Dynapac CP205 roller workshop manual

INTRODUCTION IN-01 TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures. • If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for us- age.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog • Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material MANUAL COMPOSITION • This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Work- shop Manual. Use the manuals according to purpose. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems. • Information included in the Technical Manual (Troubleshooting): technical information needed for operational per- formance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assem- ble/disassemble procedures. PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1 -3 -5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual

INTRODUCTION IN-02 SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts. • CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death. • IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. • NOTE: Indicates supplementary technical information or know-how. UNITS USED • SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units. Example : 24.5 MPa (250 kgf/cm 2 , 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees. Quantity To Convert From Into Multiply By MPa kgf/cm 2 10.197 Pressure MPa psi 145.0 kW PS 1.360 Power kW HP 1.341 Temperature °C °F °C×1.8+32 km/h mph 0.6214 Velocity min -1 rpm 1.0 Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0 Quantity To Convert From Into Multiply By mm in 0.03937 Length mm ft 0.003281 L US gal 0.2642 L US qt 1.057 Volume m 3 yd 3 1.308 Weight kg lb 2.205 N kgf 0.10197 Force N lbf 0.2248 N⋅m kgf⋅m 1.0197 Torque N⋅m lbf⋅ft 0.7375

SAFETY SA-1 RECOGNIZE SAFETY INFORMATION • This is the SAFETY ALERT SYMBOL. • Safety Alert Symbol is used to alert hazard that may cause personal injury. • Safety signs with Safety Alert Symbol is attached on this machine. • When you see this symbol on your machine or in this manual, please follow the safety precautions next to the symbol and instructions of figure in the symbol. 000-J01B-0001 SA-688 UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. • DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine. • CAUTION also calls attention to safety messages in this manual. • To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. • NOTE indicates an additional explanation for an element of information. 002-J01C-0632 SA-632

SAFETY SA-2 FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual. • Safety signs should be installed, maintained and replaced when necessary. If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). • Allow only trained, qualified, authorized personnel to operate the machine. • Learn how to operate the machine and its controls and maintenance correctly and safely. • Keep your machine in proper working condition. • Use within the determined specification. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. • The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-J01A-0003 SA-003 PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. If not handled immediately, it may result in death. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly. • To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. 004-J01B-0437 SA-437

SAFETY SA-3 WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. Fail to do so may cause personal injury. • You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. • Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-J01B-0438 SA-438 PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises when carrying out serivce for the engine, etc. 006-J01A-0434 SA-434 PERFORM PRE-START INSPECTION (DAILY INSPECTION) • Be sure to perform inspection before operate the machine. If any abnormalitis are found, remove the trouble before operating. 007-J01A-0435 SA-435

SAFETY SA-4 USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you mounting and dismounting the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when mounting and dismounting the machine. 008-J01B-0439 SA-439 ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. 009-J01A-0378 SA-462

SAFETY SA-5 Travel safely Pay attention to the surrouding area during travelling. It is especially dangerous when moving backward or travelling on slope. • Be sure to avoid travelling unstablely on slope. • When travelling on slope, never put objects that is easy to roll down on the frame. SA-1068 KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. • Only the operator should be on the machine. Keep riders off. SA-1069 CONFIRM THE WORKING AREA • When working on road sides, the machine may turnover and fall due to collapse of road shoulder, result in serious personal injury and death. • To avoid falling of the machine and collapsing of the ground during operating, investigate and record the topography and geology conditions of the area beforehand. • Lay a plan for working and use machine that is suitable for the work. • In order to avoid turnover and fall of the machine, take measures to prevent collapse of road shoulder and sinking of ground. • When working on road shoulder and slope, etc., appoint an instructor if necessary. • Other people are not allowed to enter the working range, swinging range and moving range. • When working in an area that ground condition is poor, make the ground stable first. • Take care when working on frozen ground, it is slippery, and will soften and become unstable when temperature rises.

SAFETY SA-6 PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions. SA-481 PRECAUTIONS FOR TRAVELING • When traveling on slopes, the danger of slip and overturn is always in existence. • Be sure to keep clear of obstacles. • Travel with low speed on uneven ground. • Never operate the machine suddenly when steering, it may cause the machine to turnover. • If the engine is stopped during travelling, the steering device will be inoperable, it is especially dangerous. So, brake should be applied immediately to stop the machine. PRECAUTIONS FOR SNOW • When travelling on road that is frozen or covered with snow, the danger of slip and overturn is always in existence. • Road that is frozen or covered by snow will cause accidentally side slip even for small slope. So control the speed of machine, and avoid to start, stop and swing suddenly. • On slope covered by snow, do not apply emergency brake. PRECAUTIONS FOR TRAVELLING ON PUBLIC ROAD • This machine is regarded as large vehicle for special purpose. • During travelling, be sure to take “Vehicle Inspection Card” and “Driver’s License for Large Special Vehicle”.

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Dynapac CP205 roller workshop manual

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