Dynapac CC100 Operation Manual

SVEDALA COMPACTION AND PAVING
Box 504, SE-371 23 Karlskrona, Sweden
Telephone +46 455 30 60 00
Telefax +46 455 30 60 30
DYNAPAC
CC100
O100EN1
We reserve the right to change without notice
Printed in Sweden
Vibratory Roller
CC100
Operation
O100EN1, 99-10-15
Diesel Engine:
CC100 Deutz F2L 1011F, Isuzu 3 LD1PW-05
These instructions apply from:
CC100 Deutz PIN (S/N) *60710100* Isuzu PIN (S/N) *60750100*
KEEP THIS MANUAL
AVAILABLE FOR
FUTURE USE
CC 100 are primarily designed for repair work on asphalt but are also ideal for the compaction of new layers on small streets, pavements and cycle tracks. They are frequently used as a complement
to larger rollers for the compaction of transverse joints and areas with limited access.
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CONTENS
Page
Safety Instructions ................................................................... 3
Safety decals, location/description.......................................4, 5
Machine and engine data plates...............................................6
Switches and Warning Lamps .........................................7, 8, 9
Switches and controls in the Cab...........................................10
Before Starting ...........................................................11, 12, 13
Starting...................................................................................14
Driving....................................................................................15
Vibrating/Driving.....................................................................16
Safety when driving................................................................17
Braking...................................................................................18
Emergency Braking ............................................................... 18
Stopping ................................................................................. 18
Parking................................................................................... 19
Hoisting ..................................................................................20
Towing ....................................................................................21
Transportation ........................................................................22
Driving Instructions - Summary .............................................23
WARNING - Personal safety may be involved.
CAUTION - Damage to componente or machine.
The safety manual that accompanies the machine should be studied by every operator of the roller. Always follow the safety instructions and do not take the manual away from the roller.
This manual contains instructions concerning operation of the machine. For information regarding care and maintenance, see "MAINTENANCE, CC 100"
This roller is fitted with an alternator. See the ”MAIN­TENANCE” manual and decal on the machine for instructions with regard to any electric welding.
When starting up and driving with a cold roller (cold hydraulic fluid) the braking distance will be longer than when the machine has reached normal operating temperature.
W ARNING SYMBOLS
GENERAL
SAFETY MANUAL
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.
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SAFETY INSTRUCTIONS (Read the Safety Manual also)
1. Read and clearly understand OPERATING MANUAL before starting and operating the machine.
2. Observe and follow all maintenance and service instructions.
3. Do not operate machine unless qualified by training or experience. Do not allow passengers on the roller.
4. Do not operate machine if in need of repair or adjustment.
5. Do not get on or off moving machine. Always use proper steps and hand rails.
6. Roll Over Protective Structures (ROPS) is recommended when stability conditions are questionable. Always use seat belt with ROPS.
7. Drive slowly when turning corners.
8. Avoid sidehill travel. Operate up and down the slope.
9. Ensure that at least two thirds of the drum width rests on already compacted ground when driving close to edges or holes.
10. Be alert to overhead obstacles. Look up as well as down.
11. Use special caution when operating on rough or uneven ground. Always maintain a speed consistent with working conditions.
12. Obey all safety rules and use safety equipment provided for the job.
13. Keep machine clean. Avoid dirt and grease on operator platform. Keep all instructions signs and decals clean and fully legible.
14. Exercise caution when refueling machine:
- Shut down engine.
- No smoking allowed.
- Use no open flames.
- Ground filler nozzle against tank neck to avoid a spark.
15. Block drums and/or tires and apply steering lock before servicing or repairing machine.
16. If noise levels on machine without cabs are over 85 db(A):
- Ear protection is recommended.
17. Do not modify the machine in any way which will affect safety. Any modification on this machine requires prior written approval from Svedala Dynapac.
18. Do not operate machine until hydraulic oil has reached operating temperature. Braking distance can be extended when oil is cold. See starting instruction in OPERATING MANUAL.
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Crush zone, articulated stee­ring. Maintain a safe distance from the crush zone.
Lifting point
Lifting point
Diesel fuel
DO NOT LEAVE DRIVER'S PLATFORM WHILE THE ENGINE IS RUNNING WITHOUT DEPRESSING THE EMERGENCY STOP SWITCH
The operator is urgently requested to read the safety manual, and the operation and maintenance instructions before using the machine.
Warning for hot surface. The surface must not be touched.
Warning for rotating engine components. Keep your hands at a safe distance from the danger zone.
SAFETY DECALS, LOCATION/DESCRIPTION
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SAFETY DECALS, LOCATION/DESCRIPTION
Hydraulic fluid
Warning for hot surface. The surface must not be touched.
The operator is urgently requested to read the safety manual, and the operation and maintenance instructions before using the machine.
Handbooks
Lifting point
Lifting point
Warning for rotating engine components. Keep your hands at a safe distance from the danger zone.
Crush zone, articulated stee­ring. Maintain a safe distance from the crush zone.
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MACHINE AND ENGINE DATA PLATES
Machine plate
Fig. 1 Left step
1. Machine plate
Engine plate
Fig. 3 Engine (Deutz)
1. Type plates
Serial number on frame
Fig. 2 Forward frame
1. Serial number
1
1
1
DEUTZ:
The engine type plate (1) is located on the crankcase. Depending on the type of engine, a second plate may also be found on the air cover. The plate shows the type of engine, serial number and engine data. Please state the serial number of the engine when ordering spares. See also the Engine Manual.
ISUZU:
A decal showing the engine serial number is affixed to the oil sump below the fuel and oil filter. Another decal on top of the valve cover shows the model designation for the engine. See also the engine
manual.
The PIN (serial number) of the frame is punched on the right edge of the front frame. This number is the same as the PIN on the machine plate.
The machine type plate (1) is affixed above the left footstep. The plate shows the manufacturer’s name and address, type of machine, PIN, ie, part identification number, (serial number), weight in working order, engine power and year of manufacture. Please state the PIN (serial number) of the roller when ordering spares.
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SWITCHES, WARNING LAMPS AND CONTROLS
12. *Hazard beacon
13. *Driving lights
14. *Hazard flashers
15. *Direction indicator
16. Safety and instruction manuals
17. Fuse boxes
18. Revs control
19. Vibration ON/OFF
20. Forward/Revers
21. *Fuel gauge
22. Seat switch
* Accessory
1. Horn
2. Starter power switch
3. Sprinkler Drum
4. Glow
5. Vibration selector
6. Reserve/parking brake
7. Instrument guard
8. Charging lamp
9. Brake warning lamp
10. Oil pressure/engine temperature
11. *Working lights
789101112
13
15 14
6 5 4 3 2 1
16 21 18
19 20
17
22
Fig. 4 Operator’s station
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Item in Designation Symbol Function fig. 4
1
Horn, button Press to sound the horn
2
Starter power switch Electric starter circuit is broken in mode O.
All electric switches and lamps are powered in mode | with the exception of the starter circuit.
3
Sprinkler system, drum Regulates the flow of water to the drum.
MAN mode, continuous watering. O mode, watering turned OFF. AUT mode, automatic switching of water ON/OFF on driving forward and reverse.
4
Starter button Press to energize starter motor.
5
Vibration switch Middle position = Vibration OFF.
Right position = Vibration rear drum ON.
6
Reserve brake knob/ OFF (pulled out) is the normal mode while (parking brake (Red knob) driving. ON (pushed in) applies the brakes
and stops the roller. The Forward/Reverse selector must be put in neutral before restarting.
7
Instrument shield Folds over instruments to protect against
weather and sabotage.
8
Charging lamp Warning lamp lights when alternator is not
charging.
9
Brake warning lamp The brake (reserve brake) is applied when
the red lamp lights.
10
Warning lamp, oil pressure, If the warning lamp lights, it is an indication or engine oil temperature that the lubrication oil pressure is too low or too high. that the oil temperature is too high.Stop the
engine and remedy the cause. See engine manual.
11
Working lights switch Turn to the left to switch rear working (Accessory) light ON.
12
Hazard beacon switch Turn to the right to switch hazard (Accessory) beacon ON.
13
Driving lights switch Turn one step to the right = Parking lights. (Accessory) Second step = Front working lights.
14
Hazard flashers switch Turn to the right to switch (Accessory) hazard flashers ON.
SWITCHES AND WARNING LAMPS
MAN
O
AUTO
STOP
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SWITCHES AND WARNING LAMPS
15
Direction indicator switch Turn to the left to switch left direction (Accessory) indicator on.
Flashing function is off in the middle setting.
16
Compartment for manuals Pull up and out at the top to gain access to
manuals.
17
Fuse box Contains fuses for the electrical system. (on front of steering column) See heading ”Electrical System” for
identification of the various fuses.
18
Revs control Turn anticlockwise to increase engine revs. (Diesel engine)
19
Vibration ON/OFF Press to switch on vibrator.
Press again to switch off. Applies when (5) is in mode.
20
Forward/Reverse lever Move the lever in desired direction of travel. (F/R Lever) Driving speed is proportional to movement
of the lever. The machine brakes on moving the lever towards neutral. Observe also that the engine can only be started with the lever in neutral.
21
Fuel gauge (Accessory) Indicates content of fuel tank.
22
Seat switch Remain seated for all driving. The horn will
sound or the brakes will be applied if the operator does not remain seated while driving.
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Item in Designation Symbol Function fig. 5
1 Heater control * Regulates heat in the cab. Turn clockwise to
increase heat, turn anticlockwise to reduce heat.
2 Fuses (Cab) Fuses for the electrical system. See under
heading ”Electrical system” for description of the various functions.
3 Working lights (front) * Push to turn on the front working lights.
4 Front screenwiper, switch Push to start the front wiper.
5 Rear screenwiper, switch Push to start the rear wiper. 6 Front screenwash, switch Push to wash the windscreen. 7 Rear screenwash, switch Push to wash the rear window. 8 Working lights (rear) switch * Push to turn on the rear working lights.
9 Hazard beacon, switch * Push to switch on the hazard beacon.
10 Fan, switch Push to start the fan.
11 Interior lighting, switch Push forward to turn on the interior lighting. 12 Radio (optional equipment)
SWITCHES AND CONTROLS IN THE CAB (ACCESSORIES)
1 2 3 4 5 6 7 8 9 10 11 12
Fig. 5 Cab
1 *Heater control
2. Fuses
3. *Working lights
4. Front screenwiper
5. Rear screenwiper
6. Front screenwash
7. Rear screenwash
8. *Working lights
9. *Hazard beacon
10.Fan
11.Interior lighting
12.*Radio * = Optional equipment
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BEFORE STARTING
Battery disconnecter ­Switching on
Fig. 6 Left side of engine
1. Battery disconnecter
2. Hour meter
2 1
1. Ensure that the daily service has been carried out, see MAINTENANCE Manual.
2. Open the engine cover and set the battery discon­necter (1) to ON.
Item (2) is the engine hourmeter. The number of hours are counted so long as the engine is running.
For compaction operations on asphalt, ensure that the water tank at the front and the emulsion tank at the rear are filled.
1
Sprinkler system/drum
Fill the water tank and check that the sprinkler pipe (2) is positioned to distribute a water mist over the surface of the drum. Loosen the fastening screws (3) of the pipe clamps to adjust the pipe.
32
Fig. 7 Water tank
1. Filler cap
2. Sprinkler pipe
3. Fastening screws
Safety belt
Use the safety belt (1) if ROPS or a cab is fitted on the roller.
Always replace the safety belt with a new one if it is worn or has been subjected to great strain.
1
Fig. 8 Operator´s seat
1. Safety belt
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BEFORE STARTING, cont
1
2 3 4
1. Adjust the seat so that all the controls are easily reached.
2. The following adjustments are possible:
- Back support slope (1)
- Longitudinal adjustment (2)
- Weight adjustment (3)
- Transverse adjustment (4)
Comfort seat - Adjustments
Fig. 10 Comfort seat (accessory)
1. Back support slope
2. Longitudinal adjustment
3. Weight adjustment
4. Transverse adjustment (accessory)
Fig. 9 Operator´s seat
1. Weight adjustment
2. Back support slope
3. Longitudinal adjustment
4. Transverse adjustment (accessory)
1
2
3
4
1. Adjust the seat so that all the controls are easily reached.
2. The following adjustments are possible:
- Weight adjustment (1)
- Back support slope (2)
- Longitudinal adjustment (3)
- Transverse adjustment (4)
Remain seated for all driving. (The horn will sound or the brakes will be applied if the operator does not remain seated while driving).
Operator´s seat - Adjustments
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BEFORE STARTING, cont
Switches and Warning lamps – Checking
8 9 10
3 2
6 9
Emergency stop – Checking
Fig. 12 Instrument panel
6. Reserve/parking brake knob
9. Brake warning lamp
Fig. 11 Instrument panel
2. Starter power switch
3. Sprinkler switch (drum)
8,9,10. Warning lamps
1. Turn the starter power switch (2) to the right.
2. Check that warning lamps 8, 9, 10 light.
3. Turn the switch (3) to operating mode and ensure that the system is working.
Pull out the reserve/parking brake knob (6) and check that the brake warning lamp (9) goes out.
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Starting the engine
Fig. 13 Forward/Reverse lever
20
ST ARTING
1. Set the forward/reverse lever (20) in neutral. The engine can only be started with the lever in neutral.
On some variants the F/R control is located at the side of the instrument panel, but the function is the same.
2. Set the vibration control (5) to O.
3. Put the revs control (18) in the idling mode (far right). On some variants the control is located at the right side of the instrument column.
4. Make sure the starter power switch (2) is set at position |. Press the starter button (4) and release it as soon as the engine starts.
If the engine does not start immediately, wait a few seconds before making another attempt.
5. Run the engine warm at increased idling speed. A longer period at low ambient temperature.
6. Check while warming up that the warning lamps for charging and oil pressure are out. The warning lamp for the brake (9) shall go out when the reserve/ parking brake knob (6) is pulled out.
7. The engine stops if the starter power switch (2) is turned to O.
Braking distance is longer when starting up and driving with a cold engine than when the oil has reached normal working temperature.
When starting up and driving with a cold roller (cold hydraulic fluid) the braking distance will be longer than when the machine has reached normal operating temperature.
Fig. 14 Instrument column
2. Starter power switch
4. Starter button
5. Vibration switch
6. Reserve/parking brake knob
9. Brake warning lamp
18. Revs control
18
659
4 2
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DRIVING
Driving the roller
1. Set the revs control lever (18) to the full revs mode, ie, fully to the left, to give maximum engine speed.
2. Ensure that the steering is working properly by turning the steering wheel once to the right and once to the left while the machine is standing still. Steering shall operate smoothly without jerking or interruption.
Make sure that the area in front and behind the roller is clear.
3. Before driving on asphalt, turn the switch (3) of the watering system to the right or left, depending on whether you require continuous or automatic watering.
4. The reserve/parking brake knob (6) shall be pulled out and the lamp (9) out.
5. Carefully move the forward/reverse lever (20) in the desired direction of travel. Speed increases as the lever is moved from the neutral position.
Speed must always be regulated with the forward/reverse lever and not by changing speed of the engine.
Check operation of emergency braking by pressing the reserve/parking brake knob (6) while the roller is running slowly forward or reverse.
The roller should then slow down and stop as the warning lamp (9) lights.
6. The forward/reverse lever (20) must be put in neutral before operation can continue.
7. Check while driving that warning lamps do not light.
18
69
Fig. 15 Instrument column
3. Sprinkler switch (drum)
6. Reserve/parking brake knob
9. Brake warning lamp
18.Revs control
3
20
Fig. 16 Forward/Reverse lever
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VIBRATION/DRIVING
Vibration - Operation
Vibration is not permitted while the machine is standing still.
1. Turn the vibrator switch (5) ON to start the vibrator.
5
Fig. 17 Instrument panel
5. Vibration switch
2. Carefully move the forward/reverse lever forward or backward.
3. Turn vibration ON by pressing the button (19) on the tip of the forward/reverse lever. Disengage by pressing once more.
Do not switch vibration ON until the roller is moving. Danger of damage to the machine; never allow vibration on extremely hard surfaces such as concrete, cold asphalt, etc.
19
Fig. 18 Forward/Reverse lever
19. Vibration ON/OFF
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SAFETY WHEN DRIVING
Close to edges
Minimum
2/3
Fig. 19 Location of drum close to cavities
At least two thirds of the drum width must rest on a surface that ensures full support when driving close to cavities.
Remember that the centre of gravity of the machine is displaced outwards on turning the steering wheel. Eg, to the right when steering to the left.
ROPS (Roll Over Protecting Structure) is recommended for all operations on sloping ground and on unreliable ground.
Seated position
Remain seated for all driving. The horn will sound, or for some models the brakes will be applied, if the operator does not remain seated while driving.
Always use the seat belt if the machine is fitted with one. If the roller topples over there is a big risk that the operator will be thrown off and crushed underneath the machine if the seat belt is not used.
A seat belt is standard equipment on rollers equipped with a cab or with ROPS (Roll Over Protective Structure) (1).
1
Max 30° or 58%
Slope
Fig. 20 Tilt angle on side slopes
Avoid all driving across slopes if possible. Instead, drive straight up and down when working on inclines. The machine will topple over on slopes with an angle greater than 30° or 58%, to the right or left.
The toppling angle noted above applies to flat, hard ground and stationary machine. Steering angle zero, vibration switched off and water tanks full. Remember that loose ground, steering of the machine, applied vibration, driving speed and increase in height of the centre of gravity (eg, accessories) may cause the machine to topple even on a smaller slope than that stated above.
Fig. 21 Operator’s station
1. ROPS arch
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Normal and emergency braking
Fig. 22 Instrument panel
6. Reserve/parking brake knob
9. Brake warning lamp
69
Braking is normally done with the forward/reverse lever. The hydrostatic transmission brakes the roller when the lever is moved to neutral. In addition, a disc brake on the drive motor is applied when the reserve/ parking brake knob (6) is pressed in. Lamp (9) lights when the brake is applied.
EMERGENCY BRAKING
In an emergency, press the reserve/parking brake knob (6). Hold the steering wheel firmly as the roller brakes.
After emergency braking: Restore the forward/ reverse control lever to neutral. Pull out the reserve/ parking brake knob.
The multi-disc brake is automatically applied and stops the roller if the engine stops or the hydraulic pressure drops for any other reason.
When starting up and driving with a cold roller (cold hydraulic fluid) the braking distance will be longer than when the machine has reached normal operating temperature.
BRAKING
STOPPING
18
Fig. 23 Instrument post
2. Starter power switch
5. Vibrator ON/OFF
6. Emergency stop knob
18. Revs control
5 6
2
Switching off the engine
1. Disengage the vibrator by pressing the button on the forward/reverse lever. Set the vibrator switch (5) to O.
2. Stop the roller by moving the forward/reverse lever to neutral.
3. Turn back the revs control (18) until the engine runs at idling speed. Allow the engine to run for a few minutes to even out the engine temperature.
4. Push the reserve/parking brake knob (6).
5. Stop the engine by turning the switch (2) to position O.
6. Place the protective cover over the control panel. Lock it if required.
7. Turn the battery disconnecter OFF, and remove the handle.
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PARKING
Chocking the drum
Fig. 24 Drum
1. Brake chock
1
Before leaving the roller, turn OFF the battery master disconnect switch (1) and remove the handle.
The handle for the battery master disconnect switch should be removed when the operator leaves the machine overnight, during the weekend, etc. This will prevent premature discharging of the battery, and will also make it difficult for unauthorized persons to start and drive the machine. Lock the engine cover also.
Battery disconnecter
Fig. 25 Engine compartment
1. Battery disconnecter
1
Long-term parking
Fig. 26 Weather-protected roller
For parking periods longer than one month, see the Engine Manual, and the Maintenance Manual of the roller and study the chapters dealing with preservation of the engine and long-term parking respectively.
A suitable alternative to inhibition is to start the engine once a month and run the roller for about half an hour while operating all of the hydraulic functions. Then grease all the nipples and fill the fuel tank. Remember to empty the water tank and the sprinkler system.
Never leave the machine with the engine running unless the emergency stop knob is pressed in.
Make sure the roller is parked safely and is not a traffic hazard. Chock the drum and wheels when parking on a slope.
Remember the risk of freezing during the winter. Empty the water tank, pumps and leads.
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HOISTING
Locking the articulated joint
3 2
1
The steering link must be locked before hoisting the machine.
1. Turn the steering wheel until the forward and rear drums are in line with each other.
2. Then pull the bright zinc plated locking bar (1) down from its holder (3), and insert it from below into the hole in the lower steering link mount. Push it through the bar until its upper end is visible in the
hole in the upper steering link mount.
3. Secure the bar with the locking pin (2).
Remember to release the articulated joint interlock and fit the locking bar (1) back into its holder before driving.
2
13
Releasing the articulated joint
Steel wires, chains, etc, must comply with current regulations. Make sure that hoisting hooks are securely anchored.
Keep well clear of the hoisted machine. Check the weight of the machine stamped
on the hoisting plate (1).
Fig. 28 Hoisting the roller
1. Hoisting plate (rear plate on left side)
Fig. 27 Left side of articulated joint
1. Locking bar
2. Locking pin
3. Holder
Fig. 29 Left side of articulated joint
1. Locking bar
2. Locking pin
3. Holder
Weight: See hoisting sign on roller
1
1
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TOWING
Disengaging the brakes (Optional)
Fig. 30 Left side of drum
1. Disengaging bolt
2. Brake housing
3. Drive motor
12
The following instructions apply to the rear wheel motor.
Push the reserve/parking brake knob, and stop the engine. Chock the drum to pre­vent the roller from moving when the brakes become disengaged.
The disc brake on the drive motor must be disengaged mechanically, as described below, before the roller can be towed.
Fig. 31 Brake housing
1. Disengaging bolt
1
1. Use an 18 mm socket wrench.
2. To disengage the brake, turn the disengaging bolt (1) 1 1/2 turns clockwise.
3. Disengage the brake on the rear drum.
4. After towing, turn the same screws 1½ turn counter clockwise to activate the brake again.
3
Towing the roller
2
3
1
Fig. 32 Towing
1. Direction of travel
2. Counter-braking
3. Towbar
When towing downhill a towing bar must be used, the roller has no braking power of its own.
The roller must be towed slowly, and only for a short distance.
Before using the machine after towing, allow the engine to run at idling speed for at least half a minute to ensure correct hydraulic pressure.
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TRANSPORTATION
Locking the articulated joint
Lock the articulation prior to transportation. See the heading ”Lifting” for detailed instructions for locking.
3 2
1
Fig. 33 Left side of articulated joint
1. Locking bar
2. Locking pin
3. Holder
Remember to restore the locking bar to its holder before driving.
2
13
Fig. 35 Left side of articulated joint
1. Locking bar
2. Locking pin
3. Holder
1. Chock the drum securely (1).
2. Support the lower part of the roller frame with blocks (2) to prevent overloading of the rubber suspension when the lashing wires are stretched.
3. Secure the roller tightly at each of the four corners with lashing wire (3).
Fig. 34 Transporting the roller
1. Chocks
2. Supporting blocks
3. Lashing wire
Roller prepared for transportation
Restoring the articulated joint
3 2 1 3
23
4
23
4
23
4
23
4
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OPERATING INSTRUCTIONS - SUMMARY
1. Follow the SAFETY INSTRUCTIONS for the machine, see the Safety Manual.
2. Ensure that all instructions in the MAINTENANCE MANUAL are followed.
3. Turn the battery disconnecter to ON.
4. Ensure that the reserve/parking brake knob is in the OFF mode, ie, pulled out.
5. Move the forward/reverse lever to NEUTRAL.
6. Set the vibration switch to position O.
7. Start the engine and allow it to warm up at idling speed.
8. Test the brakes. Remember that the braking distance is longer when the roller is cold.
9. Drive the roller. Operate the forward/reverse controls with care.
10. Use the vibration only when the roller is in motion.
11. Check that the drums are watered sufficiently as required.
12. In an EMERGENCY: - Push in the reserve/parking brake knob.
- Hold the steering wheel firmly.
- Prepare yourself for a dead stop.
13. When parking: - Stop the engine and chock the drums.
14. When towing: - See towing instructions in this OPERATION MANUAL.
15. When lifting: - See hoisting instructions in this OPERATION MANUAL.
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