Dynapac CP221 Instruction Manual

Reservation for changes.
Printed in Sweden.
Pneumatic rollers
CP221/271
Operation
O221EN5, September 2004
Diesel engine:
Cummins 4B4.5 - 99C
These instructions apply from:
CP221 PIN (S/N) *2262(BR)0600*
CP271 PIN (S/N) *2362(BR)0700*
KEEP THIS MANUAL FOR
FUTURE REFERENCE
CP221 and 271 are heavy pneumatic rollers designed for the surface sealing and compacting of
asphalt together with steel-drum rollers. Due to their very high weight these pneumatic rollers are
also suitable for the compacting of subbases and base courses.
CP221 has three steered wheels at the front and four drive wheels
at the rear, mounted on a rigid axle.
CP271 has five wheels at the front and four at the rear, mounted on a rigid axle.

2CP221/271 O221EN5
CONTENTS
Safety instructions—Personal safety.
Special caution—Machine or component damage.
Each operator of the roller must study the
safety manual that accompanies each machi-
ne. Always follow the safety rules and do not
remove the manual from the roller.
This manual contains instructions for operation and use of
the roller. For care and maintenance information, see the
MAINTENANCE, CP221/271 manual.
WARNING SYMBOLS
GENERAL
SAFETY 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.
Page
Safety instructions (Also read the safety manual) ........... 3
Safety when driving ....................................................... 4-5
Safety decals, location and description ......................... 6-7
Machine and engine plates ............................................... 8
Instruments and controls .................................................. 9
Instruments and controls, functional description ....... 10-12
Before starting ........................................................... 13-15
Starting ........................................................................... 16
Operation ....................................................................... 17
Operation (Optional) .................................................. 18-19
Contact pressure ........................................................... 19
Ground pressure ............................................................ 20
Ballast ............................................................................ 21
Ballast compartment ...................................................... 22
Braking ........................................................................... 23
Hoisting .......................................................................... 24
Parking ........................................................................... 24
Towing ............................................................................ 25
Transportation ................................................................ 25
Operating instructions – Summary ................................. 26

3CP221/271 O221EN5
SAFETY INSTRUCTIONS (Also read the safety manual)
1. The operator must be familiar with the contents of the OPERATION
MANUAL before starting the roller.
2. Make sure that all instructions in the MAINTENANCE MANUAL are
followed.
3. Only trained and/or experienced operators are allowed to drive the
roller. Passengers are not allowed on the roller. Remain seated during
all operation.
4. Never use the roller if it is in need of adjustment or repairs.
5. Board and leave the roller only when it is stationary. Use the grips and
railings that are provided. A ”three-point grip” is recommended
whenever you board or leave the machine—both feet and one hand, or
one foot and both hands in contact with the machine.
6. Always use the Roll Over Protective Structure (ROPS) when the
machine is used on risky ground.
7. Drive slowly in sharp bends.
8. Avoid driving at an angle on slopes; drive straight up or down.
9. When driving close to unsafe edges or holes, make sure that at least 1/4
of the outer tire width is firmly on material that has already been
compacted.
10. Make sure that there are no obstacles in the direction of travel, on the
ground or overhead.
11. Drive extra carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on
machines fitted with ROPS.
13. Keep the roller clean. Clean dirt and grease from the operator’s platform
without delay. Keep all signs and decals clean and clearly legible.
14. Safety measures before refueling:
– Stop the engine.
– Don’t smoke.
– No naked flame in the vicinity.
– Ground the nozzle of the filling device against the tank to prevent
sparks.
15. Before repairs or service:
– Place chocks against the drums/wheels and against the strike-off
blade.
– Lock the articulation if necessary.
16. Hearing protectors are recommended if the noise level is higher than 85
db(A). The noise level will vary depending on the surface being worked
on by the machine.
17. Make no changes or modifications on the roller that could affect safety.
Changes may only be made following written consent by Dynapac.
18. Do not use the roller until the hydraulic fluid has reached its normal
working temperature. Braking distance can be longer than usual if the
fluid is cold. See starting instructions in the OPERATION MANUAL.

4CP221/271 O221EN5
SAFETY WHEN DRIVING
Driving near an edge
When driving close to unsafe edges or holes, make
sure that at least 1/4 of the outer tire width is firmly on
material that has already been compacted.
At least
1/4
Fig. 1 Wheel position when driving close
to edge

5CP221/271 O221EN5
SAFETY WHEN DRIVING
Slopes
Fig. 2 Tipping angle on side slopes
Max. 20°
or 36%
ROPS (Roll Over Protective Structure) is
always recommended when driving on
slopes or insecure ground.
Where possible, avoid all driving
across a
slope. Instead, drive up and down on slop-
ing ground.
Always use 1st gear when driving on a
slope.
The tipping angle is measured on level, hard ground
and a stationary machine without ballast. The steering
angle is zero (machine moving straight forward) and all
tanks full. Remember that loose ground, steering of the
machine, driving speed and increase in height of the
center of gravity (for example, with accessories) may
cause the machine to topple even on a smaller slope
than that specified here.
Emergency braking
Fig. 3 Service cover, under operator’s
station
1. Adjusting screw (2x)
2. Lock nut (2x)
3. Brake yoke (2x)
If emergency braking has occurred at transport speed,
loosen the lock nut (2) and the adjusting screw (1) on
both brake yokes (3).
Place a 0,3 mm (0.012 in) thick shim between the
brake disc and one of the brake linings.
Tighten the adjusting screw (1) until it is just possible to
remove the shim. Tighten the lock nut (2).
Repeat the procedure on the other brake yoke.
3
212

6CP221/271 O221EN5
SAFETY DECALS, LOCATION AND DESCRIPTION
1316
2
4
83 5
13 4
11 14 12
9
413113
10
6
2 353 7
9
15
= Option

7CP221/271 O221EN5
SAFETY DECALS, LOCATION AND DESCRIPTION
Crush zone, articulation.
Maintain a safe distance
from the crush zone.
Warning for hot surface.
The surface must not be
touched.
Warning for rotating engine
components. Keep your
hands at a safe distance
from the danger zone.
The operator is urgently
requested to read the
safety manual, and the
operation and maintenance
instructions before using
the machine.
1.
2.
3.
4.
903424
903459
903423
903422
5.
Lifting
point
Diesel fuel
Tire pressure
9.
8.
588176
14.
6.
Hydraulic
fluid
10.
Battery
disconnector
12.
7.
11.
Handbooks
903425
Mass Kg
904870
Hoisting plate
Warning, hand and arm
entanglement. Never reach
into the hazardous area.
903832
Securing
point
13.
382751
791276
15.
Sound Power
level
106
374765
Min 250kPa/ 35psi
Max 850kPa/ 120psi

8CP221/271 O221EN5
MACHINE AND ENGINE PLATES
Machine plate
Serial number on frame
Fig. 4 Left hand side
1. Machine plate
Fig. 5 Front frame
1. serial number
Fig. 6 Engine
1. Type plate
2. EPA sign (USA)
1
1
Engine plate
1
The PIN (1) of the machine is punched on the front right
edge of the forward frame beam. This number is
identical with the PIN (serial number) on the machine
data plate.
IMPORTANT ENGINE INFORMATION
This engine conforms to YYYY U.S. EPA
and California regulations for
heavy duty non-road compression
ignition diesel cycle engines as
applicable.
THIS ENGINE IS CERTIFIED TO OPERATE
ON DIESEL FUEL
XXXXXXX
2
The machine type plate (1) is located on the left side of
the steering column. The plate shows the
manufacturer’s name and address, type of machine,
PIN “Part Identification Number” (serial number), weight
in working order, engine power and year of
manufacture. CE markings and the year of
manufacture may be omitted on machines supplied to
markets outside the EU.
Please state the machine´s PIN when ordering
spares.
The engine type plate (1) on Cummins engines is
located on the left side of the toothed-belt cover. The
plate shows the type of engine, serial number and
engine data. Please state the serial number of the
engine when ordering spares. See also the engine
manual.
Cummins Engine Company, Inc
Columbus, Indiana
47202-3005
Warning Injury may result and warranty is voided
if fuel rate, rpm or altitude exceed published
maximumvaluesfor this model and application.
DateofMFG.
Made in Great Britain.
XXXXXXX
CID/L. CPL Engine Serial No.
Family Cust. Spec.
Engine Model
Valve lash Timing-TDCInch Int. Exh.
MM Int. Exh. Fuel rate at rated HPcold
#
Firing Order
RatedHP/KW at RPM
FR

9CP221/271 O221EN5
INSTRUMENTS AND CONTROLS
1. Tachometer/Hourmeter
2. Fuel gauge
3. Coolant temperature gauge, engine
4. Voltmeter
5. Warning lamp for low brake air pressure and
low brake fluid level on machines with level
sensor.
6. Oil pressure lamp
7. Indicating lamp, neutral mode
8. Tire pressure gauge
9. Brake air pressure gauge
10. Gearbox oil pressure
11. Gearbox oil temperature
12. Alarm, low air pressure, brakes
13. Sprinkler contact
14. Hazard beacon
15. Working lights, rear
16. Working lights/Driving lights
17. Hazard flashers changeover switch
18. Changeover switch, direction indicator
19. -
20. Starter button
21. Ignition changeover switch
22. Direction indicator
23. Direction indicator
24. Panel cover
25. Warning lamp, air filter
26. Tire pressure control valve
27. Fuse box
28. -
29. Forward/reverse lever
30. Gear selector
31. -
32. Horn
33. Accelerator
34. Foot brake
35. Parking brake knob
36. Warning lamp for parking brake
= Optional
Fig. 7 Instruments and control panel
22 1 23 2 3 4 25 5 7 36 6 35 8 9 10 11
21 20 18 17 16 15 14 13 12
26
27
30
33
29
34
26
32 29 30 24
CP221CP271
24
34
33

10 CP221/271 O221EN5
1 Tachometer/
Hourmeter
2 Fuel gauge
3 Coolant temperature
4 Voltmeter
5 Warning lamp for low brake
air pressure and low brake
fluid level on machines with
level sensor.
6 Warning lamp,
low oil pressure
7 Neutral lamp
8 Gauge, tire pressure
(Optional)
9 Brake air pressure
10 Gauge, transmission oil
pressure
11 Gauge, transmission oil
temperature
12 Alarm, low brake pressure
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
Item in Designation Symbol Function
fig. 7
Indicates engine speed. Multiply meter
reading by 100. Operating time is shown in
hours.
Indicates level in the fuel tank.
Indicates engine operating temperature.
Normal 82°C to 93°C.
See engine manual.
Indicates voltage of the system. Normal
12 to 15 V.
The lamp lights if pressure drops below 4 kg/
cm2(58 psi).
Stop the engine immediately if the warning
lamp LIGHTS and locate and remedy the
cause. See engine manual.
Lights when the forward/reverse lever is in
neutral.
Indicates tire pressure.
Indicates operating pressure of the brakes.
Normal reading 6,5 bar (94 psi).
Indicates operating pressure of the
transmission. Normal reading 1270–1550
kPa (184–225 psi).
Indicates temperature of transmission oil.
Normal working range 80 to 95°C.
Alarm signal sounds if pressure is below
4 kg/cm2(58 psi).

11CP221/271 O221EN5
13 Sprinkler
14 Hazard beacon, switch
(Opition)
15 Changeover switch, working
lights, rear
16 Working lights, front,
Driving lights (optional),
switch
17 Hazard flashers (Optional)
18 Direction indicator, switch
(Optional)
20 Starter button
21 Ignition switch
22 Direction indicator (Optional)
23 Direction indicator (Optional)
24 Panel cover
25 Air filter service indicator
26 Tire pressure control valve
(Optional)
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
Item in Designation Symbol Function
fig. 7
Controls watering of the tires. O= No
watering. I= Watering of the tires.
Turn right to activate the hazard beacon.
Turn to the right to switch on the working
lights.
Turn right to switch on the working lights.
Turn to switch on the parking lights and turn
further to switch on the dipped headlights.
Turn to the right to switch on the warning
flashers.
Turn left for the left direction indicator, etc.
Flashing is switched off in the middle
position.
Press to energize the starter motor. Release
immediately the engine fires.
The electric circuit is broken in mode .
In mode all instruments and electric
controls are powered.
Flashes for left turn.
Flashes for right turn.
Lower over the panel as protection against
the weather and sabotage.
Clean the air filter if the red service indicator
lights at full engine speed.
Controls the tire pressure.

12 CP221/271 O221EN5
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
27 Fuse box
29 Forward/reverse control
30 Gear selector
31 -
32 Horn
33 Accelerator
34 Brake pedal
35 Parking brake
36 Brake warning lamp
Item in Designation Symbol Function
fig. 7
Contains fuses for the electrical system. See
under “Electrical system” for various
functions of the fuses
Move forward to drive forward, backward to
reverse.
Move the lever forward for 1st gear, middle
position 2nd gear and backward 3rd gear.
-
Press to sound the horn.
Press downward to increase engine revs
and speed.
Driving brake. Use for normal braking when
driving. The brake system contains 2
circuits, where the second circuit is reserve
brake.
Activates by the knob in depressed position.
Normally used only for not moving machine
and parking. Can be used in an emergency
situation, but this requires readjustment.
The lamp lights when the parking brake knob
is pushed in and the brakes are applied.

13CP221/271 O221EN5
BEFORE STARTING
Master switch
– Switching on
Fig. 8 Engine compartment
1. Master switch
1
Remember to carry out daily service. See maintenance
manual.
The master switch is located on the right side in the
engine compartment. Open the engine hood and turn
the key (1) to the ON mode. This will power the entire
roller.
The engine hood must be unlocked during
operation, so the battery power can be
disconnected quickly if necessary.
Operator’s seat – Setting
Adjust the operator’s seat so that all controls can be
easily reached.
The seat has the following adjustment features:
– Length adjustment (1)
– Back slope adjustment (2)
– Weight adjustment (3)
Always make sure that the seat is secure
before beginning operation.
3
2
Fig. 9 Operator’s seat
1. Length adjustment
2. Back slope adjustment
3. Weight adjustment
1

14 CP221/271 O221EN5
BEFORE STARTING
Turn the starter switch (21) to position I and all warning
lamps should light for about five seconds.
Ensure that the voltmeter (4) indicates at least 12 volt.
Ensure that the fuel gauge (2) shows a reading.
Check that the warning lamps for low brake pressure
(5), oil pressure (6), neutral mode (7) and parking brake
(36) light.
Instruments and lamps
– Checking
Seat belt
Fig. 10 Instrument panel
2. Fuel gauge
4. Voltmeter
5. Warning lamp for low brake air pressure
and low brake fluid level on machines with
level sensor.
6. Oil pressure lamp
7. Neutral lamp
21. Starter button
35. Parking brake knob
36. Warning lamp for parking brake
Fig. 11 Operator’s station
1. Seat belt
2. Anti-slip
Always fasten the seat belt (1) that is provided if a
ROPS (Roll Over Protective Structure) is fitted on the
roller, and wear a protective helmet.
Replace the seat belt if it shows signs of
wear or has been subjected to severe force.
Make sure that anti-slip (2) on the platform
is in good condition; replace with new anti-
slip if friction is poor.
12
Make sure that the parking brake knob (35)
is pushed in. If the parking brake is not
applied, the roller may start to roll when
starting the engine on sloping ground.
Parking brake – Check
2 4 5 7 6
21 36 35

15CP221/271 O221EN5
BEFORE STARTING
Position the seat to ensure that the accelerator (1) and
the foot brake (2) are easily reached and the driving
posture is comfortable.
As a general rule, 2nd gear is normally used for
compaction operations. The final speed of the roller
depends on the speed range selected with the gear
lever. Use the accelerator pedal (1) to increase or
reduce speed of the roller within the range.
Accelerator and brake pedal
1
Fig. 13 Pedals
1. Accelerator
2. Foot brake
Ensure that the forward/reverse control is in neutral.
Check the forward/reverse
control
Fig. 12 Forward/reverse control
2
CP221 CP271

16 CP221/271 O221EN5
STARTING
Starting the engine
Set the forward/reverse lever (29) in neutral. The
engine can only be started with the lever in neutral.
Make sure that the parking brake knob (35) is
really pushed in. If the parking brake is not
applied, the roller may start to roll when you
start the engine on sloping ground.
Press the accelerator down about ¼.
Turn the ignition switch (21) to position “I”. The switch
lights until the demanded pre-heater is ready. Ensure
that the fuel gauge (2) and voltmeter (4) show readings
and that the oil pressure warning lamp (6) is on.
Within 10 seconds after the pre-heater is ready:
Briefly press the starter button (20). Release the button
as soon as the engine fires.
Do not run the starter motor too long;
preferably wait a minute or so if the engine
does not start.
Warm up the engine at idling speed for a few minutes,
longer if the ambient temperature is below +10°C (50°F).
Check while warming up that the warning lamp for oil
pressure (6) is out, and also that the voltmeter (4)
indicates 13–14 volts. The warning lamp (36) for the
parking brake should still light.
After warming up the engine, ensure that the tempera-
ture gauges for transmission oil (11) and coolant (3)
show readings.
Ensure that ventilation (evacuation) is
adequate if the engine is run indoors. Ie,
danger of carbon monoxide poisoning.
Check all tires for correct pressure:
Minimum pressure 2.5 kg/cm² (35 psi)
Maximum pressure 8.5 kg/cm² (120 psi)
Tire pressure can be checked with the tire pressure
gauge (8). Move the control valve lever (26, fig. 19) to
its middle position. Up to increase and down to reduce
(optional).
Test the driving brake. It is essential that
the brakes are in working order.
Test by pressing the brake pedal. The brake pressure
gauge (9) should then indicate 6,5 bar (94 psi). This is
the maximum pressure.
Do not move the roller before pressure of
the system has reached the specified
operating level.
Test the brake by pressing the parking
brake knob (37) while the roller is running
slowly forward.
Fig. 14 Instrument panel
2. Fuel gauge
3. Coolant temperature gauge
4. Voltmeter
5. Warning lamp for low brake air pressure
and low brake fluid level on machines with
level sensor.
6. Oil pressure lamp
8. Tire pressure gauge
9. Brake pressure gauge
11. Transmission oil temperature gauge
20. Starter button
21. Ignition switch
29. Forward/reverse control
35. Parking brake knob
36. Warning lamp for parking brake
Brake test
Fig. 15 Brake pedal
29 29
CP271CP221
3 2 4 5 6 8 9 11
21 20 36 35

17CP221/271 O221EN5
Check now and then while driving that the gauges
show normal readings. In the event of abnormal values
or if the beeper sounds, stop the roller and the engine
immediately. Check and remedy any fault, see also the
maintenance manual and the engine manual.
Inspect the tire tread now and then to detect
asphalt compound that has fastened—this is
likely before the tires are sufficiently warm.
Mixing 2-4% cutting fluid in the sprinkler water
for the tires can prevent sticking.
Under no circumstances may the machine
be operated from the outside. The operator
must remain seated inside the machine
during all operation.
Check that the steering is working by turning the ste-
ering wheel once to the right and once to the left, while
the roller is stationary.
When compacting asphalt, remember to turn on the
watering unit (13).
Make sure that the area in front of and
behind the roller is clear.
Pull up the parking brake knob (35) and
check that the warning lamp (36) for the
parking brake is out. When starting the
roller on a slope, be prepared that it may
begin to roll.
OPERATION
The following speeds are recommended:
1st
Steep slopes.
Driving in a cramped area with many obstacles.
With full ballast.
Driving on and off a transport vehicle.
In the event of strong resistance to rolling.
Maneuvering.
2nd
Rolling of compacted material. Eg, following a first run.
3rd
Used only for transport runs.
STOP the machine before changing the
direction of travel or shifting gear.
Selecting the speed range
Fig 17 Gear selection lever
1. 1st
2. 2nd
3. 3rd
Fig 16 Instrument panel
1. Tachometer
2. Fuel gauge
5. Warning lamp for low brake air pressure
and low brake fluid level on machines with
level sensor.
7. Indicating lamp, neutral mode
13. Sprinkler contact
35. Parking brake knob
36. Warning lamp for parking brake
Driving the roller
Fig. 18 Instrument panel
3. Coolant temperature gauge, engine
6. Oil pressure lamp
8. Tire pressure gauge
10. Gearbox oil pressure
11. Gearbox oil temperature
1 2 5 7
1336 35
CP221 CP271
1
3
2
1
2
3
3 6 8 10 11

18 CP221/271 O221EN5
Coconut mats (optional)
– Applied
Fig. 20 In measure mode
1. Coconut mats
OPERATION (Optional)
Remove the locking pin at each end of the rod.
Pull out the rod and allow the scrapers to rest in their
working mode against the tires.
Insert the rod in the existing holes above the scraper.
Fit the locking pins.
Remove the locking pins and pull out the rod.
Lift the scrapers and put the rod in the same place
through existing holes under the scrapers.
Fit the locking pins.
Disengaged
Fig. 21 Out of measure mode
1. Coconut mats
1
1
Adjusting tire pressure while
driving (optional)
Fig. 19 Operator’s station
26. Tire pressure control valve
Using the tire pressure control on the roller, the opera-
tor can vary the pressure while work is in progress.
Using control valve (26) on the instrument panel, the
pressure can be adjusted infinitely between 240 kPa
and 830 kPa (35 to 120 psi).
26

19CP221/271 O221EN5
Wheel Tire pressure, psi
pressure
kg 240 350 480 620 720 830
Ground pressure, psi
1125 200 240 270 300 330 340
1375 220 260 300 330 350 380
1825 240 280 340 380 400 430
2250 250 310 360 410 440 480
2750 260 320 390 440 480 520
3000 270 330 410 460 490 540
OPERATION (Optional)
Ground pressure
Fig. 22 Ground contact area
1. Contact area with high tire pressure
2. Contact area with low tire pressure
Contact area of the tires can be altered by altering the
pressure.
High tire pressure gives smaller contact area (1).
Low tire pressure gives greater contact area (2).
The gross service weight dived by the number of tires
gives the pressure per wheel. See table.
The ground contact area of the tires is relevant for
compacting results.
CONTACT PRESSURE
Wheel Tire pressure, psi
pressure
lbs 35 50 70 90 105 120
Ground pressure, psi
2500 29 35 39 44 47 49
3000 31 38 44 48 51 55
4000 35 41 49 55 58 62
5000 37 45 52 60 64 69
6000 38 47 57 64 70 75
6500 39 48 59 66 71 78
21

20 CP221/271 O221EN5
Low tire pressure
– 240 kPa (34.8 psi)
Fig. 23 Low pressure, larger area
GROUND PRESSURE
The lower the tire pressure the lower the pressure on
the contact surface, ie, due to the larger contact area.
Used on very loose material.
Used for degradation run.
Normal tire pressure
– 480 kPa (69.6 psi)
Fig. 24 Normal pressure
High tire pressure
– 830 kPa (120.4 psi)
Fig. 25 High pressure, smaller area
The higher the tire pressure the higher the contact
pressure.
Used on thicker courses and finishing run.