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Maintenance: Dynapac CC 422/422C/CC 422HF/422CHF CC 432 CC 522/522C/CC 522HF/522CHF

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DYNAPAC

CC 422/422C/CC 422HF/422CHF
CC 432
CC 522/522C/CC 522HF/522CHF
MAINTENANCE
M422EN5

Box 504, SE-371 23 Karlskrona, Sweden


Telephone +46 455 30 60 00
Telefax +46 455 30 60 30
Web www.dynapac.com
ILF015WO1 19
Vibratory roller
CC 422/422C/CC 422HF/CC 422CHF/CC 432
CC 522/522C/CC 522HF/522CHF

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

Safety instructions - Personal safety

Special caution - Machine or component damage

GENERAL
Read the entire manual before starting any
service work.

Make sure that ventilation (extraction) is


adequate if the engine is run indoors.

The machine must be cared for properly to ensure


satisfactory operation. Keep the machine clean to
facilitate quick and timely detection of any leakage, loose
bolts and loose connections.

Make a habit each day, before starting up, of checking the


roller to detect any leakage or damage. Also check the
ground underneath the roller, where it is most often easier
to detect any leakage.

TAKE CARE OF THE ENVIRONMENT! Do not


leave behind any oil, fuel or other substances CALIFORNIA
that are detrimental to the environment.
Proposition 65 Warning
This manual contains instructions for periodic measures
that should normally be performed by the operator. Diesel engine exhaust and some of its
constituents are known to the State of
The manufacturer’s instructions noted in the California to cause cancer, birth defects,
engine manual also apply. This is placed under a and other reproductive harm.
separate flap in the product folder for the roller.

2 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


LUBRICANTS AND SYMBOLS
Always use high-quality lubricants in the recommended amounts. Too much grease or oil can
cause overheating and subsequent increased wear.

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.

COOLANT GlycoShell or corresponding.


mixed 50/50 with water Anti-freeze protection down to about -41°C (-106°F).

Other fuel and lubricants are required for operation in extremely high or extremely low
ambient temperature. See the “Special instructions” chapter, or consult Dynapac.

Engine, oil level Air filter

Engine, oil filter Battery

Hydraulic reservoir, level Sprinkler

Hydraulic fluid filter Sprinkler water

Drum, oil level Recycling

Lubricating oil Fuel filter

Air pressure Sprinkler, tyres

Coolant, level Transmission, oil level

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 3


TECHNICAL SPECIFICATIONS

Weights & dimensions CC422/HF CC422C/CHF CC432

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)

Weights & dimensions CC522/HF CC522C/CHF

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)

Fluid volumes, Litres CC422/HF CC422C/CHF CC432 CC522/HF CC522C/CHF

Drum (qts) 14 (14.8) 14 (14.8) 6 (6.3) 14 (14.8) 14 (14.8)


Hydraulic reservoir (qts) 40 (42.3) 40 (42.3) 40 (42.3) 40 (42.3) 40 (42.3)
Fuel tank (gal) 200 (52.8) 200 (52.8) 200 (52.8) 200 (52.8) 200 (52.8)
Emulsion tank (gal) – 485 (128) – – 485 (128)
Water tank (gal) 485 (128) 485 (128) 485 (128) 485 (128) 485 (128)
Diesel engine, lubr. oil (qts) 11 (11.6) 11 (11.6) 11 (11.6) 11 (11.6) 11 (11.6)
Transmission (qts) 0,8 (0.9) 0,8 (0.9) 0,8 (0.9) 0,8 (0.9) 0,8 (0.9)
Diesel engine, coolant (qts) 7,9 (8.4) 7,9 (8.4) 7,9 (8.4) 7,9 (8.4) 7,9 (8.4)

4 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


TECHNICAL SPECIFICATIONS

Electrical system

Battery 12 V 170 Ah
Alternator 12 V 95A
Fuses 5, 7,5, 15, 20 och 25 Ampére

Vibrationsdata CC422/HF CC422C/CHF CC432 CC522/HF CC522C/CHF

Static linear load, (kg/cm)


Front: 30,7/30,7 30,7/30,7 35,1 30,2/30,2 30,2
Rear: 31,2/31,2 – 35,7 30,6/30,6 –
Amplitude, (mm)
High: 0,8/0,7 0,8/0,7 0,6 0,67/0,59 0,67/0,59
Low: 0,4/0,28 0,4/0,28 0,3 0,34/0,24 0,34/0,24
Frequency, (Hz)
At High amplitude: 49/49 49/49 49 49/49 49/49
At Low amplitude: 49/62 49/62 49 49/62 49/62
Centrifugal force, (kN)
At High amplitude: 128/111 128/111 133 128/111 128/111
At Low amplitude: 65/72 65/72 68 65/72 65/72

Vibrationsdata CC422/HF CC422C/CHF CC432 CC522/HF CC522C/CHF

Static linear load, (pli)


Front: 171.9/171.9 171.9/171.9 196.6 169.1/169.1 169.1
Rear: 174.7/174.7 – 199.9 171.4/171.4 –
Amplitude, (in)
High: 0.031/0.028 0.031/0.028 0.024 0.026/0.023 0.026/0.023
Low: 0.016/0.011 0.016/0.011 0.012 0.013/0.009 0.013/0.009
Frequency, (vpm)
At High amplitude: 2940/2940 2940/2940 2940 2940/2940 2940/2940
At Low amplitude: 2940/3720 2940/3720 2940 2940/3720 2940/3720
Centrifugal force, (lb)
At High amplitude: 28,800/24,950 28,800/24,950 29,925 28,800/24,950 28,800/24,950
At Low amplitude: 14,625/16,186 14,625/16,186 15,287 14,625/16,186 14,625/16,186

Traction CC422/HF CC422C/CHF CC432 CC522/HF CC522C/CHF

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

Tires CC422C/CHF CC522C/CHF

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)

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 5


TECHNICAL SPECIFICATIONS

Tightening torque Tightening torque in Nm (lbf.ft) for oiled, bright


galvanized bolts tightened with a torque wrench.

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.

Bolt size: M24 (P/N 903792)


Strength class: 10,9
Tightening torque: 800 Nm (590lbf.ft)
(for Dacromet treated)

Hydraulic system Opening pressure, MPa (psi) CC 422/432/522

Drive system 42,0 (6,100)


Charge system 2,4 (350)
Vibration system 35,0 (5,100)
Steering system 20,0 (2,900)
Brake release 1,5 (220)

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.

Refrigerant designation: HFC-R134:A


Weight of refrigerant newly filled: 1600 gram

6 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


TECHNICAL SPECIFICATIONS

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.)

Vibration levels may vary when driving on


different courses and with different seat
positions.

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.

Model Guaranteed Acoustic Acoustic


acoustic pressure level, pressure level,
power level operator’s ear operator’s ear
dB(A) (platform) (cab) dB(A)
dB(A)
CC 422 110 - -
CC 422HF 110 - -
CC 422C 110 - -
CC 422CHF 110 - -
CC 432 110 - -
CC 522 109 - -
CC 522HF 109 - -
CC 522C 109 - -
CC 522CHF 109 - -

Noise level can vary when driving on different


courses and with different seat positions.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 7


MAINTENANCE SCHEDULE

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

Fig. 1 Service and maintenance points

1. Air cleaner 10. Articulated steering 19. Rubber element


2. Engine oil 11. Steering cylinder 20. Pivot bearing
3. Fuel cap 12. Hydraulic fluid filter 21. Battery
4. Seat bearing 13. Hydraulic fluid level 22. Hydraulic fluid cooler/Radiator
5. Water tanks 14. Hydraulic reservoir cap 23. Tire (Combi)
6. Watering system 15. Hydraulic reservoir 24. Pump gearing
7. Scrapers 16. Diesel engine 25. Rail catch
8. Drums 17. Hinge
9. Fuel tank 18. Pivot cylinder

8 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


MAINTENANCE MEASURES

The periodic measures should be performed primarily


after the specified hours of operation. Use the daily,
weekly, etc. time periods only where this is not possible.

Remove all dirt before filling, when checking


oils and fuel, and when lubricating with oil or
grease.

The engine manual specifies additional ser-


vice/maintenance instructions which relate to
the diesel engine.

Every 10 hours of operation (Daily)


Item in Measure See page Comments
fig. 1

Before starting each day


2 Check level of engine oil 11 See engine manual
22 Check level of engine coolant 11
13 Check level in hydraulic reservoir 12
3 Refuel 12
5 Fill the water tanks 12
6 Check the watering system/drum 13
6 Emergency watering 14
7 Check setting of scrapers/drum 14
Inspect spring-action scrapers 14
23 Check the watering system/tyres 15
23 Check setting of scrapers/tyres 15
Check brakes 16

Every 50 hours of operation (Weekly)


Item in Measure See page Comments
fig. 1

10 Lubricate the steering articulation 17


11 Lubricate steering cylinder mounts 17
18 Lubricate control cylinder for pivot steering 17 Optional
1 Inspect and if necessary clean the filter
element in the air cleaner 18 Replace as required
23 Check the tire pressure (Combi) 19
24 Check oil level in pump gearing 19
Inspect the air conditioning 20 Optional
Inspect/lubricate the edge cutter 20 Optional

After the first 50 hours of operation change only the drum oil and all the oil filters.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 9


MAINTENANCE MEASURES

Every 250 hours of operation (Monthly)


Item in Measure See page Comments
fig. 1

22 Clean the hydraulic cooler and the


water radiator 21 Or when required
21 Check level of battery fluid 21
Inspect the air conditioning 23 Optional

Every 500 hours of operation (Every three months)


Item in Measure See page Comments
fig. 1

16 Change engine fuel filter See engine manual


2 Change the engine oil and oil filter 22, 23 See engine manual
8 Check oil level in drums 24
20 Lubricate the pivot bearing 25 Optional
19 Check the rubber elements and bolted joints 25
14 Check the cap/vent of the hydraulic reservoir 25
17 Lubricate hinges and controls 26
4 Lubricate the seat bearing 26
Grease the steering chain 27
16 Change/clean the engine prefilter 27

Every 1000 hours of operation (Every six months)


Item in Measure See page Comments
fig. 1

16 Check engine valve clearance See engine manual


16 Check the engine belt-drive system See engine manual
12 Change hydraulic filter 28
1 Change main filter of the air cleaner 28
24 Change oil in the pump gearing 29
Replace air cleaner filter in cab 29
8 Change oil in drum/drums (HF version) 29

Every 2000 hours of operation (Yearly)


Item in Measure See page Comments
fig. 1

15 Change fluid in hydraulic reservoir 30


8 Change oil in drum/drums 30
9 Empty and clean the fuel tank 30
5 Empty and clean the water tanks 31
Lubricate the Forward/Reverse control 31
10 Check the condition of the articulation 32
Overhaul air conditioning 33 Optional
Overhaul compressor 34 Optional
Overhaul drying filter 34 Optional

10 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 10 HOURS OF OPERATION (Daily)

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.

The oil dipstick is accessible through the right door of


the engine compartment.

Beware of hot parts of the engine and ex-


haust pipe when taking out the oil dipstick.
Observe caution. Wear gloves and safety
goggles.

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.

Coolant level – Check


Check that level of the coolant is between the max. and
1 2 3
min. marks.

Observe caution if the filler cap must be


4 opened while the engine is hot. Wear glo-
ves and safety goggles.

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


See page 3 in these instructions and in the engine
manual.
6
Flush the system every other year and
change the coolant. Ensure also that air can
flow unrestricted through the radiator.

Fig. 3 Radiator
1. Filler cap
2. Level/max. mark
3. Level/min. mark
4. Intercooler
5. Radiator
6. Hydraulic fluid cooler

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 11


EVERY 10 HOURS OF OPERATION (Daily)

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.

Open the right door of the engine compartment.

Make sure that the oil level is between the max/min


marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.

Fig. 4 Hydraulic reservoir


1. Oil sight glass
2. Filler hose
3. Filler cap

Fuel tank – Refueling


Refuel every day before starting to work. Screw off the
lockable tank cap (1) and fill diesel fuel to the lower
1 edge of the filler pipe (2).

Never refuel while the engine is running,


2 do not smoke, and avoid spilling fuel.

See the engine handbook for the grade of diesel fuel.

The tank holds 200 litres (52.8 gal) of fuel.

Fig. 5 Fuel tank


1. Tank cap
2. Filler pipe

Water tanks – Filling


Screw off the tank cap (1) and fill with pure
1
water. Do not remove the strainer (2).
2
Fill both water tanks; they hold 485 liters (128 gal)
each.

A step is located on the hydraulic reservoir behind the


right door of the engine compartment to facilitate ac-
cess to the tank cap, and also a retractable step on the
right front drum fork.

Sole additive: A small amount of environment


Fig. 6 Rear water tank friendly antifreeze, and for combi-models
1. Tank cap possibly cutting fluid.
2. Strainer

12 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 10 HOURS OF OPERATION (Daily)

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.

A pump system is located underneath each water tank


3 behind the cover (2), which is opened by turning the
quick-screws (3) a 1/4 turn counter-clockwise. To lock
the cover, place the screws with the slot vertical and
push straight in.

2 1
Fig. 7 Rear drum
1. Nozzle
2. Pump system/cover
3. Quick-screws

Dismantle the clogged nozzle by hand. Blow the nozzle


2 (2) and fine filter (4) clean with compressed air, or
3
4 install replacement parts and clean the clogged parts at
a later opportunity.

Use protective goggles when working with


compressed air.

Fig. 8 Nozzle
1. Sleeve
2. Nozzle
3. Seal
4. Fine filter

When cleaning the coarse filter (1), close the stopcock


5 4 2 1 (2) and loosen the filter housing (3).

Clean the filter and filter housing, ensure that the rubber
gasket in the filter housing is intact.

After inspection and any cleaning, start the system and


check that it works.

3 A drain cock (5) is located in the left part of the pump


system area. This facilitates draining of both tank and
pump system.
Fig. 9 Pump system
1. Coarse filter
2. Stop cock
3. Filter housing
4. Water pump
5. Drain cock

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 13


EVERY 10 HOURS OF OPERATION (Daily)

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.

To operate with only one pump, open the stopcock (1)


in the water hose in the engine compartment, and also
the stopcock on the coarse filter by the pump that has
stopped, see pump system.

Fig. 10 Engine compartment, right side


1. Stopcock

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 1 Asphalt remnants can accumulate on the scraper and


affect the contact force.

Loosen the screws (2) to adjust the scraper blade up or


down.
1-2 mm 1-2 mm
Loosen the screws (3) to adjust the contact pressure of
the scraper blade against the drum.
Fig. 11 Rear drum scrapers
1. Scraper blade
2. Adjusting screws
Remember to tighten all the screws after any
3. Adjusting screws adjustment.

Scrapers, spring loaded


(Optional) – Checking
Make sure that the scrapers are undamaged. The
spring loaded scrapers require no adjustment because
the spring force provides the correct contact force.
Asphalt remnants can accumulate on the scraper and
affect the contact force.

1 Clean as needed.

2 The scrapers must be retracted from the drum


during transport driving.

Fig. 12 Spring loaded scrapers


1. Spring mechanism
2. Scraper blade

14 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 10 HOURS OF OPERATION (Daily)

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.

Fluids that are flammable or detrimental to


2 the environment may not be used in the
emulsion tank.

Inspect the tire tread now and then to detect


asphalt compound that has fastened. This is
Fig. 13 Wheel rack
1. Rear water tank likely until the tires are sufficiently warm.
2. Sprinkler nozzle

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

The scrapers shall hang freely away from the tyres


2
during transport driving. Lift up the scraper blades (1)
and latch them in the raised position with locking
bracket (2).

1
Fig. 15 Tire scrapers
1. Scraper blade
2. Locking bracket

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 15


EVERY 10 HOURS OF OPERATION (Daily)

Brake function
– Check
Check operation of the brakes as follows:
38 40

Drive the roller slowly forward.

Push the reserve/parking brake knob (38); the warning


lamp on the instrument panel should light and the roller
should stop.

After testing the brakes, set the forward/reverse lever


(40) in neutral.

Pull up the reserve/parking brake knob.


Fig. 16 Control panel
38. Reserve/parking brake knob
40. Forward/reverse lever
The roller is now ready for operation.

16 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 50 HOURS OF OPERATION (Weekly)

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.

Turn the steering wheel fully to the left to gain access


to all four grease nipples (1) from the right side of the
machine.

1 Wipe the grease nipples (1). Grease each nipple with


five strokes of the hand-operated grease gun. Make
Fig. 17 Right side of articulation sure that grease penetrates the bearings. If grease
1. Grease nipples does not penetrate the bearings, it may be necessary
to relieve the articulation joint with a jack while repea-
Steering cylinder ting the greasing process.
– Lubrication
Turn the machine back for driving straight ahead. This
makes the two grease nipples of the steering cylinder
accessible from the left side of the machine.

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

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 17


EVERY 50 HOURS OF OPERATION (Weekly)

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).

Do not remove the backup filter (4).

1 4 5

Fig. 20 Air cleaner


1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing

Main filter – Cleaning with


compressed air
Use compressed air at a maximum pressure of 5 bar
(72 psi) to clean the main filter by blowing up and down
along the inside of the pleated paper filter.

Hold the air nozzle at least 2 to 3 cm (0.8-1.2 in) from


the paper pleats so as not to tear the paper.

Use protective goggles when working with


compressed air.

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.

Change the main filter after cleaning it five


Backup filter times.
– Replacement
Replace the backup filter with a new one after cleaning
4 or changing the main filter five times. The backup filter
cannot be cleaned and reused.

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.

Fig. 22 Air filter


4. Backup filter

18 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 50 HOURS OF OPERATION (Weekly)

Tires
– Tire pressure
Check the tire pressure with a pressure gauge.

Make sure that the tires have equal pressure.

Recommended pressure: See Technical


Specifications.

The figure shows the position of the air valve on the


outer tires.

Fig. 23 Outer wheel


1. Air valve
The figure shows the position of the air valve on the
inner tires.

Check the safety manual that accompanies


the roller before filling the tires with air.

1
Fig. 24 Inner wheel
1. Air valve

Pump drive, oil level


– Checking/Topping up
Position the roller on a flat surface.
1
When checking the oil level, the engine must
be switched OFF and the parking brake
applied.
Open the right door of the engine compartment and
screw off the dipstick (1).
The oil level must be between the two marks at the
bottom of the dipstick.
Fill with transmission oil if required; see lubricant
specification.
Fig. 25 Pump gearing
1. Dipstick Ensure that the rubber packing between the dipstick
and gear housing is in place, and firmly screw in the
dipstick.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 19


EVERY 50 HOURS OF OPERATION (Weekly)

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.

When the unit is in operation, check in the sight glass


(1) that no bubbles are visible in the dryer filter.

Steer the roller fully to the right for easier access to the
dryer filter.
1
Always push the parking brake knob.

The filter is located on the left side underneath the cab.


If bubbles are visible in the sight glass it is a sign that
the level of refrigerant is too low. The sight glass is
visible where the hoses go in under the cab floor, see
figure. If so, stop the unit. There is a risk of damage to
the unit if it is run with insufficient level of refrigerant. Fill
2
with refrigerant.
Fig. 26 Drying filter
1. Sight glass
2. Filter housing

In the event of noticeable deterioration of cooling capa-


1 city, clean the condenser element (1), which is located
at the rear of the cab roof. Also clean the cooling unit
inside the cab.

Fig. 27 Cab
1. Condenser element

Edge cutter – Lubrication


See the Operation manual for how to ope-
rate the edge cutter.
2
Grease the four points indicated in the figure.
1
Additional lubrication should also be with grease, see
Lubricant specifications.

Grease all bearing points with five strokes of a


3
handoperated grease gun.

Fig. 28 Four lubrication points

20 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 250 HOURS OF OPERATION (Monthly)

Hydraulic fluid cooler


– Check/Cleaning
Place the roller on a level surface. Switch
the engine off and push in the reserve/parking-
1 brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Open the left-hand door to the engine compartment to
2 gain access to the radiator and the hydraulic fluid
cooler.
Ensure that air can flow unrestricted through the cooler
3 and radiator, (1), (2) and (3).
Blow a dirty cooler and radiator clean with compressed
air, or wash using a high-pressure washing jet.
Take care when using a high-pressure
washing jet, do not hold the nozzle too close to
the cooler.
Fig. 29 Radiator
1. Intercooler Use protective goggles when working with
2. Radiator compressed air.
3. Hydraulic fluid cooler

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.

Fig. 30 Air conditioning


1. Refrigerant hoses
2. Condenser element

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 21


EVERY 250 HOURS OF OPERATION (Monthly)

Battery – Checking the


electrolyte level
Open the left door of the engine compartment.

Pull out the battery that is located on the floor behind


3 2 the coolers.

4
Use safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.

Never use an open flame when checking


the electrolyte level. Explosive gas is genera-
ted when the alternator is charging.
1
Fig. 31 Battery space Take off the cell caps and make sure that electrolyte is
1. Battery about 10 mm (0.4 in) above the plates. Check the level
2. Cell cap of all cells. Top off with distilled water to the right level if
3. Cable shoes
the level is low. The engine should be run for a while
4. Pull-out handle
before topping off with distilled water if the ambient
temperature is below freezing. Otherwise, the electrolyte
might freeze.
Battery cell Make sure that ventilation holes in the cell cover are
not clogged. Then put the cover back on.
1
The cable shoes should be clean and well tightened.
2 Clean corroded cable shoes and grease them with
acid-free Vaseline.
When disconnecting the battery, always
10 mm disconnect the negative cable first. When
connecting the battery, always connect the
positive cable first.
3
Discard used batteries properly. Batteries
Fig. 32 Electrolyte level in battery contain lead, which is detrimental to the
1. Cell cap environment.
2. Electrolyte level
3. Plate Before doing any electric welding on the
machine, disconnect the battery ground
cable and then all electrical connections to
the alternator.

22 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 500 HOURS OF OPERATION (Every three months)

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.

Run the engine warm before draining the oil.

Ensure that ventilation (evacuation) is


adequate if the engine is run indoors.
(Risk of carbon monoxide poisoning).
2 1
Place a suitable receptacle, for at least 15 litres (4 gal),
Fig. 33 Engine compartment, left side under the drain plug.
1. Oil drain
2. Radiator Observe caution when draining the engine
oil. Wear gloves and safety goggles.

Unscrew the oil drain plug (1). Allow all of the oil to
drain off, and refit the plug.

Fill with fresh engine oil; see lubricant specification or


the engine manual for the correct grade of oil.

Check the dipstick to ensure that the engine oil level is


Engine correct, for details see the engine manual.
– Changing the oil filter
The oil filter (1) can be reached most easily through the
right-hand door of the engine compartment.

See the engine manual for details concerning changing


of the filter.

1
Fig. 34 Engine compartment, right side
1. Oil filter

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 23


EVERY 500 HOURS OF OPERATION (Every three months)

Drum, oil level


– Inspection/Filling
Position the roller with the filler plug (1) - the large plug -
1 straight up.

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.

Wipe clean round the sight glass (2).


2
Ensure that the oil level reaches half way in the sight
glass, top up with fresh oil if the level is not correct.
See Lubricant specification.

When removing the filler plug, wipe it clean from any


metal on its magnet.

Refit the plug.


Fig. 36 Drum, vibration side (CC432)
1. Filler plug
2. Sight glass Inspect all four drum halves.

Drive a distance and ensure that the plugs are tight.

24 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 500 HOURS OF OPERATION (Every three months)

Pivot bearing (Optional)


– Lubrication
Grease each nipple (1) with five strokes of a
1 handoperated grease gun.

Use grease according to the lubricant specification.

Fig. 37 Rear drum, right side


1. Grease nipples, 4 off

Rubber elements and


fastening screws – Check
Check all rubber elements (1), replace all of the
1 elements if more than 25% of them on one side of the
drum are cracked deeper than 10-15 mm (0.4-0.6 in).

Use the blade of a knife or pointed object to assist


when checking.

Make sure that the fastening screws (2) are tightened.

Fig. 38 Drum, vibration side


1. Rubber element
2. Fastening screws

Hydraulic reservoir cap


– Check
Open the right door of the engine compartment.
1
Unscrew and make sure that the reservoir cap is not
clogged, air must have unobstructed passage through
the cap in both directions.

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.

Use protective goggles when working with


Fig. 39 Engine compartment, right side compressed air.
1. Tank cap

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 25


EVERY 500 HOURS OF OPERATION (Every three months)

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
2 control arm of the hydraulic pump. Apply a few drops of
oil to the mouth of the control sleeve.

Fig. 40 Engine hood


1. Hinge
2. Control wires

Seat bearing – Lubrication


Remove both steps from under the operator’s platform,
or one step and cover plate on the other side of the roller
1 if fitted with a cab.
3
Lubricate the seat sliding rails for transverse travel with
five strokes of a hand-operated grease gun. Grease all
2 four nipples, two of which (1) are accessible from each
2 side.

1 Also grease the slew bearing of the seat with a few


strokes of the gun. The lubrication nipple (3) is
accessible after the cover on the seat frame underneath
the front of the seat is removed.
Fig. 41 Seat bearing, underneath
1. Grease nipples Also lubricate the seat locking mechanism, both for
2. Slide rails transverse travel and slewing. Use engine oil or drum oil.
3. Lubrication nipple
If the seat begins to bind when resetting, then it
should be lubricated more often than specified
here.

26 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 500 HOURS OF OPERATION (Every three months)

Seat bearing
– Lubrication
Remember that the chain is a vital part of the
5
steering mechanism.

6 Remove the cover (5) to gain access to the lubrication


nipple (1). Lubricate the slew bearing of the operator’s
seat with three strokes of a hand-operated grease gun.

Lubricate the seat locking latch (7), accessible from


below.

Also grease the slide rails of the seat (6).

If the seat begins to bind when resetting, it


7 needs to be lubricated more often.

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

Fig. 42 Seat bearing


1. Lubrication nipple
2. Cogwheel
3. Steering chain
4. Adjusting screw
5. Cover
6. Slide rails
7. Slew interlock

Diesel engine fuel filter


– Change/cleaning 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.

1 Prefilter, loosen the screw (1) and remove the glass


bowl (2).
3
5
2 Take out the strainer (3) and clean using a non-
flammable fluid. Reinstall the strainer and the bowl.
4
Replace fuel filter. See engine manual.
Fig. 43 Diesel engine
1. Prefilter Start the engine and check that the pre-filter does not leak.
2. Glass bowl
3. Strainer Make sure there is adequate ventilation
4. Nut (extraction) if the diesel engine is run in-
5. Fuel filter doors. Risk of carbon monoxide poisoning.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 27


EVERY 1000 HOURS OF OPERATION (Every six months)

Hydraulic fluid filter


– Changing
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.
1
Open the right door of the engine compartment.

Remove the oil filter (1) and discard it in a safe


manner, it is of the expendable type and
cannot be cleaned.

Thoroughly clean the sealing surface of the filter holder.


2
3
Apply a thin coat of fresh hydraulic fluid on the rubber
Fig. 44 Hydraulic reservoir gasket of the new filter.
1. Hydraulic filter
2. Reservoir
3. Sight glass Screw on the filter by hand, first until the filter gasket
makes contact with the filter base and then a further ½
turn.

Start the engine and check that the filter does not leak.

Check level of the hydraulic fluid in the sight glass (3)


and top up as required, see under the heading “Every
10 hours of operation”.
Air filter – Replacement
Replace the main filter (3) of the air cleaner even if it
has not yet been cleaned five times; see under the
heading “Every 50 hours of operation” for changing the
filter.

If a clogged filter is not replaced the exhaust


fumes will be black and the engine will loose
3 power. There will also be danger of severe
damage to the engine.
Fig. 45 Air cleaner
3. Main filter

28 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 1000 HOURS OF OPERATION (Every six months)

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.

Unscrew the drain plug (1) and also unscrew the


dipstick to allow the oil to flow freely, see under the
”Every 50 hours of operation” heading.

Wipe away any metal particles from the magnetic drain


plug, and refit the plug and its packing.

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

Fresh air filter – Replacement


2 1 2 Use a stepladder to reach the filter (1).

There are two fresh-air filters (1), one on each side of


the cab. Unscrew the screws (2), take down the entire
housing and remove the filter insert.

Replace with new filters.

It may be necessary to change the filters more often if


the machine is run in a dusty environment.

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.

Switch off the engine and push the reserve/


parking brake knob.

Place a receptacle that will hold at least 20


liters (21 qts) under the plug. Save the oil and
1 dispose of it in an approved manner.

Fig.48 Drum, vibration side


Remove the plug (1) and allow all the oil to run out. See
1. Drain plug under the heading ”Every 500 hours of operation” for
filling oil.
CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 29
EVERY 2000 HOURS OF OPERATION (Yearly)

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.

Switch off the engine and push the reserve/


parking brake knob.

Place a receptacle that will hold at least 20


liters (7 qts) under the plug. Save the oil and
1
dispose of it in an approved manner.
Fig. 50 Drum, vibration side
1. Drain plug
Remove the plug (1) and allow all the oil to run out. See
under the heading ”Every 500 hours of operation” for
filling oil.

CC 432 (four drum halves)

Position the roller with the drain plug (1) straight down.

Place a receptacle that will hold at least 7


liters (21 qts) under the plug. Save the oil and
dispose of it in an approved manner.

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

30 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 2000 HOURS OF OPERATION (Yearly)

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.

Remember the danger of fire when hand-


ling fuel.

The fuel tank is made of recyclable plastic


(polyethylene).
Fig. 52 Fuel tank
1. Oil emptying pump

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.

The easiest way to empty the tank is to screw off the


filter housing (1) and disconnect the hoses by releasing
the quick-couplings.
2 3 1
There is also a drain cock (red square) under each
Fig. 53 Pump system water tank.
1. Filter housing
2. Drain cock Open the drain cock (2) to empty the water pump.
3. Quick-couplings

Water tank – Cleaning


Clean the tanks with water and a suitable detergent for
plastic surfaces.

Refit the filter housing (1) or the drain plug (2), fill with
water and check for tightness.

The water tanks are made of recyclable


plastic (polyethylene).
1

2
Fig. 54 Water tank
1. Pump system
2. Drain plug

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 31


EVERY 2000 HOURS OF OPERATION (Yearly)

Forward/Reverse lever
– Lubrication
Remove the screws (1) and take off the plate (2).

Lubricate the sliding surface of the cam disc (3) with


grease.

Refit the plate (2) and the screws (1).

1 2 3

Fig. 55 Forward/Reverse lever


1. Screw
2. Plate
3. Cam disc

Steering joint – Check


Inspect the steering joint to detect any damage or
cracks.

Check and correct any loose bolts.

Check also for any stiffness and play.

Fig. 56 Steering joint

32 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


EVERY 2000 HOURS OF OPERATION (Yearly)

Air conditioning
– Overhaul (Optional)
Regular inspection and maintenance are necessary to
1 ensure satisfactory long-term operation.

Clean the condenser element (1) free from dust with


the aid of compressed air. Blow from above.

The air jet could damage the flanges of the


elements if it is too powerful.

Wear protective goggles when working


with compressed air.

Inspect the fastening of the condenser element.


Fig. 57 Cab
1. Condenser element

Clean the cooler unit and the cooling elements (1) free
from dust with the aid of compressed air.

Inspect the system hoses for chafing. Make sure that


drainage from the cooling unit is unobstructed so that
condensation does not accumulate inside the unit.

Check the drain by squeezing the valves (2) underne-


ath the cab.

1 2

Fig. 58 Aircondition
1. Cooling element
2. Drain valve (x2)

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 33


EVERY 2000 HOURS OF OPERATION (Yearly)

Compressor – Inspection
Inspect fastening of the compressor and hydraulic
motor. These components are located behind the steps
to the cab. Dismantle the steps.

The unit should be run at least five minutes every


week, if possible, to ensure that the rubber gaskets in
the system remain lubricated.

1 2

Fig. 59 Compressor
1. Hydraulic motor
2. Compressor

Drying filter – Inspection


Never work under the roller with the engi-
ne running. Park on a level surface, chock
the wheels and press the parking brake
control.

Open the engine hood while the unit is operating and


check in the sight glass (1) that no bubbles are visible
on the dryer filter. If bubbles are visible through the
sight glass, it is a sign that the level of refrigerant is too
low. If so, stop the unit. There is a risk of damage to the
unit if it is run with insufficient refrigerant.

Check the moisture indicator (2). The color should be


blue; if it is beige the dryer cartridge must be replaced
1 by an authorized service company.

The compressor will be damaged if the unit


is run with too little refrigerant.

2 Do not disconnect the hose coupling.

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.

34 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


LONG-TERM STORAGE

The following instructions should be followed


for storage longer than one month:

The measures apply for a period of up to 6


months.

The items marked * must be restored before


using the roller.

Fig. 61 Roller protected against the weather

Diesel engine * See manufacturer’s instructions in the engine


manual that accompanies the roller.

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.

Fuel tank Fill the fuel tank completely to prevent condensation.

Hydraulic reservoir Fill the hydraulic reservoir to the uppermost level


mark, see under the heading ”Every 10 hours of
operation.”

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).

Hoods, tarpaulin * Lower the instrument shield plate on the steering


column. Cover the entire roller with a tarpaulin. The
tarpaulin must be free from the ground. Store the
roller indoors if possible, preferably on premises with
an even temperature.

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 35


SPECIAL INSTRUCTIONS

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).

A maximum temperature of +35°C (95°F)


applies for biological hydraulic fluid.

Higher ambient temperature The following recommendations apply for operation in


above +50°C (122°F) higher ambient temperatures up to a maximum of
+50°C (122°F):

The diesel engine can be run at this temperature using


the normal oil, but for other components, the following
fluids must be used: Hydraulic system: mineral fluid
Shell Tellus TX100 or equivalent.

Temperature The temperature limits apply to standard versions of


the roller.

Rollers that are fitted with additional equipment, such


as noise suppression, etc., may require extra observa-
tion in the higher temperature ranges.

High-pressure washing Never aim a water jet directly at the cap of


the fuel tank or hydraulic reservoir. This is
especially important when using a high-
pressure jet.

Do not spray water directly on electric components or


the instrument panel. Put a plastic bag over the filler
cap of the fuel tank and secure with a rubber band.
This will prevent water from entering the venting hole
in the filler cap. This could otherwise cause
operational disturbance, for example, a clogged filter.

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.

Protective structure (ROPS), If the roller is equipped with a protective structure


protective cab (ROPS, Roll Over Protective Structure), or protective
cab, never subject the structure or cab to welding or
drilling. Never attempt to repair a damaged structure or
cab; they must be replaced with new ones.

Starting aid When using an auxiliary battery to assist starting,


always connect the positive terminal of the auxiliary
battery to the positive terminal of the roller battery, and
negative to negative.

36 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


ELECTRICAL SYSTEM, FUSES

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

Fuses in the engine compartment are located together


with the battery disconnecter, behind the left cover of
the engine compartment.

The machine is equipped with a 12 V electrical system


and an alternator.
Connect the battery to the correct polarity
(– to ground). The cable between battery-
2 1 and alternator must not be disconnec-
tedwhen the engine is running.
Fig. 63 Battery space
1. Battery disconnector
2. Main fuse panel

The main fuse panel is located behind the left cover of


1 2
the engine compartment.

The main fuses and start relay are easily accessible on


lowering the cover forward.

4 3

Fig. 64 Main fuse panel


1. Battery disconnecter
100A 2. Main fuse,,
Cab/standard electricity
125A 3. Preheating, engine
4. Start relay

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 37


ELECTRICAL SYSTEM, FUSES

The control unit and relays for preheating the diesel


1 engine are located behind the left door of the engine
2 compartment on the wall adjacent to the rear drum.

Fig. 65 Engine compartment, left side


1. Control unit for preheating
2. Heating relay

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

Fig. 66 Instrument panel

38 CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5


ELECTRICAL SYSTEM, FUSES

Fuses on the machine


The figure shows the rating and function of the different
fuses. All fuses are flat pin fuses..
1 7

2 8

3 9

4 10

5 11

6 12

Fig. 67 Fuse boxes, left side Fuse boxes, right side


1. Vacant 7,5A 1. Brake valve, start relay, control relay cab
10A 2. Direction indicators, main fuse 10A 2. Vibration relay, VBS
7,5A 3. Left position lights, front and rear, 3A 3. Indicator panel
brake lights 7,5A 4. Horn
5A 4. Right position lights, front and rear 7,5A 5. Vibration Front/Both/Rear, AVC-relay
5A 5. Left direction indicator, 10A 6. Hazard beacon
front and rear, side blinkers
5A 6. Right direction indicator,
front and rear, side blinkers
*/20A 7. Right working lights 7,5A 7. Sprinkler pump front
*/20A 8. Left working lights 7,5A 8. Sprinkler pump rear
7,5A 9. Left front headlight, 15,0A 9. Sprinkler system main fuse
instrument lighting 15,0A 10. Steering, offset up/down
7,5A 10. Right front headlight 7,5A 11. Reversing alarm
7,5A 11. Edge cutter, sprinkler Up/Down 7,5A 12. Instruments, voltmeter, temperature level,
12. Vacant speedometer, tachometer, frequency meter
*/ If driving lights 10A

Fuses in the cab


The electrical system in the cab has an individual fuse
box located in the right front side of the cab roof. The
figure shows the rating and function of the different
1 ´ 3 4 5 6 fuses. All fuses are flat pin fuses.

Fig. 68 Fuse box in cab


15A 1. Rear cab working light
15A 2. Front cab working light,
drum headlight
5A 3. Cab interior lighting
20A 4. Heating/fresh-air fan
15A 5. Windshield wiper/washer
15A 6. Front windshield wiper/washer

CC 422/HF/422C/CHF - CC 432 - CC 522/HF/522C/CHF M422EN5 39

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