Workshop manual

W3015EN2.pdf
Hydraulic circuit diagrams
(propulsion, vibration, steering,
brakes)

Vibratory roller
CC800/CC900/CC1000
CC900S

Serial number :
xxxx0006 -

Subject to changes
Printed in Sweden
 Table of Contents
Introduction .............................................................................................................................. 1
Safety regulations .................................................................................................................... 3
Pressure settings ..................................................................................................................... 5
Hydraulic symbols.................................................................................................................... 7
Propulsion system.................................................................................................................... 9
Vibration system (vibration on) .............................................................................................. 11
Vibration system (front drum off, rear drum on) ..................................................................... 13
Vibration system (front drum on, rear drum off) ..................................................................... 15
Vibration system (both drums vibrating) ................................................................................ 17
Steering system (right turn).................................................................................................... 19
Brake system (brakes released) ............................................................................................ 21

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 Introduction

Introduction
These Workshop Instructions for the CC800/900/1000
vibratory rollers show the hydraulic components,
hosing and hydraulic cicuit diagrams for the four
different systems; propulsion, vibration, steering and
brakes.
These circuit diagrams are to be used for training and
improved understanding of the functions in the
hydraulic systems, together with simple definitions of
the hydraulic symbols.
The opening and working pressures of the various
systems are also stated, but can vary between models
(the working pressures may also vary depending of
the working conditions).

Warning symbols

WARNING ! Marks a danger or a hazardous

procedure that can result in life threatening or
serious injury if the warning is ignored.

CAUTION ! Marks a danger or hazardous

procedure that can result in damage to the
machine or property if the warning is ignored.

Safety information

Ensure good ventilation (extraction of air by fan)

where the engine is run indoors.

General
- Familiarize yourself with the equipment on the
machine.
- Only operate the machine if you are familiar with how
the controls work and how the machine functions.
- Use your safety equipment such as helmet,
protective shoes and hearing protection.
- Familiarize yourself with the machine's area of work.
- Only use the machine for its intended purpose.

The safety manual supplied with the machine

must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.

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 Introduction

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 Safety regulations

Safety regulations

Before start

- Study and understand the operating instructions before start.

- Check the machine for any serious faults.
- Do not operate the machine with defective instruments, warning lights or control elements.
- All safety devices must be in a secure position.
- Do not carry loose or secure them to the machine.
- Keep oily and inflammable material away from the machine.
- Before entering the driver's platform, check if persons or obstacles are in the way of or
underneath the machine.
- Be careful when entering the driver's platform, use the steps.
- Adjust your seat before starting.

Start

- When starting, all operating levers must be in "neutral position".

- Only start the machine from the driver's seat.
- Check the indicating instruments after start to ensure that all functions are in order.
- Do not leave the machine unattended when the engine is running.

Jump starting

Do not connect the negative cable to the

negative terminal on the dead battery. A spark
can ignite the oxy-hydrogen gas formed
around the battery.

Check that the battery used for jump starting

has the same voltage as the dead battery.

2 1
Turn the ignition and all power consuming equipment
off. Switch off the engine on the machine which is
providing jump start power.
First connect the jump start battery's positive terminal
(1) to the flat battery's positive terminal (2).Then
3 connect the jump start battery's negative terminal (3)
to, for example, a bolt (4) or the lifting eye on the
machine with the flat battery.
4 Start the engine on the power providing machine. Let it
run for a while. Now try to start the other machine.
Disconnect the cables in the reverse order.
Fig. Jump starting

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 Safety regulations

Electrical and hydraulic equipment

Personal safety must be observed when batteries are handled or tested.

A fully equipped medical kit, including eye-wash facilities, should be available and
protective clothing, including eye protection, should be worn.

Acid splashes in the eye should be treated immediately with plenty of clean water and
neutralized with sodium bicarbonate solution.

Acid splashes on clothing must be treated with an alkali, such as ammonia, if holes are to
be avoided.

A safety hazard exist during or after battery charging due to emission of a highly
flammable hydrogen gas. Any testing involving production of sparks, e.g. electrical load
test, must not be performed until the gas has dispersed from the cell. A similas hazard
occurs when a battery is fitted on to a vehicle immediately after the battery has been
removed from a charging plant.

Hydraulic equipment is under high pressure. Fluids (fuel, hydraulic oil) which escape
under high pressure can penetrate the skin and cause serious injury. Therefore
immediately consult a doctor if such injury occurs.

Notice that failure on the hydraulic or electrical system may give the roller an
unpredictable and dangerous function.

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 Pressure settings

Pressure settings
Do not change any pressure setting in the
hydraulic systems.
To avoid personal injuries, all pressure settings
must follow Dynapac specification. All
adjustments must be carried out by qualified
personnel only.

Pressure settings, new components, all values +-10%

at operating temperature and higher than 1500 rpm:

System Pressure MPa Psi

Propulsion Charge pressure 2,0 290
with forward & reverse lever in neutral
Forward & reverse relief pressure 35 5350
Normal working pressure 5-15 720-2150
depending on rolling resistance
Vibration Relief pressure 22 3200
to be measured during the first
second after vibration is switched
Normal working pressure 8-14 1150-2050
depending on working conditions
Steering Relief pressure 7 1000
Normal working pressure 3-5 450-720
depending on working conditions
Brake Release pressure 1,7 250
fully released

Hydraulic system volyme: 20 litre (5,3 gal)

Conversion values Convert from into Multiply by

MPa bar 10
MPa psi 145.04
Liter gal (U.S.) 0.264

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 Pressure settings

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 Hydraulic symbols

Hydraulic symbols

Symbol Description
Main line
Drain or pilot line
Limit line for functions or component
Line connection
Orifice

Flexibe pipe, hose

Regulator, variable

Rotating shaft

Manual control: General symbol

Manual control: Lever

Mechanical control: Spring

Electrical control: Solenoid, single coil

Pressure control: Indirect., pilot controlled

Check valve

Pressure relief valve

Flow divider

Filter or strainer

Cooler

Pressure switch

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 Hydraulic symbols

Symbol Description
Cylinder

Reservoir: Open to atmosphere

Hydraulic pump

Hydraulic motor

Valves

Flow paths

Combustion engine

Transmission

Brake

Steering wheel

Steering valve (simplified symbol)

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 PROPULSION SYSTEM Forward drive

To brake
valve

35 Mpa

2600rpm

2 Mpa

35 Mpa

From steering valve

0.15 Mpa
High pressure
Charge pressure
Low pressure
Suction line
CC800/CC900/CC900S/CC1000 Case drain
 VIBRATION SYSTEM Vibration on

22 MPa

To steering valve

High pressure
Low pressure
Suction line
CC800/CC900/CC1000 Case drain
 VIBRATION SYSTEM Vibration front drum off/rear drum on

22 MPa

To steering valve

Front vibr.motor Rear vibr.motor

High pressure
Low pressure
Suction Line
CC800/CC900/CC900S/CC1000 Case drain
 VIBRATION SYSTEM Vibration front drum on/rear drum off

22 MPa

To steering valve

Front vibr.motor Rear vibr.motor

High pressure
Low pressure
Suction Line
CC800/CC900/CC900S/CC1000 Case drain
 VIBRATION SYSTEM Both drums vibrating

22 MPa

To steering valve

Front vibr.motor Rear vibr.motor

High pressure
Low pressure
Suction Line
CC800/CC900/CC900S/CC1000 Case drain
 STEERING SYSTEM Right turn

P L
12 Mpa

To charge pump

7 Mpa

12 Mpa
T R

0,15 Mpa

High pressure
Low pressure
Suction line
Return oil from cylinder to valve
CC800/CC900/CC900S/CC1000 Oil from valve to cylinder
 BRAKE SYSTEM Brakes released

2 Mpa

From steering valve

0.15 Mpa

Charge pressure
Low pressure
Suction line
CC800/CC900/CC900S/CC1000 Case drain
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