Dynapac CP142 User manual

DYNAPAC
CP142
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
M142EN1
MAINTENANCE

19
ILF015WO1

Reservation for changes.
Printed in Sweden.
Pneumatic Tire Roller
CP142
Maintenance
M142EN1, May 2004
Diesel engine:
Cummins 4B4.5 - 99C
These instructions apply from:
CP142 PIN (S/N) *2163BR2000*
The CP142 Pneumatic Tire Roller uses a modular ballast system which consists of bolt
on ballast boxes that provide an accurate and uniform tire load. The roller is designed for
compaction of roads, airfields, dams and similar constructions.
The CP142 compacts asphalt, concrete, base courses and subbase courses efficiently
and at a high rate. Seperate information is available on request concerning accessories
and optional equipment.
The illustrated machine in this manual can be equipped with optional equipment.
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2CP142 M142EN1
INNEHÅLL
Sida
Smörjmedel och symboler ................................................ 3
Tekniska specifikationer ................................................ 4-6
Skötselschema ................................................................ 7
Skötselåtgärder ............................................................ 8, 9
Var 10:e drifttimme (Dagligen) ................................... 10-14
Var 50:e drifttimme (Varje vecka) .............................. 15-17
Var 250:e drifttimme (Varje månad) .......................... 18, 19
Var 500:e drifttimme (Var tredje månad) ......................... 20
Var 1000:e drifttimme (Varje halvår) ......................... 21, 22
Var 2000:e drifttimme (Varje år) ...................................... 23
Långtidsuppställning ....................................................... 24
Speciella anvisningar ..................................................... 25
Elsystem, säkringar ....................................................... 26
Read through the entire manual before
starting any maintenance operations.
Ensure good ventilation (air extraction) if the
diesel engine is run indoors.
It is important that the roller is maintained correctly to
ensure proper function. It should be kept clean so that any
leakage, loose bolts and loose connections can be
discovered in time.
Make a habit of walking round the roller to check it every day
before starting the first shift – including under the machine.
This is often the easiest way of discovering any leakage.
SPARE A THOUGHT FOR THE
ENVIRONMENT! Do not let oil, fuel and other
environmentally hazardous substances contami-
nate the environment.
This manual contains instructions for periodic attention
which should normally be carried out by the roller’s driver.
There are additional instructions relating to the diesel
engine, for which the manufacturer’s instructions
are detailed in the engine manual. This is found
under a separate flap in the roller’s product binder.
GENERAL
Safety instruction – Personal Safety
Special caution – Machine or component damage
WARNING SYMBOLS
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
CP142 M142EN1
LUBRICANTS AND SYMBOLS
ENGINE OIL Shell Rimula Super 15W/40 or equivalent
ambient air temperature API CH-4 or equivalent
-10°C – +50°C (14°F – 122°F)
HYDRAULIC OIL
ambient air temperature Shell Tellus TX 68 or equivalent.
-10°C – +40°C (14°F – 104°F)
ambient air temperature Shell Tellus TX 100 or equivalent.
above +40°C (above +104°F)
GREASE Shell Retinax LX2 or equivalent.
FUEL See the engine manual.
COOLANT GlycoShell or equivalent.
mixed 50/50 with water Anti-freeze protection down to about –37°C (-36°F).
Engine, oil level Oil for lubrication
Engine, oil filter Battery
Hydraulic oil reservoir, level Tire pressure
Hydraulic fluid filter Sprinkler
Coolant, level Sprinkler water
Fuel filter Recycling
Air filter
When driving in extremely high or low ambient
temperatures, other lubricants are needed. Refer to
the chapter entitled “Special Instructions” or contact
Dynapac.
Always use high-quality lubricants, in the quantities
specified. Excess grease or oil can promote
overheating, resulting in premature wear.
50/50

4CP142 M142EN1
TECHNICAL SPECIFICATIONS
Weights and dimensions CP142
Service weight with ROPS and STD ballast (kg/lbs) ............. 11950/26,345
Service weight with ROPS without ballast (kg/lbs) ................. 5800/12,787
Service weight with ROPS and max. ballast (kg/lbs)............. 14000/30,865
Length, std. equipped roller, (mm/inch) ......................................3580/141
Width, std. equipped roller, (mm/inch) .........................................1760/69
Height, std. equipped roller incl. ROPS, (mm/inch) ....................2990/118
Height without ROPS, (mm/inch) ................................................2275/90
Tires (standard)
Tire dimensions ............................. 7.50 x 15 14 Ply
Tire pressure:
• Minimum ...................................... 240 kPa (2,4 kp/cm2) (35 psi)
• Maximum .................................... 830 kPa (8,3 kp/cm2) (120 psi)
Electrical data
Battery ........................................... 12 V, 90 Ah
Alternator ....................................... 12 V, 105 A
Fuses ............................................ See under heading “Electrical System”
Fluid volumes Litre (gal or qts)
Hydraulic reservoir ........................................ 75 l (19.8 gal)
Hydraulic system ........................................ 100 l (26.5 gal)
Lubrication oil, diesel engine ........................9,5 l (10 qts)
Coolant, diesel engine ................................... 20 l (5.5 gal)
Fuel tank ..................................................... 150 l (40 gal)
Water tank ................................................... 480 l (127 gal)

5
CP142 M142EN1
Bolt size: M20 (P/N 904487)
Strength class: 10.9
Tightening torque: 498 Nm
ROPS
Tightening torque Tightening torque in Nm (lbf.ft) for oiled bolts when
using a torque wrench.
TECHNICAL SPECIFICATIONS
ROPS bolts must always be tightened dry.
Hydraulsystem Opening pressure (MPa)
Drive system 45,0
Supply system 2,0
Steering system 14,0
Brake release 1,5
M STRENGTH CLASS
gänga 8.8 10.9 12.9
M6 8,4 12 14,6
M8 21 28 34
M10 40 56 68
M12 70 98 117
M16 169 240 290
M20 330 470 560
M24 570 800 960
M30 1130 1580 1900
M36 1960 2800 –

6CP142 M142EN1
Vibration levels have been measured according to
the operational cycle described in the EU-directive
2000/14/EC on machines equipped for the EU-
market with operator seat in transport position.
Whole-body vibration is measured at less than the
action value of 0.5 m/s2specified in EU directive
2002/44/EC. (The limit value is 1.15 m/s2.)
Hand/arm vibration is measured at less than the
action value of 2.5 m/s2specified in the same
directive. (The limit value is 5 m/s2.)
CP142 105 89 -
Sound levels have been measured according to the operational
cycle described in the EU-directive 2004/14/EC on machines
equipped for the EU-market with operator seat in transport position.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A)
Acoustic
pressure level,
operator’s ear
(platform)dB(A)
Acoustic
pressure level,
operator’s ear
(cab)dB(A)
Noise level can vary when driving on different
courses and with different seat positions.
Vibrations – Drivers seat
(ISO 2631)
Vibration levels may vary when driving on
different courses and with different seat
positions.
TECHNICAL SPECIFICATIONS

7
CP142 M142EN1
MAINTENANCE SCHEDULE
1 29
6
10
5 4 33
7
8
16
2418 18
20
11 12
13 15 14 23
21
19 1722
25 2627
28
Fig. 1 Service points
1. Instrument panel and fuse box
2. Radiators (water/oil)
3. Scrapers
4. Tires
5. Ballast boxes
6. Wheel nuts
7. Battery
8. Fan belt
9. Air cleaner
10. Engine dipstick
11. Engine oil filter
12. Fuel filter
13. Hydraulic filter
14. Hydraulic sightglass
15. Hydraulic fluid filling
16. Water tank, sprinkler
17. Water pump
18. Sprinklers
19. Fuel tank
20. Fusebox
21. Steering bearing, oscillation shafts
22. Steering cylinder
23. Fuel filling
24. Fuel drainplug
25. Coolant, filling
26. Water tank, filling
27. Radiator (oil)
28. Pre-filter, fuel

8CP142 M142EN1
The periodic measures are intended to be performed
primarily with the specified hours of operation,
secondarily for the periods: daily, weekly, etc.
Remove all dirt before filling, when checking
oils and fuel, and when lubricating with oil or
grease.
The manufacturer’s instructions noted in the
engine manual also apply.
MAINTENANCE MEASURES
Items Action See page Comments
in fig. 1
Before starting each day
14 Check level in hydraulic reservoir 9
2, 27 Check that cooling air is unrestricted 9
19 Refuel 9
2 Check diesel engine coolant level 10 See engine manual
10 Check diesel engine oil level 10 See engine manual
3 Check setting of scrapers 11
17, 18 Check sprinkler system 11,12,13
26 Fill the water tank 13
Test the brakes 13
Every 10 hours of operation (Daily)
Items Action See page Comments
in fig. 1
9 Clean the air cleaner filter element and
ensure that hoses an connections are tight 14
4 Check the tire pressure 15
6 Check the wheel nut torque 15
5 Check the ballast bolt torque 15
21, 22 Lubricate the steering cylinder, steering bearing
and oscillation shafts 16
After the first 50 hours of operation change all the oil filters and
lubricating oils, but not the hydraulic fluid.
Every 50 hours of operation (Weekly)

9
CP142 M142EN1
MAINTENANCE MEASURES
Items Action See page Comments
in fig. 1
2, 27 Clean the radiator 17
7 Check the battery 17
Every 250 hours of operation (Monthly)
Items Action See page Comments
in fig. 1
8 Check the fan, belt tension and alternator. See engine manual
Check engine valve clearance See engine manual
13 Change the hydraulic filters 20
(14) Drain condensate from hydraulic reservoir 21
9 Change air cleaner main filter 21
24 Drain condensate from fuel tank 22
Check engine valve clearances See engine manual
Every 1000 hours of operation (Every six months)
Items Action See page Comments
in fig. 1
(14) Change fluid in hydraulic reservoir 22
16 Clean the water tank 22
19 Clean the fuel tank 22
Every 2000 hours of operation (Yearly)
Items Action See page Comments
in fig. 1
10, 11 Change engine oil and oil filter 18 See engine manual
12 Change engine fuel filter See engine manual
28 Change the fuel pre-filter 19
Lubricate controls 19
16 Drain sediments from water tank 22
Every 500 hours of operation (Every three months)

10 CP142 M142EN1
EVERY 10 HOURS OF OPERATION (Daily)
Fig. 2 Hydraulic reservoir
1. Sight glass
2. Filler pipe
3. Screw
4. Protective cover
5. Filler cap
1
5
2
4
3
Hydraulic reservoir
– Checking the level
Place the roller on a level base. The engine
must be switched off and the reserve/
parking brake knob pushed in for all check-
ing and adjustments on the roller unless
otherwise specified.
Check the sight glass reading (1)
Top up with fresh hydraulic fluid if the level is 20 mm
(0.8 in) or more below the upper edge of the glass, or if
no fluid can be seen in the sight glass.
Loosen screw (3) one turn.
Fold the protective cover (4) out of the way.
Wipe clean round the filler cap (5) before removing it.
Fill with fresh, clean hydraulic fluid of the grade
stipulated in the Lubricant Specification.
Refuel every day. Top off to the lower edge of the filler
pipe. Use diesel fuel in accordance with the engine
manufacturer’s specifications.
Stop the diesel engine. Short (press) the
filler gun against a non-insulated part of
the roller before refueling, and against the
filler pipe (2) while refueling is in progress.
Never refuel while the engine is running,
do not smoke, and avoid spilling fuel.
The tank holds 140 litres (37 gal).
Fig. 4 Fuel tank
1. Tank cap
2. Filler pipe
Fuel tank – Refueling
1
2
Make sure that the engine has unimpeded circulation of
cooling air through the protective grille (1) to the engine.
Air circulation – Checking
Fig. 3 Cooling air grille
1. Protective grille
1

11
CP142 M142EN1
EVERY 10 HOURS OF OPERATION (Daily)
Diesel engine
– Checking the oil level
Place the roller on a level base. The engine
must be switched off and the reserve/
parking brake knob pushed in for all check-
ing and adjustments on the roller unless
otherwise specified.
Beware of hot parts of the engine and the
hot radiator when taking out the oil dip-
stick. Risk for burns.
Pull the dipstick (1) up and check that the oil level is
between the upper and lower marks. See the engine
manual for further details.
Check that level of the coolant is between the max. and
min. marks.
Danger of scalding. Take great caution if
the radiator cap must be opened while the
engine is hot. Wear protective gloves and
goggles.
Fill with coolant consisting of 50% water and 50%
antifreeze. See the lubricant specification in these
instructions and the engine manual.
Flush the system every other year and
change the coolant. Ensure also that air can
flow unrestricted through the radiator.
Coolant level – Check
Fig. 6 Diesel engine
1. Dipstick
1
Fig. 5 Radiator
1. Filler cap
1

12 CP142 M142EN1
Scrapers – Check / Adjustment
EVERY 10 HOURS OF OPERATION (Daily)
1
Fig. 7 Scrapers
1. Scraper blade
2. Adjustment screw
2
Sprinklersystem
– Kontroll / Rengöring
Check the sprinkler system for proper operation.
Solenoid (5) valve must emit sound to indicate that it is
working.
Start the sprinkler system and make sure that no
nozzle is blocked. If necessary, clean any clogged
nozzle.
The filter (3) is accessible for cleaning after you have
emptied the tank (2) and removed the filter bowls.
Empty the bowls and clean them using water. Listen, or
place a hand on the pump (4), to ensure that it is
working.
It is not necessary to empty the tank to clean the filter if
the machine has a stop valve (6). It is enough to turn
off the water.
Check that the scraper blades (1) touch the tire surface
evenly. Blades can be adjusted for full and even tire
contact.
If necessary, adjust the distance to the tire as follows:
Undo the two screws (2) holding the scraper blade.
Position the scraper blade (1) then retighten the
attachment screws.
Adjust all scraper blades in the same way.
Fig. 8 Sprinklersystem
1. Påfyllningslock/sil
2. Tank
3. Filter
4. Vattenpump
5. Magnetventil
6. Avstängningsventil
7. Avtappningsplugg
1
2
5
4
3
6
7

13
CP142 M142EN1
Dismantle the clogged nozzle by hand. Blow the nozzle
(2) and fine filter (4) clean with compressed air, or
install replacement parts and clean the clogged parts at
a later opportunity.
Use protective goggles when working with
compressed air.
EVERY 10 HOURS OF OPERATION (Daily)
Check and exchange or clean clogged or worn nozzles
and strainers. Cap is removed with one quarter turn by
hand without tools.
Fig. 10 Nozzle
Nozzle
– Disassembling / Clean
4
3
2
1
Fig. 9 Nozzle
1. Sleeve
2. Nozzle
3. Seal
4. Fine filter

14 CP142 M142EN1
EVERY 10 HOURS OF OPERATION (Daily)
Water tank – Filling
18
Fig. 11 Water tank
17. Water pump and filter
18. Nozzle
26. Filler cap
18
17
26
Brakes – Check
Check operation of the brakes as follows:
Drive the roller slowly forward.
Push in the reserve/parking brake knob (15).
The brake warning lamp (26) on the instrument panel
should light and the roller should stop.
After testing the brakes, set the forward/reverse lever
(17) in neutral.
Pull up the reserve/parking brake knob (15).
The roller is now ready for operation.
Fig. 12 Instrument panel
15. Reserve/parking brake knob
17. Forward/reverse controls
26. Brake warning lamp
17
26
15
Watering is required until the tires reach working
temperature when rolling asphalt compounds.
Only use clean water in the tank to keep the
nozzles (18) free from dirt.
Screw off the tank cap (26) and fill with pure water; do
not remove the strainer.
Check the sprinkler system before operation.
Sole additive: Small amount of environment-
friendly antifreeze liquid.

15
CP142 M142EN1
EVERY 50 HOURS OF OPERATION (Weekly)
Main filter – Cleaning with
compressed air
Fig. 14 Main filter
Use compressed air at a maximum pressure of 5 bar
(72 psi) to clean the main filter by blowing up and down
along the inside of the pleated paper filter.
Hold the air nozzle at least 2 to 3 cm (0.8-1.2 in) from
the paper pleats so as not to tear the paper.
Use protective goggles when working with
compressed air.
Wipe the inside of the cover (2) and the filter housing (5).
Ensure that the hose clips between the filter
housing and the intake hose are tightened and
that the hoses are intact. Inspect the entire
hose system all the way to the engine.
Change the main filter after cleaning it five
times.
Air cleaner
– Check/Cleaning
Fig. 13 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
Place the roller on a level base. The engine
must be switched off and the reserve/
parking brake knob pushed in for all check-
ing and adjustments on the roller unless
otherwise specified.
Replace or clean the main filter of the air
cleaner when the warning lamp on the instru-
ment panel lights at full engine revs.
Release the three locking braces (1) and pull off the
cover (2), pull out the main filter (3).
Do not remove the backup filter (4).
Backup filter
– Replacement
5
23
1
Fig. 15 Air filter
4. Backup filter
4
Replace the backup filter with a new one after cleaning
or changing the main filter five times. The backup filter
cannot be cleaned and reused.
To change the backup filter (4), pull out the used filter
from its holder, insert a new filter and reassemble the
air cleaner in the reverse order to the instructions given
in the figure above.
4

16 CP142 M142EN1
EVERY 50 HOURS OF OPERATION (Weekly)
Tire pressure – Check
Fig. 16 Wheel
1. Filling nipples
Check the tires with a pressure gauge.
Check tire and No. of Ply, use the GROUND CON-
TACT PRESSURES table in the Operation Manual to
find correct pressure as the actual ballast and roller
weight is confirmed.
When changing tires it is essential that all tires have the
same rolling radius and amount of bearings.
Ballast bolts – Check
Fig. 18 Ballast boxes
1. Bolts
Check that the ballast bolts (1) are tightened (see
tightening torque under the Technical Specifications
heading).
Tightening torque of wheel nuts
– Check
Fig. 17 Wheel
1. Wheel nut
Check that all the nuts (1) are tight, 204 Nm (20,4 kpm)
tightening torque.
Check all tires and all the nuts.
(New machines or newly fitted wheels only).
1
1
1
Wear protective goggles when working
with compressed air.

17
CP142 M142EN1
EVERY 50 HOURS OF OPERATION (Weekly)
Front suspension
– Lubrication
Lubrication nipples to the steering bearing is located
under the rotating suspension flange.
Lubricate the steering bearing with 2 strokes of the
grease gun.
The suspension tap (2) must not rotate. Check
if the lock plate is missing or damage.
Grease the front suspension main pin (2) with 3
strokes of the grease gun.
1
Fig. 19 Steering joint, assembly
1. Steering bearing
2. Suspension tap
3. Grease fitting
4. Lock plate
2
3
Front oscillation shaft
– Lubrication
Fig. 20 Oscilleringsaxel
Wipe all the fittings clean from dirt and grease.
Lubricate each fitting with five strokes of the grease
gun. Make sure that grease enters the pin.
If grease does not enter the pin it may be necessary to
relieve the articulated joint with a jack and repeat the
greasing procedure.
Steering cylinder
– Lubrication
Fig. 21 Steering cylinder
Wipe all the fittings clean from dirt and grease.
Lubricate each fitting with two strokes of the grease
gun.
Leave a little grease on the fittings after greasing. This
will prevent dirt from entering the fittings.
4

18 CP142 M142EN1
Hydraulic fluid cooler
Checking – Cleaning
Fig. 22 Engine compartment
1. Hydraulic fluid cooler
1
EVERY 250 HOURS OF OPERATION (Monthly)
Battery
– Check electrolyte level
Fig. 23 Battery
1. Master switch
2. Battery
1
2
Place the roller on a level base. The engine
must be switched off and the reserve/
parking brake knob pushed in for all check-
ing and adjustments on the roller unless
otherwise specified.
Check the radiator for leakage, damage or
accumulation of dirt.
Clean a dirty radiator using compressed air or a high-
pressure water jet.
Blow or wash the radiator in the opposite direction to
that of the cooling air.
Take care when using a high-pressure water
jet; do not hold the nozzle too near the cooler.
Wear protective goggles when working
with compressed air or with high pressure
washing.
Make sure there are no open flames in the
vicinity when checking the electrolyte
level. An explosive gas is formed in the
battery during the charging process.
Open the engine cover at the far rear of the machine.
Wipe the top of the battery (2).
Use protective goggles. The battery con-
tains corrosive acid. In the event of con-
tact, rinse with water.