DYNAPAC
CA 602
Box 504, SE-371 23 Karlskrona, Sweden
Telephone +46 455 30 60 00
Telefax +46 455 30 60 30
Web www.dynapac.com
M602EN2
MAINTENANCE
19
ILF015WO1
Vibratory Roller
CA 602
Maintenance
M602EN2, A ugust 2003
Diesel engine:
CA 602: Cummins QSB 5.9-C
These instructions apply from:
CA 602 PIN (S/N) *71420603*
Reservation for changes.
Printed in Sweden.
The Dynapac CA 602 is available in D (smooth drum) and PD (padfoot) versions, of which the CA
602D is designed for compacting rock fill. The main range of application for the PD versions is on
cohesive material and weathered stone material.
All types of base courses and subbase courses can be compacted deeper and the interchangeable
drums, D to PD, and vice versa, facilitate even greater variety in the range of application.
Certain accessories, such as the compaction meter, tachograph and the CCS/RA field computer,
are described in separate instructions.
KEEP THIS MANUAL FOR
FUTURE REFERENCE
2 CA 602 M602EN2
CONTENTS
Safety instruction – Personal Safety
Special caution – Machine or component
damage
WARNING SYMBOLS
GENERAL
Read through the entire manual before
starting any maintenance operations.
Ensure good ventilation (air extraction) if the
diesel engine is run indoors.
If the gas-springs of the hood are out of action
and the hood is put at its upper position – block
the hood so that it cannot fall.
It is important that the roller is maintained correctly to ensure
proper function. It should be kept clean so that any leakage,
loose bolts and loose connections can be discovered in time.
Make a habit of inspecting the roller every day before starting
up by checking all round and underneath the machine to
detect any sign of leakage or other faults.
SPARE A THOUGHT FOR THE ENVIRONMENT! Do not
let oil, fuel and other environmentally hazardous substances
contaminate the environment.
This manual contains instructions for periodic measures that
should normally be performed by the operator.
There are additional instructions relating to the diesel
engine, for which the manufacturer’s instructions are
detailed in the engine manual. This is found under a
separate flap in the roller’s product binder.
WARNING
CAUTION
WARNING
WARNING
CAUTION
WARNING
Page
Lubricants and symbols .................................................. 3
Technical specifications ............................................... 4-6
Maintenance schedule .................................................... 7
Maintenance measures ................................................ 8-9
Every 10 hours of operation (Daily) ......................... 10-12
Every 50 hours of operation (Weekly) ..................... 13-15
Every 250 hours of operation (Monthly) ................... 16-20
Every 500 hours of operation (Every three months) 21-22
Every 1000 hours of operation (Every six months) . 23-25
Every 2000 hours of operation (Yearly) .................... 26-29
Long-term storage ......................................................... 30
Special instructions ....................................................... 31
Electrical system, fuses ........................................... 32-34
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
3CA 602 M602EN2
LUBRICANTS AND SYMBOLS
ENGINE OIL Shell Universal SAE 15W/40 or equivalent
API Service CF-4/SG, (CD/CE)
HYDRAULIC FLUID
ambient air temperature Shell Tellus TX68 or equivalent
-10°C – +40°C (14°F - 104°F)
ambient air temperature Shell Tellus TX100 or equivalent
above +40°C (above 104°F)
BIODEGRADABLE 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.
TRANSMISSIONSOLJA
ambient air temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C – +40°C (5°F - 104°F)
ambient air temperature Shell Spirax HD85W/140 or equivalent
above +40°C (above 104°F)
DRUM CARTRIDGE OIL Mobil SHC 629
GREASE SKF LGHB2 (NLGI Class 2) or equivalent for the
articulated joint
Shell Retinax LX2 or equivalent for other grease points
FUEL See the engine manual
COOLANT GlycoShell or equivalent
mixed 50/50 with water Anti-freeze protection down to about -41°C (-106°F).
Always use high-quality lubricants, in the quantities
specified. Excess grease or oil can promote overheating,
resulting in premature wear.
CAUTION
Engine, oil level Air pressure
Engine, oil filter Air filter
Hydraulic fluid tank, level Battery
Hydraulic fluid filter Recycling
Transmission, oil level Fuel filter
Drum, oil level Coolant, level
Oil for lubrication
Other fuel and lubricants are required for operation in
extremely high or extremely low ambient temperature. See
the “Special instructions” chapter, or consult Dynapac.
CAUTION
4 CA 602 M602EN2
Vibrationdata CA602D CA602PD
Static linear load, kg/cm (pli) ..................................... 59,6 (334) –
Amplitude (High), mm (in) ...........................................1,8 (0.07) 1,8 (0.07)
Amplitude (Low), mm (in) ........................................... 1,1 (0.04) 1,1 (0.04)
Frequency (High/Low ampl.), Hz (vpm) ............. 27/31 (1620/1860) 27/31 (1620/1860)
Centrifugal force
(High amplitude), kN (lb) ......................................... 276 (62,100) 276 (62,100)
Centrifugal force
(Low amplitude), kN (lb) .......................................... 229 (51,525) 229 (51,525)
TECHNICAL SPECIFICATIONS
Weights & dimensions CA602D CA602PD
Operating mass with ROPS, EN500, kg (lbs) .........18600 (41006) 18600 (41006)
Operating mass without ROPS, kg (lbs) ................. 18100 (39904) 18100 (39904)
Operating mass with cab, kg (lbs) .......................... 18600 (41006) 18600 (41006)
Length, standard-equipped roller, mm (in) ..................6000 (236) 6000 (236)
Width, standard-equipped roller, mm (in) ................... 2380 (94) 2380 (94)
Height, with ROPS, mm (in) .......................................2929 (115) 2987 (117)
Height, without ROPS, mm (in) .................................. 2134 (84) 2208 (87)
Height, with cab, mm (in) ............................................2952 (116) 2987 (118)
Fluid volumes, litres (gal or qts) CA 602
Rear axle:
• Differential ........................................ 12 (12.7 qts)
• Planetary gears ...........................................1,8 (1.9 qts)/each side
Drum gearbox ................................................ 3,5 (3.7 qts)
Drum cartridge ............................................... 2,2 (2.3 qts)/each side
Hydraulic reservoir ............................. 52 (13.7 gal)
Oil in hydraulic system ....................... 43 (11.4 gal)
Lubrication oil, diesel engine .............. 14 (14.8 qts)
Coolant, diesel engine .......................... 26 (6.9 gal)
Fuel tank ........................................... 320 (84.5 gal)
Electrical system
Battery........................................... 12 V, 170 Ah
Alternator ....................................... 14 V, 105 A / 95 A
Fuses ............................................ See under heading “Electrical System”
Tires (all-weather)
Tire dimensions ............................. 23.1 x 26.0 8 Ply, 600/60-30,5
Tire pressure ................................. 110 kPa (1,1 kp/cm
2
) (16 psi)
The tires can be optionally filled with fluid, (extra weight up to 700 kg/tire)
(1,544 lbs/tire). When servicing, bear this extra weight in mind.
WARNING
5CA 602 M602EN2
TECHNICAL SPECIFICATIONS
Tightening torque
Hydraulic system
ROPS
Tightening torque in Nm (lbf.ft) for oiled, bright
galvanized bolts tightened with a torque wrench.
Bolt size: M24 (P/N 90 39 64)
Strength class: 10.9
Tightening torque: 800 Nm (590 lbf.ft)
(for Dacromet treated)
CAUTION
ROPS bolts must always be tightened dry.
M STRENGTH CLASS
thread 8.8 10.9 12.9
M6 8,4 (6.2) 12 (8.9) 14,6 (10.8)
M8 21 (15.5) 28 (20.7) 34 (21.1)
M10 40 (15.5) 56 (41.3) 68 (25.1)
M12 70 (51.6) 98 (72.3) 117 (86.3)
M16 169 (124.7) 240 (177) 290 (213.9)
M20 330 (243.4) 470 (346.7) 560 (413.1)
M24 570 (420.4) 800 (590.1) 960 (708.1)
M30 1130 (833.5) 1580 (1165.4) 1900 (1401.4)
M36 1960 (1445.7) 2800 (2065.3) –
Opening pressure, MPa (psi)
Drive system 38,0 (5,500)
Charge system 2,0 (290)
Vibration system 37,5 (5,400)
Steering system 18,0 (2,600)
Brake release 1,4 (200)
6 CA 602 M602EN2
TECHNICAL SPECIFICATIONS
The vibration values are measured in conformance
with the driving mode described in EU directive
2000/14/EC on EU equipped machines, on soft
polymer material with vibration switched ON and
the operator’s seat in 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/s
2
.)
Hand/arm vibration is measured at less than the
action value of 2.5 m/s
2
specified in the same
directive. (The limit value is 5 m/s
2
.)
Vibrations - Drivers seat
(ISO 2631)
CA 602 111 87 79
The acoustic values are measured in conformance with EU directive
2000/14/EC on EU-equipped machines, on soft polymer material
with vibration switched ON and the operator’s seat in transport
mode.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A)
Acoustic
pressure level,
operator’s ear
(platform)
dB(A)
Acoustic
pressure level,
operator’s ear
(cab) dB(A)
Noise level can vary when driving on different
courses and with different seat positions.
Vibration levels may vary when driving on
different courses and with different seat
positions.
CAUTION
CAUTION
7CA 602 M602EN2
MAINTENANCE SCHEDULE
Fig. 1 Service and maintenance points
1 2 3 4 5 6 7 8 9 10 37 11 12 13
26 25 24 23 22 21 20 19 36 35 34 18 17 16 15
14
33
32
31
30
29
28
27
1 Radiator grille
2 Oil level, diesel engine
3 Fuel filter, initial fuel filter
4 Air filter
5 Engine cover, hinges
6 Hydraulic fluid reservoir, sightglass
7 Bleeding filter
8 Hydraulic fluid filters (2 filters)
9 Drainage, hydraulic fluidreservoir
10 Hydraulic fluid, filler
11 Fuse-box
12 Drum cartridge, filling, 2 fillers
13 Drum gearbox
14 Scrapers
15 Drum cartridge oil, level plugs, 2 pcs.
16 Rubber elements and attachment screws
17 Steering joint
18 Steering cylinders, 2 pcs.
19 Flywheel casing, hydraulic pumps
20 Wheel nuts
21 Tires, pressure
22 Rear axle, differential
23 Rear axle, planetary gears, 2 pcs.
24 Rear axle suspension, 2 sides
25 Oil filter, diesel engine
26 Drainage, fuel tank
27 Diesel engine mountings, 4 pcs.
28 Feed pump, fuel
29 Diesel fuel, filler
30 Battery
31 Radiator
32 Hydraulic fluid cooler
33 Drive belts, cooling, alternator
34 Steering chain
35 Seat bearing
36 Steering chain
37 Forward/Reverse lever
8 CA 602 M602EN2
MAINTENANCE MEASURES
Item. in Measure See page Comments
fig. 1
Before starting each day
14 Check scraper setting 10
1 Check for free circulation of cooling air 10
31 Check coolant level 11 See engine manual
2 Check diesel engine oil level 11 See engine manual
29 Top up fuel tank 12
6 Check fluid level in hydraulic reservoir 12
Check brakes 12
Every 10 hours of operation (Daily)
Item. in Measure See page Comments
fig. 1
Check that hoses and couplings are not leaking
7 Inspect/clean the filter element in the air cleaner 13 Replace as required
17 Lubricate steering joint 14
18 Lubricate steering cylinders’ attachments 14
20 Check the wheel-nuts are tightened 15
21 Check tire pressure 15
Inspect the air conditioning 15 Optional
After the first 50 hours of operation,
change only the drum oil and all the oil filters.
Every 50 hours of operation (Weekly)
CAUTION
CAUTION
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 service/
maintenance instructions which relate to the
diesel engine.
CAUTION
9CA 602 M602EN2
Item. in Measure See page Comments
fig. 1
3 Replace fuel filter See engine manual
5 Lubricate controls and joints 21
3 Replace fuel pre-filter 21
36 Lubricate the steering chain 22 Optional
35 Lubricate the seat bearing 22 Optional
MAINTENANCE MEASURES
Item. in Measure See page Comments
fig. 1
23 Check oil level in rear axle/planetary gearing 16
13 Check oil level in drum gearbox 16
15 Check oil level in the drum cartridge 17
32 Clean the radiators 18
20, 24 Re-tighten bolted joints 19 Applies only to new or
reconditioned component
16 Check rubber elements and screw fasteners 19
25 Change engine oil and oil filter 19 See engine manual
30 Check battery 20
Inspect the air conditioning 20 Optional
Every 250 hours of operation (Monthly)
Item. in Measure See page Comments
fig. 1
8 Change hydraulic fluid filter 23
9 Drain condensate from hydraulic reservoir 23
26 Drain condensate from fuel tank 24
4 Replace air cleaner main filter 24
22 Change oil in rear axle differential 24
23 Change oil in the rear axle planetary gearing 25
- Replace the fresh air filter in the cab 25 Optional
Check diesel engine valve clearance See engine manual
33 Check belt tension for drive belt system See engine manual
Every 1000 hours of operation (Every six months)
Item. in Measure See page Comments
fig. 1
9, 10 Change fluid in hydraulic reservoir 26
12, 15 Change oil in the drum cartridge 26
13 Change oil in drum gearbox 27
37 Lubricate Forward/Reverse control 27
Overhaul air conditioning 28 Optional
Every 2000 hours of operation (Yearly)
Every 500 hours of operation (Every three months)
10 CA 602 M602EN2
EVERY 10 HOURS OF OPERATION (Daily)
Loosen the screws (2) and adjust to light contact
against the drum. Tighten the screws.
2 1 1 2
Fig. 3 Scrapers
1. Scraper blade
2. Screws
Circulation of air – Inspection
Fig. 4 Cooling vents
1. Hood lock
1
Soft scrapers (Optional)
Fig. 2 Scrapers
1. Scraper blade
2. Screws
12
Scrapers
– Checking / Adjustment
Loosen the screws (2) and adjust to 20 mm (0.8 in).
Tighten the screws.
Repeat the procedure on the other scraper.
Ensure that the engine has free circulation of cooling air
through the vents in the hood.
To open the engine hood, turn the locking arms upward
(1) and raise the hood to its fully open position, checking that the red safety catch on the left gas spring is
latched.
If the gas-springs of the hood are out of
action and the hood is put at its upper
position – block the hood so that it cannot
fall.
WARNING
11CA 602 M602EN2
EVERY 10 HOURS OF OPERATION (Daily)
Fig. 6 Engine compartment
1. Oil dipstick
1
Fig. 5 Radiator
1. Max level
2. Min level
3. Filler cap
12 3
Coolant level
– Check
Diesel engine
– Check oil level
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.
Danger of burns. Take care not to touch
any hot parts of the engine or the radiator
when removing the dipstick.
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 manual.
WARNING
WARNING
Check that level of the coolant is between the max. and
min. marks.
Danger of scalding. Take great caution if
the radiator cap must be opened while the
engine is hot. Wear protective gloves and
goggles.
Fill with a mixture of 50% water and 50% anti freeze.
See page 3 in these instructions and in the engine
manual.
Flush the system every other year and
change the coolant. Ensure also that air can
flow unrestricted through the radiator.
WARNING
CAUTION
12 CA 602 M602EN2
EVERY 10 HOURS OF OPERATION (Daily)
1
Fig. 8 Hydraulic fluid reservoir
1. Sight glass
2. Filler pipe
Position the roller on a level surface and check that the
sight glass reading (1) is between the max. – min.
marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.
Hydraulic reservoir
– Check fluid level
Brake function – Check
Fig. 9 Control panel
1. Reserve/parking brake knob
2. Forward/reverse lever
12
1
Fig. 7 Fuel tank
1. Filler pipe
Fuel tank – Filling
2
Refuel daily with diesel fuel up to the lower edge of the
filler pipe (1). Follow the engine manufacturer’s
specification with regard to the quality of diesel fuel.
Switch off the diesel engine. Short-circuit
(press) the filler gun against a non-insulated part of the roller before refuelling, and
against the filler pipe (1) while refuelling.
Never refuel while the engine is running,
do not smoke, and avoid spilling fuel.
The fuel tank holds 320 liters (84.5 gal.).
WARNING
WARNING
Check operation of the brakes as follows:
Drive the roller slowly forward.
Push the reserve/parking brake knob (1); the warning
lamp on the instrument panel should light and the roller
should stop.
After testing the brakes, set the forward/reverse lever
(2) in neutral.
Pull up the reserve/parking brake knob.
The roller is now ready for operation.
WARNING
13CA 602 M602EN2
EVERY 50 HOURS OF OPERATION (WEEKLY)
Air cleaner
– Check/clean
Main filter – Cleaning with
compressed air
Fig. 11 Main filter
23
Fig. 10 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
1 4 5
Fig. 12 Air filter
4. Backup filter
Backup filter
– Replacement
4
Replace or clean the air cleaner’s main filter if
the warning lamp on the instrument panel lights
up when the diesel engine is operating at full
speed.
Undo the three locking braces (1). Then pull off the
cover (2) and pull out the main filter (3).
Do not remove the backup filter (4).
Replace the backup filter with a new one at every 5th
replacement or cleaning of the main filter. The backup
filter cannot be cleaned.
When replacing the backup filter (4), pull out the old filter from its holder, insert a new one and refit the air
cleaner in the reverse order to the instructions given in
the figure above.
If the main filter is to be cleaned, compressed air at
max. 5 bar (72 psi) pressure should be used. Blow up
and down along the paper creases on the inside of the
filter.
Hold the nozzle at least 2–3 cm (0.8-1.2 in) away from
the paper creases so that the paper does not tear under the pressure of air.
Use protective goggles when working with
compressed air.
Wipe the inside of the cover (2) and filter housing (5).
Check that the hose clamps between the filter
housing and inlet hose are tightened and that
they do not leak. Check the entire length of
the hose all the way to the engine.
Once the main filter has been cleaned a
maximum of 5 times, it must be replaced.
WARNING
CAUTION
CAUTION
CAUTION
14 CA 602 M602EN2
EVERY 50 HOURS OF OPERATION (Weekly)
Steering joint/Steering cylinders
– Lubrication
Fig. 13 Steering joint, right side
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.
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 lubricating nipples of the steering system on the
right-hand side of the machine (x7).
Use grease as per the lubricant specification.
Steering joint – Lubrication
Steering cylinder
– Lubrication
Fig. 15 Steering cylinder, right side
4. Lubricating nipple, rear right steering
cylinder mount (x1)
5. Lubricating nipple, rear left steering
cylinder mount (x1)
1
Fig. 14 Steering joint, right side
1. Lubricating nipples, steering joint (x3)
2. Lubricating nipple, steering joint
3. Lubricating nipples, cylinder mount (x1)
1
2
3
4 5
Wipe off any dirt and grease from the nipples.
Lubricate each nipple (1, 2, and 3) with five strokes of a
manual grease gun. Check that grease penetrates
through the bearings.
If grease does not penetrate through the bearings, it
may be necessary to relieve the load on the articulated
joint with a hydraulic jack and then repeat the greasing
process.
WARNING
CAUTION
WARNING
Wipe all the nipples clean from dirt and grease.
Grease the nipples (4 and 5) with five strokes of the
hand grease gun.
Turn the steering wheel fully to the right to gain access
to the front lubricating nipple on the left steering
cylinder and the lubricating nipple on the bearing bushing. Allow a little grease to remain on the nipples after
lubrication, it will prevent dirt from entering.
15CA 602 M602EN2
EVERY 50 HOURS OF OPERATION (Weekly)
1
2
Tires – Tire pressure
Wheel nuts – Tightening
Check the tire pressures using a pressure gauge.
If the tires are filled with fluid, the air valve (1) must be
in the “12 o’clock” position during pumping.
The relevant tire pressures are given under the heading
“Specifications”.
Check both tires.
When changing the tires it is important that
both of them have the same rolling radius. This
is necessary to ensure proper functioning of
the anti-slip in the rear axle.
Check the tightening torque of the wheel nuts (2) at 470
Nm (350 lbf.ft). Check both wheels and all the nuts.
(Applies only to new machine or recently fitted wheels.)
Check the safety manual that accompanies
the roller before filling the tires with air.
Note: The tires are filled with liquid.
This makes the wheels heavier than normal.
Fig. 16 Wheels
1. Air valve
2. Wheel nut
Never work under the roller with the engine running. Park on a level surface, chock
the wheels and press the parking brake
control.
Open the engine hood while the unit is running and look
at the sight glass (1) to make sure that no bubbles are
visible on the dryer filter. The filter is located on the left
side in the front of the engine compartment. 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.
Air conditioning (Optional)
– Inspection
Fig. 17 Drying filter
1. Sight glass
1
Fig. 18 Cab
1. Condenser element
Clean the condenser element (1) free from dust as
necessary.
1
CAUTION
WARNING
WARNING
WARNING
16 CA 602 M602EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Rear axle differential
– Check oil level
1
1
Fig. 19 Oil level check – differential housing
1. Oil level/Filler plug
Rear axle planetary gears
– Check oil level
Fig. 20 Oil level check – planetary gear
1. Oil level/Filler plug
Fig. 21 Oil level check – Drum gearbox
1. Oil level plug
2. Filler plug
3. Drainplug
Drum gearbox
– Check oil level
1
2
3
Never work under the roller with the engine running. Park on a level surface. Block
the wheels securely.
Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
specification.
Position the roller with the level plug (1) at 3 o’clock.
Wipe clean the area around the plug (1) and then undo
the plug.
Ensure that the oil level reaches up to the lower edge of
the plug hole.
Top off with oil to the right level if the level is low. Use
transmission oil according to the lubricant specification.
Clean and screw in the plugs tightly.
WARNING
Position the roller with the level plug (1) in the planetary
gears at 9 o’clock.
Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
specification.
Check the oil level in the same way in the rear axle’s
other planetary gear.
17CA 602 M602EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Fig. 23 Roller, right-hand side
1. Filler plug
2. Drain plug
3. Level plug
Drum cartridge
– Checking the oil level
1
2
1
Drum cartridge
– Checking the oil level
Fig. 22 Left side of drum
1. Indicator pin
Drum cartridge
3
2
Fig. 24 Drum cartridge
2. Drain plug
3. Level plug
3
Position the machine level so that the indicator pin (1)
on the inside of the drum is aligned with the top of the
drum frame.
Then unscrew the level plug (3) at the bottom of the
cartridge (wrench width 24 mm (0.9 in)) until the hole in
the middle of the plug becomes visible.
Top off with oil through the filling plug (1), until oil begins
to run out from the level-plug hole. The level is correct
when it stops running.
Ensure that only MOBIL SHC 629 is used in
the cartridges.
Do not overfill with oil – risk for overheating.
Clean and refit the plugs. Repeat the procedure on the
opposite side.
CAUTION
CAUTION
Wipe the filling plug and level plug clean from dirt.
Unscrew the filling plug (1)
18 CA 602 M602EN2
EVERY 250 OPERATING HOURS (Monthly)
Fig. 26 Engine room
1. Water cooler
2. Hydraulic fluid cooler
3. Intercooler
Radiator
– Check/clean
1 2
Fig. 25 Drum
1. Ventilated screw
Drum cartridge
– Cleaning the ventilation screw
1
3
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.
Check that air can flow freely through the radiators (1)
and (2).
A dirty radiator should be blown clean with compressed
air, or alternatively cleaned with a high-pressure washer.
Blow or wash 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.
Use protective goggles when working with
compressed air or a high-pressure washer.
WARNING
CAUTION
Clean the drum ventilation hole. The hole is required to
eliminate excess pressure inside the drum.
WARNING
19CA 602 M602EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Bolted joints
– Checking tightening torque
Fig. 27 Right side of machine
1. Steering pump
2. Rear axle
3. Engine suspension
4. Wheel nuts
Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.
Steering pump against engine (1) 38 Nm (28 lbf.ft).
Engine suspension (3). Check that all M12 bolts (x20)
are tightened, 78 Nm (57 lbf.ft).
Wheel nuts (4). Check that all nuts are tightened, 470
Nm (347 lbf.ft), oiled.
(The above applies to new or replaced components only.)
Check all the rubber elements (1), and replace them all if
more than 25% of the elements on the same side of the
roller have cracks deeper than 10–15 mm (0.4-0.6 in).
Use a knife blade or other pointed tool when carrying
out this check.
Check also that the screw fasteners (2) are tightened.
Fig. 28 Roller, vibration side
1. Rubber element
2. Screw fasteners
Rubber elements and screw
fasteners – Check
3
2
1
Fig. 29 Left side of engine
1. Drain plug
2. Oil filter
Diesel engine
– Changing the filter and oil
12
4
1
2
Position the roller on a level surface. Stop
the engine and apply the parking brake/
reserve brake.
The oil drain plug (1) is most easily accessible from
underneath the engine. It is fitted on a tube to the rear
axle. Drain the oil when the engine is warm. Place a
receptacle for at least 15 litres (16 qts) underneath the
drain plug.
Danger of being scalded when draining off
hot oil. Protect your hands.
Change the engine oil filter (2) at the same time.
See also the engine manual.
Dispose of the drained oil and filter in an
approved manner.
WARNING
WARNING
20 CA 602 M602EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Battery
– Check electrolyte level
123 1
Fig. 30 Battery box
1. Quick-release screws
2. Battery cover
3. Battery
Battery cell
Fig. 31 Electrolyte level in battery
1. Cell cover
2. Electrolyte level
3. Plate
1
2
3
10 mm
(0.4 in)
Inspect refrigerant hoses and connections and make
sure that there are no signs of oil film that could indicate
leakage of refrigerant.
Air conditioning (Optional)
– Inspection
Fig. 32 Air conditioning
1. Refrigerant hoses
2. Condenser element
1
2
Make sure there are no open flame in the
vicinity when checking the electrolyte level.
An explosive gas is formed in the battery
during the charging process.
Lift up the engine compartment cover and undo the
quick-release screws (1).
Raise the battery cover (2).
Dry the upper face of the battery.
Use protective goggles. The battery contains corrosive acid. In the event of contact, rinse with water.
WARNING
WARNING
WARNING
CAUTION
Remove the cell covers and check that the fluid level
is about 10 mm (0.4 in) above the plates. Check the
level in all the cells. If the level is lower, top up to the
correct level with distilled water. If the ambient air temperature is below freezing point, the engine should be
run for a while after the distilled water is added, otherwise there is a risk that the water might freeze.
Check that the ventilation holes in the cell covers are
not blocked, then refit the covers.
The cable terminals must be properly tightened and
clean. Corroded cable connections should be cleaned
and greased with alkaline Vaseline.
When disconnecting the battery, always
disconnect the negative cable first. When
connecting the battery, always connect the
positive cable first.
Discard used batteries properly. Batteries
contain lead, which is detrimental to the
environment.
Before doing any electric welding on the
machine, disconnect the battery ground
cable and then all electrical connections
to the alternator.
21CA 602 M602EN2
EVERY 500 HOURS OF OPERATION (Every three months)
Fig. 33 Engine hood
1. Hinge
Controls and moving
joints – Lubrication
1
Fig. 34 Engine
1. Screw
2. Glass bowl
3. Strainer
Prefilter – 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.
Loosen the screw (1) and remove the glass bowl (2).
Take out the strainer (3) and clean using a nonflammable fluid. Reinstall the strainer and the bowl.
Start the engine and check that the pre-filter does not leak.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning.
3
2
1
Lubricate engine hood hinges (1) and the slide rails of
the operator’s seat with grease, other joints and
controls with oil. Lubricate the cab hinges with grease.
See lubricant specification.
WARNING
WARNING
22 CA 602 M602EN2
EVERY 500 HOURS OF OPERATION (Every three months)
Seat bearing – Lubrication
4
5
6
3
2
1
Fig. 36 Seat bearing
1. Lubrication nipple
2. Cogwheel
3. Steering chain
4. Adjusting screw
5. Cover
6. Slide rails
7. Slew interlock
7
Fig. 35 Underneath operator’s position
1. Steering chain
2. Chain-tightening device
3. Adjusting nut
4. Nuts
5. Control valve mount
Steering chain and
Seat bearing – Lubrication
a
1
2
4
5
3
Optional on rollers without cab
Remember that the chain is a vital part of the
steering mechanism.
Clean and lubricate the chain (1) between the seat
bearing and steering valve with grease. The chain is
accessible underneath the platform.
It is not necessary to remove the chain.
Adjust the chain as follows if it has slackened so that
size “a” is less than 30 mm (1.2 in): Loosen the nuts (4)
and adjust the mount (5) backwards with the adjusting
nut (3) until size “a” is 50 mm (2 in).
CAUTION
Remember that the chain is a vital part of the
steering mechanism.
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
needs to be lubricated more often.
Clean and grease the chain (3) between the seat and
the steering column.
If the chain becomes slack on the cogwheel (2), loosen
the screws (4) and move the steering column forward,
tighten the screws and check the tension of the chain.
CAUTION
CAUTION
23CA 602 M602EN2
EVERY 1000 HOURS OF OPERATION (Every six months)
Hydraulic reservoir
– Drainage
Fig. 39 Hydraulic reservoir, underside
1. Drainage tap
2. Plug
1
2
Fig. 38 Engine compartment
1. Hydraulic fluid filters (x2)
Fig. 37 Hydraulic fluid reservoir
2. Filler cover/bleeder filter
3. Sight glass
1
Hydraulic fluid filter
– Change
3
2
Condensate in the hydraulic reservoir is removed via
the drainage tap (1).
Drainage should be performed when the roller has been
standing for a long period of time, for example overnight. Drain as follows:
Remove the plug (2).
Place a container under the tap.
Open the tap (1) and let any trapped condensate run out.
Shut the drainage tap.
Refit the plug.
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.
Undo the cover/bleeder filter (2) on top of the reservoir
so that over-pressure inside the reservoir can be eliminated.
Check that the bleeder filter (2) is not blocked – air
should flow freely through the cover in both directions.
If there is a blockage in either direction, clean the filter
with a little diesel oil and blow through with compressed
air until the blockage disappears, or replace the cover
with a new one.
Always use protective goggles when working with compressed air.
Clean thoroughly around the oil filters.
Remove the oil filters (1) and dispose of them
in an approved manner. They are single-use
filters and cannot be cleaned.
Check that the old sealing rings do not remain
stuck on the filter holders, otherwise this might
give rise to oil leakage between the old and
new seals.
Clean the filter holder sealing surfaces thoroughly.
Apply a thin film of hydraulic fluid on the seals of the
new filter. Screw on the filter by hand.
First tighten the filter until its seal is in contact
with the filter attachment. Then turn an additional half revolution. Do not over-tighten the
filter as this might damage the seal.
Start the engine and ensure that there is no leakage of
hydraulic fluid from the filters. Check level of fluid in the
sight glass (3) and top up as required.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning
WARNING
WARNING
CAUTION
WARNING
CAUTION
24 CA 602 M602EN2
Never work under the roller with the engine running. Park on a level surface and
block the wheels securely.
Wipe clean and remove the level/filler plug (1) and all
three drain plugs (2) and drain the oil into a suitable
receptacle. The volume is almost 12 litres (12.7 qts).
Save the oil and deposit it in an approved
manner.
Refit the drainage plugs and top up with fresh oil until
the correct level is reached.
Note: It takes a while for the oil to flow into the axle. Do
not fill the entire volume all at once.
Refit the oil-level/filler plug. Use transmission oil, see
the lubrication specification.
EVERY 1000 HOURS OF OPERATION (EVERY SIX MONTHS)
Fig. 40 Fuel tank
1. Drainage plug
Fuel tank – Drainage
1
23
Fig. 41 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
1 4 5
Air filter – Replacement
Fig. 42 Rear axle
1. Oil level/Filler plug
2. Drainage plugs
Rear axle differential
– Oil change
1
2
Water and sediment in the fuel tank are removed via
the drainage plug in the bottom of the fuel tank.
Be very careful during draining. Do not drop
the plug or else all the fuel will flow out.
Drainage should be performed when the roller has been
standing for a long period of time, for example overnight. The fuel level should be as low as possible.
The roller should preferably have been standing with
this side somewhat lower, so that water and sediment
will gather near the drainage plug (1). Drain as follows:
Place a container under the plug (1).
Undo the plug and drain off the water and sediment until
only clean diesel fuel appears through the plug opening.
Refit the plug.
Replace the main filter (3) of the air cleaner even if it
has not yet been cleaned five times, see under 50
hours for filter replacement.
If a clogged filter is not replaced the exhaust
fumes will be black and the engine will loose
power. There will also be danger of severe
damage to the engine.
CAUTION
CAUTION
WARNING
25CA 602 M602EN2
EVERY 1000 HOURS OF OPERATION (Every six months)
1
Fig. 44 Planetary gear/filling position
1. Plug
Rear axle planetary gears
– Oil change
Fig. 43 Planetary gear/drainage position
1. Plug
1
Fig. 45 Cab
1. Fresh air filter
2. Screw (x2)
Fresh air filter – Replacement
1
2
2
Position the roller with the plug (1) at its lowest position.
Wipe clean, unscrew the plug (1) and drain the oil into a
suitable receptacle. The volume is about 2 litres (2.1 qts).
Save the oil and deposit it in an approved
manner.
Loosen the two screws (2) at the rear of the cab roof.
Take down the whole holder and remove the filter
insert.
Replace with a new filter.
It may be necessary to replace the filter more often if
the machine is used in a dusty environment.
Position the roller with the plug at 9 o’clock.
Fill with oil to lower edge of level hole.
Refit the plug and repeat the process on the other side.
Use transmission oil. See the lubrication specification.
26 CA 602 M602EN2
EVERY 2000 HOURS OF OPERATION (Yearly)
Hydraulic reservoir
– Fluid change
Fig. 46 Hydraulic reservoir, underside
1 Drainage tap
2. Plug
Drum cartridge
– Oil change
Fig. 48 Right side of the drum
1. Filler plug
2. Drain plug
3. Level plug
1
2
1
2
1
Fig. 47 Left side of drum
1. Indicator pin
3
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.
Danger of being burned when draining hot
oil. Protect your hands.
Obtain a container for collecting the used fluid. The container should have a volume of at least 60 litres (16 gal).
A suitable container may be an empty oil drum or similar item which is placed beside the roller. The fluid then
runs in a hose from the drainage plug (1) to the oil
drum, after the plug (2) has been removed and the tap
opened.
Save the oil and deposit it in an approved
manner.
Fill up with fresh hydraulic fluid as per the instructions
under the heading “Hydraulic reservoir – Check fluid
level”.
Replace the hydraulic fluid filters at the same time.
Start the diesel engine and operate the various hydraulic functions.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run
indoors.
(Risk of carbon monoxide poisoning)
Check the fluid level and top up if necessary.
Position the machine level so that the indicator pin (1)
on the inside of the drum is aligned with the top of the
drum frame.
WARNING
WARNING
WARNING
Place a receptacle for about 5 litres (5.3 qts)
underneath the level/drain plug (2).
Save the oil and deposit it in an approved
manner.
Clean and unscrew the filler plug (1) and the drain plug
(2). Allow all of the oil to drain off. Fit the drain plug, and
fill with fresh synthetic oil according to the instructions
under the "Drum cartridge-checking the oil level"
heading, page 17.
Repeat the procedure on the opposite side.
CAUTION
Ensure that only MOBIL SHC 629 is used in
the cartridges.
27CA 602 M602EN2
EVERY 2000 HOURS OF OPERATION (Yearly)
Drum gearbox
– Changing the oil
Fig. 49 Drum gearbox
1. Drain plug
2. Filler plug
3. Level plug
Place the roller on a level surface with the plugs (1) and
(2) as illustrated.
Wipe clean, unscrew the plugs (1, 2 and 3) and drain
the oil into a suitable receptacle, capacity about 3.5
liters (3.7 qts).
Refit the plug (1) and fill with oil up to the level plug (3),
according to “Drum gearbox – Checking the oil level”
(see page 16).
Use transmission oil, see Lubricant Specification.
Clean and refit the level plug (3) and filler plug (2).
2
1
3
Forward/Reverse lever
– Lubrication
Fig. 50 Forward/Reverse lever
1. Screw
2. Plate
3. Cam disk
12 3
Unscrew the screws (1) and remove the plate (2).
Grease the contact surface of the cam disc (3).
Refit the plate (2) with the screws (1).
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. 51 Steering joint
28 CA 602 M602EN2
EVERY 2000 OPERATING HOURS (Yearly)
Fig. 53 Aircondition
1. Cooling element
2. Drain valve (x2)
Air conditioning (Optional)
– Overhaul
Fig. 52 Cab
1. Condenser element
1
1
2
Regular inspection and maintenance are necessary to
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.
CAUTION
WARNING
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.
Drain by pressing the valves (2) that are located under
the cab.
29CA 602 M602EN2
EVERY 2000 OPERATING HOURS (Yearly)
Fig. 54 Compressor
Fig. 55 Drying filter in engine compartment
1. Sight glass
2. Moisture indicator
1
2
Never work under the roller with the engine 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
by an authorized service company.
The compressor will be damaged if the unit
is run with too little refrigerant.
Do not disconnect the hose coupling.
The cooling system is pressurized.
Incorrect handling can result in serious
personal injuries.
The system contains pressurized refrigerant. Releasing refrigerants into the air is
prohibited. The refrigerant circuit may only
be repaired by an authorized company.
Inspect the compressor and hydraulic motor
fastenings.
The unit should be run at least five minutes every
week, if possible, to ensure lubrication of rubber
gaskets in the system.
The air unit should not be run when the
outdoor temperature is below 0°C (32°F).
CAUTION
WARNING
WARNING
WARNING
WARNING
WARNING
30 CA 602 M602EN2
LONG-TERM STORAGE
Fig. 56 Protecting the roller from the
elements
* See the manufacturer’s instructions in the engine
instruction manual, which is supplied together with
the roller.
* Remove the battery from the roller, clean it’s
exterior, check its electrolyte level and recharge it
once a month.
* Cover the air cleaner or its opening with plastic or
tape, and cover also the exhaust pipe’s opening.
This is done so as to prevent moisture from
penetrating into the engine.
Fill the fuel tank completely to prevent condensation.
Drain off any condensation water and fill the hydraulic reservoir to the upper mark.
Lubricate the steering joint bearings and the steering
cylinder’s two bearings with grease.
Grease the steering cylinder’s piston with
conservation grease.
Grease also the engine compartment cover’s hinges, the seat slide rails, the engine-speed control
and the forward/reverse control mechanism.
Check that tire pressure is 110 kPa (1,1 kp/cm2),
(16 psi).
* Place the instrument cover on the steering column.
Cover the entire machine with a tarpaulin, which
should hand some way off the ground. If possible,
store the roller indoors, preferably in a building with a
uniform temperature.
Diesel engine
Battery
Air cleaner, exhaust pipe
Covers, tarpaulin
Fuel tank
Tires (All-weather)
Steering cylinder, hinges etc.
Hydraulic reservoir
For long-term storage (longer than one month),
the following instructions should be followed.
These instructions apply for storage lasting up
to 6 months.
Before re-commissioning the roller, the points
marked with an asterisk * must be restored.
CAUTION
31CA 602 M602EN2
SPECIAL INSTRUCTIONS
Standard lubricants and other
recommended oils
Upon delivery from the factory, the various systems
and components are filled with the oils specified see
lubricant specification and they can be used at ambient
temperatures from -10°C to +40°C (14°F - 104°F).
A maximum temperature of +35°C (95°F)
applies for biological hydraulic fluid.
When operating in hotter ambient temperatures, but up
to max. +50°C (122°F), the following instructions apply:
The diesel engine can handle this temperature with the
standard oil, but the following oils must be used in the
other components:
Hydraulic system with mineral fluid: Shell Tellus TX100
or corresponding.
Other components using transmission oil:
Shell Spirax HD 85W/140 or corresponding.
The temperature limits apply for a roller with standard
features.
Rollers with extra equipment such as noise suppressers etc. may require additional attention at the upper
temperatures.
When washing the machine, do not direct the
jet of water directly at the fuel or hydraulic fluid
tank covers. This is particularly important
when using a high-pressure washing unit.
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.
If there is a fire in or on the machine, it is best to use an
ABE-class fire extinguisher. However, a BE-class CO
2
extinguisher is also suitable.
If the roller is equipped with a protective structure
(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.
When an auxiliary starter battery is used, always
connect the positive terminal on the auxiliary battery to
the positive terminal on the roller’s battery, and
negative to negative.
Higher ambient temperature
max. +50°C (122°F)
Temperatures
High-pressure washing
Extinguishing fires
ROPS, protective cab
Starting assistance
CAUTION
CAUTION
32 CA 602 M602EN2
ELECTRICAL SYSTEM, FUSES
Fig. 57 Instrument panel
1,2,3,4. Fuse boxes
5. Quick-screws
6. Relays
5 3 4 5
Fuses and relays
5 1 2 5
Fuses on the machine
Fig. 58 Fuse box, left side (1)
7,5A 1. Brake valve, starter relay, hourmeter
7,5A 2. VBS relay
7,5A 3. Indicating panel
7,5A 4. Horn
7,5A 5. Low/High speed/Strike-off blade
3A 6. Reversing alarm
Fuse box, left side (2)
7.5A 1. Instrumentation
3A 2. Compaction meter
7.5A 3. Hazard beacon
7.5A 4. Anti-spin
20A 5. Air cond.
20A 6. Air cond.
= Optional
Fuse box, right side (3)
20A 1. Working lights, left
20A 2. Working lights, right, instrument illumination
7,5A 3. Headlight, left
7,5A 4. Headlight, right, instrument illumination*
5. –
6. –
Fuse box, right side (4)
10A 1. Hazard beacon
10A 2. Direction indicators, main fuse
7.5A 3. Position light, left, front and rear
5A 4. Position light, right, front and rear
5A 5. Direction indicator, left, front, rear and side
5A 6. Direction indicator, right, front, rear and side
* When driving lights are fitted
6
The electrical regulating and control system is
protected against overload by 27 fuses and 12 relays.
The number depends on how much extra equipment is
fitted on the machine.
The four fuse boxes (1,2,3,4) and the relays are
located behind the lower instrument plate, which can be
removed by turning the four quick-screws (5) a ¼-turn.
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
and alternator must not be disconnected
when the engine is running.
WARNING
The figure shows the rating and function of the different
fuses.
All fuses are flat pin fuses.
The tachograph and memory for the radio are protected
at the battery master disconnect switch by a 0,5A and
3A fuse, respectively.
33CA 602 M602EN2
ELECTRICAL SYSTEM, FUSES
Main fuses
Engine compartmentMotorrum
1. Main fuses
2. Fuel solenoid relay
3. Starter relay
There are four main fuses (1). These are located behind
the battery master disconnect switch. The three screws
need to be unscrewed to remove the plastic cover.
The fuses (1) are of the flat pin type.
Supply, machine 30 A (Green)
Supply, cab 50 A (Red)
Supply, lighting 40 A (Orange)
Supply, Aircondition 30 A (Green)
The start relay (2) and the preheating relays (3) for the
engine are also fitted here.
Fuses in the cab
Fig. 59 Fuse box overhead in cab
20A 1. Rear cab spotlight
10A 2. Front cab spotlight. radio
5A 3. Cab interior lighting
25A 4. Heater/fresh air fan
10A 5. Rear screen wiper/screen-wash
10A 6. Front screen wiper/screen-wash
The electric system in the cab is equipped with its own
fuse box, located overhead at the front right part of the
cab.
The figure shows the ampere rating and function of the
different fuses. All fuses are of the flat pin type.
31 2
K2 VBS relay
K3 Main relay
K4 Horn relay
K5 Hourmeter relay
K6 Fuel level relay
K7 Reverse alarm relay
K8 Lights relay
K9 Direction indicator relay
K10 Brakes relay
K11 Air cond. relay
= Optional
Relays
Fig. 61 Instrument panel
34 CA 602 M602EN2
ELECTRICAL SYSTEM, FUSES
Fuses at the battery
disconnecter
Fig. 62 Fuse box in engine compartment
5A 1. QSB engine (ignition)
5A 2. Diagnostic lamps, engine
7.5A 3. ECM electronic
7.5A 4. ECM electronic
7.5A 5. ECM electronic
10A 6. Fuel pump
10A 7. Fuel pump
8. Vacant
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