Atlas Copco Dynapac CP142 User manual

Instruction manualInstruction manual
ICP142-BR2EN3.pdfICP142-BR2EN3.pdf
Operation & MaintenanceOperation & Maintenance
Pneumatic tire rollerPneumatic tire roller
CP142CP142
EngineEngine
Cummins QSB3.3Cummins QSB3.3
Serial numberSerial number
*2163BR3001* -*2163BR3001* -
10000500x0B000001 -10000500x0B000001 -
Translation of original instructions.Translation of original instructions.
Subject to changesSubject to changes
Printed in SwedenPrinted in Sweden

2000h-Maintenance
ICP142-BR2EN3.pdf2011-11-01
Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Warning symbols......................................................................................... 1
Safety information ....................................................................................... 1
CE marking and Declaration of conformity.................................................. 2
General ....................................................................................................... 2
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Driving near edges ...................................................................................... 7
Slopes ......................................................................................................... 8
Special instructions .................................................................................................................. 9
Standard lubricants and other recommended oils and fluids ...................... 9
Higher ambient temperatures, above +40°C (104°F).................................. 9
Lower ambient temperature - Freeze risk ................................................... 9
Temperatures.............................................................................................. 9
High pressure cleaning ............................................................................... 9
Fire fighting ............................................................................................... 10
Roll Over Protective Structure (ROPS), ROPS approved cab .................. 10
Battery handling ........................................................................................ 10
Jump starting............................................................................................. 11
Technical specifications ......................................................................................................... 13
Vibrations - Operator station ..................................................................... 13
Noise level................................................................................................. 13
Technical specifications - Dimensions ................................................................................... 15
Dimensions, side view............................................................................... 15
Dimensions, top view ................................................................................ 16
Dimensions, front view .............................................................................. 17
Weights and volumes................................................................................ 18
Working capacity....................................................................................... 18

2000h-Maintenance
ICP142-BR2EN3.pdf 2011-11-01
General ..................................................................................................... 19
Tightening torque ...................................................................................... 20
ROPS - bolts ............................................................................................. 21
Hydraulic system....................................................................................... 21
Machine description ............................................................................................................... 23
Identification ............................................................................................................ 23
Product identification number on the frame .............................................. 23
Machine plate............................................................................................ 23
Explanation of 17PIN serial number.......................................................... 24
Engine plates ............................................................................................ 24
Machine description- Decals.................................................................................................. 25
Location - decals ....................................................................................... 25
Safety decals............................................................................................. 26
Info decals................................................................................................. 27
Locations - Instruments and controls ........................................................ 28
Function descriptions............................................................................................... 29
Electrical system...................................................................................................... 32
Fuses ........................................................................................................ 32
Fuses and relays....................................................................................... 33
Relays ....................................................................................................... 33
Maxi-fuses................................................................................................. 33
Operation ............................................................................................................................... 35
Before starting ......................................................................................................... 35
Engine compartment cover ....................................................................... 35
Master switch - Switching ON ................................................................... 35
Interlock..................................................................................................... 36
Operator’s seat - Adjusting....................................................................... 36
Seat belt .................................................................................................... 37
Installation/removal - ballast boxes ........................................................... 38
View .......................................................................................................... 39

2000h-Maintenance
ICP142-BR2EN3.pdf2011-11-01
Instruments and lamps - Checking............................................................ 39
Operator position....................................................................................... 40
Start of diesel engine ................................................................................ 41
Driving ....................................................................................................... 42
Freewheel ................................................................................................. 43
Operating the roller ................................................................................... 44
Driving (Ground Pressure) ........................................................................ 47
Ground pressure ....................................................................................... 47
Low tire pressure - 240 kPa (34.8 psi). ..................................................... 47
Normal tire pressure - 480 kPa (69.6 psi) ................................................. 47
High tire pressure - 830 kPa (120.4 psi). .................................................. 48
Ground pressure ....................................................................................... 48
Interlock/Emergency stop/Parking brake - Check ..................................... 49
Braking .................................................................................................................... 50
Normal braking.......................................................................................... 50
Emergency braking ................................................................................... 51
Switching off.............................................................................................. 52
Chocking the wheels ................................................................................. 52
Master switch ............................................................................................ 53
Long-term parking.................................................................................................................. 55
Engine ....................................................................................................... 55
Battery....................................................................................................... 55
Air cleaner, exhaust pipe........................................................................... 55
Sprinkler system........................................................................................ 55
Fuel tank ................................................................................................... 55
Hydraulic reservoir .................................................................................... 56
Steering cylinder, hinges, etc. ................................................................... 56
Tires .......................................................................................................... 56
Hoods, tarpaulin ........................................................................................ 56
Watering system ....................................................................................... 56

2000h-Maintenance
ICP142-BR2EN3.pdf 2011-11-01
Miscellaneous ........................................................................................................................ 57
Lifting ....................................................................................................................... 57
Lifting the roller.......................................................................................... 57
Towing/Recovering.................................................................................................. 57
Towing the roller........................................................................................ 58
Trailer eye ................................................................................................. 59
Roller prepared for transport ..................................................................... 59
Operating instructions - Summary ......................................................................................... 61
Preventive maintenance ........................................................................................................ 63
Acceptance and delivery inspection.......................................................... 63
Warranty.................................................................................................... 63
Maintenance - Lubricants and symbols ................................................................................. 65
Maintenance symbols ............................................................................... 66
Maintenance - Maintenance schedule ................................................................................... 67
Service and maintenance points ............................................................... 67
General ..................................................................................................... 67
Every 10 hours of operation (Daily)........................................................... 68
After the FIRST 50 hours of operation ...................................................... 68
Every 50 hours of hourly operation (Weekly) ............................................ 69
Every 250 hours of operation (Monthly) .................................................... 69
Every 500 hours of operation (Every three months) ................................. 69
Every 1000 hours of operation (Every six months) ................................... 70
Every 2000 hours of operation (Yearly) .................................................... 70
Maintenance - 10h ................................................................................................................. 71
Hydraulic reservoir, Level check - Filling................................................... 71
Air circulation - Check ............................................................................... 71
Fuel tank - Filling....................................................................................... 72
Coolant level - Check ................................................................................ 72
Diesel engine Check oil level ................................................................... 73
Scapers Checking - Setting....................................................................... 73

2000h-Maintenance
ICP142-BR2EN3.pdf2011-11-01
Sprinkler system - Check/Cleaning ........................................................... 74
Nozzle - Dismantling/Cleaning .................................................................. 74
Water tank - Filling .................................................................................... 75
Brakes - Check ........................................................................................................ 76
Maintenance - 50h ................................................................................................................. 79
Air intake system - Check ......................................................................... 79
Air cleaner
- Cleaning.................................................................................................. 79
Backup filter - Change............................................................................... 80
Tire pressure - Check................................................................................ 80
Tightening torque for wheel-nuts - check .................................................. 81
Ballast bolts - Check ................................................................................. 82
Steering cylinder suspension - Lubrication ............................................... 82
Front oscillation axle - Lubrication............................................................. 83
Steering cylinder - Lubrication................................................................... 83
Maintenance - 250h ............................................................................................................... 85
Radiator - Check/Cleaning ........................................................................ 85
Diesel engine - Oil and filter replacement ................................................. 86
Battery (maintenance-free) ....................................................................... 87
Maintenance - 500h ............................................................................................................... 89
Diesel engine - Oil and filter replacement ................................................. 90
Hinges, controls - Lubrication.................................................................... 91
Diesel engine pre-filter - replacement/cleaning......................................... 91
Maintenance - 1000h ............................................................................................................. 93
Hydraulic reservoir, Level check - Filling................................................... 94
Hydraulic fluid reservoir - Draining condensate ........................................ 95
Maintenance - 2000h ............................................................................................................. 97
Hydraulic reservoir - Fluid change ............................................................ 97
Fuel tank - Cleaning .................................................................................. 98
Water tank - Filling .................................................................................... 98

2000h-Maintenance
ICP142-BR2EN3.pdf 2011-11-01

Introduction
ICP142-BR2EN3.pdf2011-11-01
Introduction
The machine
Dynapac CP142 is a rubber wheel roller in the 12
tonnes class, with a working width of 1760 mm.
It has five guide wheels at the front and four drive
wheels at the back. An exclusive modular ballast
system comprising ballast boxes, allowing a precise
control of wheel load.
Intended use
CP142 is mainly used for compaction of asphalt for
surface sealing. It is also used for base courses,
subbase courses and stabilized soil.
Warning symbols
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
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.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
Safety information
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
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.
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.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
1

Introduction
ICP142-BR2EN3.pdf 2011-11-01
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
CE marking and Declaration of conformity
(Applies to machines marketed in EU/EEC)
This machine is CE marked. This shows that on
delivery it complies with the basic health and safety
directives applicable for the machine in accordance
with machinery directive 2006/42/EC and that it also
complies with other directives applicable for this
machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable directives and
supplements, as well as the harmonized standards
and other regulations that are applied.
General
This manual contains instructions for machine
operation and maintenance.
The machine must be correctly maintained for
maximal performance.
The machine should be kept clean so that any
leakages, loose bolts and loose connections are
discovered at as early a point in time as possible.
Inspect the machine every day, before starting.
Inspect the entire machine so that any leakages or
other faults are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
2

Introduction
ICP142-BR2EN3.pdf2011-11-01
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
This manual contains instructions for periodic
maintenance normally carried out by the operator.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
Additional instructions for the engine can be
found in the manufactuer's engine 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.
3

Introduction
ICP142-BR2EN3.pdf 2011-11-01
4

Safety - General instructions
ICP142-BR2EN3.pdf2011-11-01
Safety - General instructions
(Also read the safety manual)
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
2. Ensure that all instructions in the MAINTENANCE section are followed.2. Ensure that all instructions in the MAINTENANCE section are followed.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
4. Never use the roller if it is in need of adjustment or repair.4. Never use the roller if it is in need of adjustment or repair.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
7. Drive slowly in sharp bends.7. Drive slowly in sharp bends.
8. Avoid driving across slopes. Drive straight up or straight down the slope.8. Avoid driving across slopes. Drive straight up or straight down the slope.
9. When driving close to edges or holes, make sure that at least 2/3 of the
wheels are on previously compacted material.
9. When driving close to edges or holes, make sure that at least 2/3 of the
wheels are on previously compacted material.
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
11. Drive particularly carefully on uneven ground.11. Drive particularly carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
14. Safety measures before refueling:
- Shut off the engine
- Do not smoke
- No naked flame in the vicinity of the machine
- Ground the filling device nozzle to the tank to avoid sparks
14. Safety measures before refueling:
- Shut off the engine
- Do not smoke
- No naked flame in the vicinity of the machine
- Ground the filling device nozzle to the tank to avoid sparks
15. Before repairs or service:
- Chock the wheels.
15. Before repairs or service:
- Chock the wheels.
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
5

Safety - General instructions
ICP142-BR2EN3.pdf 2011-11-01
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. Refer to the operating instruction in the STOP section.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. Refer to the operating instruction in the STOP section.
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
6

Safety - when operating
ICP142-BR2EN3.pdf2011-11-01
Safety - when operating
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
Driving near edges
Fig. Position of wheels driving near and
edge
≥ 1/4
When driving close to edges or holes, make sure that
at least 1/4 of the outer tires is on the previously
compacted materials.
Keep in mind that the machine's center of
gravity moves outwards when steering. For
example, the center of gravity moves to the right
when you steer to the left.
Keep in mind that the machine's center of
gravity moves outwards when steering. For
example, the center of gravity moves to the right
when you steer to the left.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
7

Safety - when operating
ICP142-BR2EN3.pdf 2011-11-01
Slopes
Fig. Operating on slopes
Max 18° or 32%
The angle of dumping has been measured on a flat,
hard surface with a stationary machine without ballast.
The steering angle is zero and all tanks are full.
Remember that loose ground, steering of the machine,
driving speed and raising the center of gravity may
cause the machine to topple even on a slope smaller
than that stated here.
It is recommended that ROPS (Roll Over
Protective Structure) is always used when
driving on slopes or unsafe ground.
It is recommended that ROPS (Roll Over
Protective Structure) is always used when
driving on slopes or unsafe ground.
8

Special instructions
ICP142-BR2EN3.pdf2011-11-01
Special instructions
Standard lubricants and other recommended
oils and fluids
Before leaving the factory, the systems and
components are filled with the oils and fluids specified
in the lubricant specification. These are suitable for
ambient temperatures in the range -15°C to +40°C
(5°F - 104°F).
The maximum temperature for biological
hydraulic fluid is +35°C (95°F).
The maximum temperature for biological
hydraulic fluid is +35°C (95°F).
Higher ambient temperatures, above +40°C
(104°F)
For operation of the machine at higher ambient
temperatures, however maximum +50°C (122°F), the
following recommendations apply:
The diesel engine can be run at this temperature using
normal oil. However, the following fluids must be used
for other components:
Hydraulic system - mineral oil Shell Tellus T100 or
similar.
Lower ambient temperature - Freeze risk
Make sure that the watering system is empty/drained
of water (sprinkler, hoses, tank/s) or that anti-freeze
has been added, to prevent the system freezing.
Temperatures
The temperature limits apply to standard versions of
rollers.
Rollers equipped with additional equipment, such as
noise suppression, may need to be more carefully
monitored in the higher temperature ranges.
High pressure cleaning
Do not spray water directly onto electrical components
or the instrument panels.
Place a plastic bag over the fuel filler cap and secure
with a rubber band. This is to avoid high pressure
water entering the vent hole in the filler cap. This could
cause malfunctions, such as the blocking of filters.
Never aim the water jet directly at the fuel tank
cap. This is particularly important when using a
high-pressure cleaner.
Never aim the water jet directly at the fuel tank
cap. This is particularly important when using a
high-pressure cleaner.
9

Special instructions
ICP142-BR2EN3.pdf 2011-11-01
Fire fighting
If the machine catches fire, use an ABC-class powder
fire extinguisher.
A BE-class carbon dioxide fire extinguisher can also
be used.
Roll Over Protective Structure (ROPS), ROPS
approved cab
If the machine is fitted with a Roll Over
Protective Structure (ROPS, or ROPS approved
cab) never carry out any welding or drilling in
the structure or cab.
If the machine is fitted with a Roll Over
Protective Structure (ROPS, or ROPS approved
cab) never carry out any welding or drilling in
the structure or cab.
Never attempt to repair a damaged ROPS
structure or cab. These must be replaced with
new ROPS structure or cabs.
Never attempt to repair a damaged ROPS
structure or cab. These must be replaced with
new ROPS structure or cabs.
Battery handling
When removing batteries, always disconnect the
negative cable first.
When removing batteries, always disconnect the
negative cable first.
When fitting batteries, always connect the
positive cable first.
When fitting batteries, always connect the
positive cable first.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
10

Special instructions
ICP142-BR2EN3.pdf2011-11-01
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.
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.
Check that the battery used for jump starting
has the same voltage as the dead battery.
Fig. Jump starting
1
2
3
4
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
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.
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.
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Special instructions
ICP142-BR2EN3.pdf 2011-11-01
12