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.
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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.
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