HYPAC C766C & C778B VIBRATORY COMPACTOR Operation & Maintenance Manual

SERVICE MANUAL Revision R0 Form 0852737 9/2005 C766 C C778 B chodina@live.co.uk chodina@live.co.uk

chodina@live.co.uk chodina@live.co.uk

DANGER: Do not operate machine with the Roll Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT properly installed. 9/2005 DANGER: If the machine was received with the Roll/Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets) NOT installed, they MUST be installed BEFORE the machine is operated, using the installation instructions drawing, included with the installation kit, and/or the illustration below. In the event of a machine roll over, serious injury, or death, can occur due to failure to correctly install the Roll Over/Falling Object Protection Structure (ROPS/FOPS) and Operator Restraints (Seat Belt Sets). Structure Hexbolt - M20x110 - 10.9 (4 used on far side). Tighten to a Torque of 375 ft. lbs. (509 N . m). M20 Washers (4 used on far side) Seat Belt Set (2 used) Eyebolt Washer Lock Washer Nut Install each Seat Belt. Close Attaching Mechanisms Around Eyebolts. Install Cotter Pins and Bend. Install Eybolts (2). One on each Side of the Seat. Tighten Nuts to a Torque of 35 ft. lbs. (47 N . m). Hexbolt - M20x65 - 10.9 (4 used on near side). Tighten to a Torque of 375 ft. lbs. (509N . m). M20 Washers (4 used on near side) chodina@live.co.uk chodina@live.co.uk

SYMBOLS USED IN THIS MANUAL The following symbols have been used in THIS Manual to help communicate the intent of instructions. When one of the symbols appears, it conveys the meaning defined below: DANGER: Serious personal injury, death and/or extensive property damage can result if the DANGER instructions are not followed. CAUTION: Minor personal injury can result or a part, an assembly, or the engine can be damaged if the CAUTION instructions are not followed. WARNING: Serious personal injury and/or extensive property damage can result if the WARNING instructions are not followed. NOTE: Gives additional, and/or clarification details, which are to be used in conjunction with previously presented information. CALIFORNIA Proposition 65 Warning WARNING: Diesel engine exhausts and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA Proposition 65 Warning WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer, birth defects, and other reproductive harm. Wash hands after handling. chodina@live.co.uk chodina@live.co.uk

SERVICE AND REPAIR PRECAUTIONS ALWAYS inspect all slings, chains, or cables when lifting components, be sure that they are properly tied, fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the weight to be lifted. NEVER attempt to lift heavy parts by hand when a lifting device should be used. ALWAYS wear safety glasses when performing any maintenance or repair work on the machine. NEVER attempt to remove or repair any component, on the machine, while the engine is running. NEVER leave the machine and/or heavy parts in an unstable position during repair. ALWAYS support the machine with sound blocking. ALWAYS keep the machine and work area clear of lubricants and dirt. ALWAYS use the correct tools for the repair procedures being done on the machine, ALWAYS keep tools in a good and clean condition. ALWAYS use approved parts, that are designed for the machine being repaired. This helps to ensure maxi- mum service life of the machine. ALWAYS be sure that all necessary nuts, bolts, snap rings, and other fastening devices, are removed before using force to remove components. ALWAYS attach a sign in the machine operator’s area, stating “DO NOT OPERATE” when the machine is being repaired. ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and Service Manual and found on the machine decals. chodina@live.co.uk chodina@live.co.uk

MANUAL - TABLE OF CONTENTS PAGE SECTION 1 - INTRODUCTION ................................................................................................................ 1-1. SECTION 2 - SPECIFICATIONS ............................................................................................................. 2-1. SECTION 3 - OPERATION ...................................................................................................................... 3-1. SECTION 4 - MAINTENANCE ................................................................................................................. 4-1. SECTION 5 - FRAME, HITCH AND FALLING OBJECT/ ROLL OVER PROTECTION STRUCTURE ........................................................................................... 5-1. SECTION 6 - ENGINE .............................................................................................................................. 6-1. SECTION 7 - ELECTRICAL SYSTEM ..................................................................................................... 7-1. SECTION 8 - TRANSMISSION SYSTEM ................................................................................................ 8-1. SECTION 9 - BRAKE SYSTEM ............................................................................................................... 9-1. SECTION 10 - STEERING SYSTEM ......................................................................................................10-1. SECTION 11 - DRUM, VIBRATION AND DRUM CLEANING SYSTEMS ............................................ 11-1. SECTION 12 - WATER SPRAY SYSTEM ............................................................................................. 12-1. SECTION 13 - OPERATING LIGHTS AND DIRECTIONAL SIGNALS................................................. 13-1. i 9/2005 chodina@live.co.uk chodina@live.co.uk

9/2005 Section 1 INTRODUCTION 1-1 TABLE OF CONTENTS PAGE GENERAL INFORMATION ......................................................................................................................1-2. SPECIFICATIONS ....................................................................................................................................1-2. OPERATING INSTRUCTIONS .................................................................................................................1-2. MAINTENANCE PROCEDURES .............................................................................................................1-2. REPAIR PROCEDURES ..........................................................................................................................1-2. NAME PLATE / SERIAL NUMBER PLATE .............................................................................................1-2. SERIAL NUMBER ....................................................................................................................................1-3. chodina@live.co.uk chodina@live.co.uk

Section 1 INTRODUCTION 1-2 9/2005 REPAIR PROCEDURES. MAJOR machine component REPAIR PROCEDURES are found in the “SYSTEM REPAIR PROCEDURE” sections of "Instruction for Repair". CAUTION: For CORRECT machine component repair procedures, USE the REPAIR procedures given in the above service manual, and/or other referenced written materials ONLY. NAME PLATE /SERIAL NUMBER PLATE [See Figure 1-3]. The SERIAL NUMBER indicates the design series, manufacturing location, serial number and year of machine shipment (older machines) [see Table 1-1]. The machine serial number is located ON the nameplate [see figure 1-3]. The serial number is also stamped on the flat surface of the hitch assembly at the left hand side of the machine [see figure 1-4]. CAUTION: ALL numbers and letters, contained in the SERIAL NUMBER, MUST be given when requesting service and/or part information. GENERAL INFORMATION. THIS manual contains SPECIFICATION information and OPERATION, MAINTENANCE and REPAIR procedures for the 66 Inch and 78 Inch Compac- tors. SPECIFICATIONS. See Section 2 - SPECIFICATIONS, of THIS manual, for specifications on major systems used on the machine. OPERATING INSTRUCTIONS. READ, UNDERSTAND and FOLLOW ALL the operating instructions given in the FRONT, and in Section 3 - OPERATION, of THIS manual. The name plate/serial number plate is located BELOW, and to the left side of, the steering wheel. The plate MUST stay fastened to the machine at ALL times. If the plate is missing, or damaged, it MUST be replaced IMMEDIATELY. Contact your nearest Distributor to obtain a replacement plate. SERIAL NUMBER [See Figures 1-3 and 1-4]. WARNING: ONLY authorized personnel, who are fully trained in the machine operation procedures, can operate the 66 Inch and 78 Inch Compactors. Follow ALL instructions given in THIS manual, and written on the “Machine Operation and Warning” decal, found on the flat plate on the right side of, and below, the control panel. MAINTENANCE PROCEDURES. The maintenance schedules and procedures are found in Section 4 - MAINTENANCE, of THIS manual. CAUTION: Follow ALL the maintenance schedules and instructions given in THIS manual. chodina@live.co.uk chodina@live.co.uk

HYPAC C766C & C778B VIBRATORY COMPACTOR Operation & Maintenance Manual

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