 1
Start the engine and check that the filter does not leak.
Pump drive
– Oil change
Observe caution when draining hot oil.
Wear gloves and safety goggles.
Use a receptacle that will hold at least 1.5 litre (1.6 qts)
for draining the oil.
The gearbox holds 0.8 liter (0.85 qts). For topping off,
1
see under the ”Every 50 hours of operation” heading.
Fig. 46 Pump gearing
1. Drain plug
Fig. 47 Cab
1. Fresh air filter (x2)
2. Screw (x2)
Drum
– Oil change (HF version)
Make sure there is adequate ventilation
(extraction) if the diesel engine is run in-
doors. Risk of carbon monoxide poisoning.
Drive the roller until the drain plug (1) - the large plug -
is straight down.
Hydraulic reservoir
– Changing the fluid
Place the roller on a level surface. Switch the
engine off and push in the reserve/parking-
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Observe caution when draining hot oil.
Wear gloves and safety goggles.
Place a receptacle that will hold at least 50
liters (53 qts) under the plug. Save the oil and
dispose of it in an approved manner.
Remove the drain plug (1) and allow all the oil to run
2 1 out, wipe and refit the drain plug.
Fig. 49 Engine compartment, right side Fill with fresh hydraulic fluid of the grade
1. Drain plug indicated in the Lubricant specification.
2. Hydraulic reservoir
Replace the hydraulic filter as described under the
heading ”Every 1000 hours of operation.”
Start the engine and operate the various hydraulic
functions. Check the level in the reservoir and top off
Drum – Oil change as required.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors. Risk
of carbon monoxide poisoning.
Drive the roller until the drain plug (1) - the large plug -
is straight down.
Position the roller with the drain plug (1) straight down.
Remove the plug (1) and allow all the oil to run out. See
under the heading ”Every 500 hours of operation” for
filling oil.
1
Fig. 51 Drum, vibration side (CC432) Change the oil in all four drum halves.
1. Drain plug
Fuel tank
– Cleaning
It is easiest to clean the tank when it is almost empty.
1
Pump out any bottom sediment with a suitable
pump; for example, an oil emptying pump.
Save the oil in a can and dispose of it in an
approved manner.
Watering system
– Draining
Remember the risk of freezing during the
winter period and drain the tank, pump and
leads; or mix the water with a small amount of
environmentally friendly antifreeze.
Refit the filter housing (1) or the drain plug (2), fill with
water and check for tightness.
2
Fig. 54 Water tank
1. Pump system
2. Drain plug
Forward/Reverse lever
– Lubrication
Remove the screws (1) and take off the plate (2).
1 2 3
Air conditioning
– Overhaul (Optional)
Regular inspection and maintenance are necessary to
1 ensure satisfactory long-term operation.
Clean the cooler unit and the cooling elements (1) free
from dust with the aid of compressed air.
1 2
Fig. 58 Aircondition
1. Cooling element
2. Drain valve (x2)
Compressor – Inspection
Inspect fastening of the compressor and hydraulic
motor. These components are located behind the steps
to the cab. Dismantle the steps.
1 2
Fig. 59 Compressor
1. Hydraulic motor
2. Compressor
3
The cooling system is pressurized.
Fig. 60 Dryer filter, underneath cab Incorrect handling can result in serious
1. Sight glass personal injuries.
2. Moisture indicator
3. Dessicator cartridge The system contains pressurized refriger-
ant. Releasing refrigerants into the air is
prohibited. The refrigerant circuit may only
be repaired by an authorized company.
Battery * Remove the battery from the roller, clean it, check
that the electrolyte level is correct (see under the
heading ”Every 50 hours of operation”) and
tricklecharge the battery once a month.
Air cleaner, exhaust pipe * Cover the air cleaner (see under the heading ”Every
50 hours of operation” and also under the heading
”Every 1000 hours of operation”) or its opening with
plastic or tape, and also cover the exhaust opening.
This is necessary to prevent moisture from entering
the engine.
Sprinkler system * Empty the water tank completely (see under the
heading ”Every 10 hours of operation”), also hoses,
filter housing and water pump. Remove all the
sprinkler nozzles (see under the heading ”Every 10
hours of operation”).
Steering cylinder, hinges, etc. Lubricate bearings of the steering joint and both
bearings of the steering cylinder with grease (see
under the heading ”Every 50 hours of operation”).
Grease the piston rod of the steering cylinder with
inhibitor grease. Grease the hinges on doors to the
engine compartment and the cab, and also grease
both ends of the forward/reverse control (bright
parts) (see under the heading ”Every 500 hours of
operation”).
Tires (Combi) Make sure that tire pressure is at least 200 kPa,
(2,0 kp/cm²) (29 psi).
Standard oils and other When they leave the factory, the systems and
recommended fluids components are filled with oil or fluid as indicated in the
Lubrication specification and are thus suitable for
operation in ambient temperatures between -10°C and
+40°C (14°F - 104°F).
Fire fighting In the event of fire in the machine, use an ABE powder
fire extinguisher if possible. A BE-type carbon dioxide
fire extinguisher may also be used.
Fuses
The electrical regulating system and control system are
protected by 24 fuses, located in the instrument panel
and in the engine compartment.
The four fuse boxes (1) are located behind the lower
instrument plate, which is opened by turning the four
quick-screws (2) a 1/4 turn counter-clockwise.
2 1 2 2 1 2
Fig. 62 Instrument panel
1. Fuse boxes
2. Quick-screws
4 3
Relays
K1 Lights relay
K2 Direction indicator relay
K3 Brakes relay
K4 Reverse alarm relay
K5 Fuel level relay
K7 Horn relay
K8 Sprinkler
K9 Main relay
K10 AVC
K11 Neutral switch
K12 VBS relay
2 8
3 9
4 10
5 11
6 12