Dynapac CS 141 Guide

DYNAPAC
CS 141
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
M141EN4
MAINTENANCE

19
ILF015WO1

StaticThree-drum Roller
CS141
Maintenance
M141EN4, April 2002
Diesel engine:
Cummins 4BT-3.9
These instructions apply from:
CS 141 PIN (S/N) *21720192*
CS 141 PIN (S/N) *21720211* (New instrument panel)
Reservation for changes.
Printed in Sweden.
Dynapac CS 141 is a static 10–13 tonne articulated 3-drum roller. The drums have the same dia-
meter and the line load is equal over the entire width. Propulsion and brakes on all three drums.
Good working environment for the operator. The ergonomically designed cab, with its amply sized
windows facilitates a complete all-round view. The cab is an optional feature,
but is described in this manual.
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2CS 141 M141EN4
CONTENTS
GENERAL
WARNING SYMBOLS
Read the entire manual before starting any
service work.
Make sure that ventilation (extraction) is ade-
quate if the engine is run indoors.
If the gas springs of the engine hood are
disconnected and the hood is put in the upper
position—latch the hood to prevent it from
closing inadvertently.
It is essential that the machine is properly cared for to ensure
satisfactory operation. Keep the machine clean to facilitate
quick and timely detection of any leakage, loose bolts and
loose connections.
Make a habit each day, before starting up, of checking the
roller to detect any leakage or damage. Also check the gro-
und underneath the roller, where it is most often easier to
detect any leakage.
PROTECT THE ENVIRONMENT!
Do not leave behind any oil, fuel or other
substances that are harmful to the environment.
This manual contains instructions for periodic measures that
should normally be performed by the operator.
The manufacturer’s instructions in the engine
manual also apply. This is placed under a
separate flap in the product folder for the roller.
Safety instructions—Personal safety.
Special caution—Machine or component damage.
WARNING
CAUTION
WARNING
WARNING
CAUTION
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.
WARNING
Page
Lubricants and symbols ................................................... 3
Technical specifications ............................................... 4, 5
Maintenance schedule ..................................................... 6
Maintenance measures ................................................ 7, 8
Every 10 hours of operation (Daily) ............................9-12
Every 50 hours of operation (Weekly) ......................13-15
Every 250 hours of operation (Monthly) ................... 16, 17
Every 500 hours of operation (Every three months) ...... 18
Every 1000 hours of operation (Every six months) .. 19-20
Every 2000 hours of operation (Yearly) ................... 21, 22
Long-term parking .......................................................... 23
Special instructions ........................................................ 24
Electrical system, fuses ........................................... 25, 26

3
CS 141 M141EN4
LUBRICANTS AND SYMBOLS
Other fuel and lubricants are required for
operation in extremely high or extremely low
ambient temperature. See chapter “Special
instructions”, or consult Dynapac.
Engine, oil level Battery
Engine, oil filter Sprinkler
Hydraulic reservoir, level Sprinkler water
Hydraulic fluid, filter Fuel gauge
Lubricating oil Fuel filter
Coolant, level Recyclable
Air cleaner
Always use high-quality lubricants in the
amounts recommended. Too much grease or oil
can cause overheating and subsequent
increased wear.
ENGINE OIL, Shell Rimula TX SAE 15W/40 or equivalent
ambient temperature -10°C - +50°C API CF-4/SG, (CD/CE)
(14°F – 122°F )
HYDRAULIC FLUID,
ambient temperature Shell Tellus TX68 or equivalent
l-10°C - +40°C (14°F – 104°F)
temperature. over +40°C Shell Tellus TX100 or equivalent
BIOLOGICAL Shell Naturelle HF-E46
HYDRAULIC FLUID When the machine leaves the factory, it may be
filled with biologically degradable fluid. The same
type of fluid must always be used when changing
or topping off.
GREASE SKF LGHB2 (NLGI-Klass 2) or equivalent for the
articulation.
Shell Retinax LX2 or equivalent for other grease
points
FUEL See engine manual
COOLANT Shell Anti Freeze 402 or equivalent
50/50 mixture with water Anti-freeze down to about -35°C (-31°F)
CAUTION
CAUTION

4CS 141 M141EN4
Fluid volumes, litres (qts or gal)
Hydraulic reservoir 66 (17.4 gal)
Fuel tank 110 (29 gal)
Water tank 550 (145.2)
Diesel engine, oil volume 9.5 l (10 qts)
Cooling system 17 (4.5 gal) (Without cab), 20 (5.3 gal) (With cab)
Ballast in the drums 2x470 (2x124 gal) (Front), 1130 (298.3) (Rear)
Electrical system
Battery 12 V, 160 Ah
Alternator 14 V, 95A
Fuses See under “Electrical system”
Propulsion
Speed range, km/h (miles/h) 0-15 (0-9.3)
Climbing capacity - theoretical (%) 45
Shipping weight not incl. ROPS/cab and ballast kg 9,600 (21,164 lbs)
Operating mass with ROPS/cab and ballast, EN500 kg 12,800 (28,219 lbs)
Operating mass without ROPS/cab (with ballast) kg 12,000 (26,455 lbs)
Max. weight, kg 13200 (29,100 lbs)
Length, standard equipped roller, mm 4800 (190 in)
Width, standard equipped roller, mm 2100 (83 in)
Height, without ROPS/cab mm 2600 (Shipping height) (8.5 feet)
Height, with ROPS/exhaust pipe 3280 / 3460 (10.75 / 11.35 feet)
TECHNICAL SPECIFICATIONS
Weight and sizes

5
CS 141 M141EN4
Hydraulic system Opening pressure (MPa)
Drive system 42,0
Supply system 2,2
Steering system 14,0
Brake disengagement 1,5
Measured on foam rubber mat, standard roller
Vibration in the operator’s seat is 0,04 m/s2
(without cab)*
Vibration in the operator’s seat is 0,1 m/s2(with cab)*
Limit value 0,5 m/s2.
Measured on hard surface, standard roller
Operator’s station, (without Cab): LpA: 82 dB(A)
7 metres from machine: LpA 82 dB (A)
Noise levels – Operator’s station
(ISO 6394)
Vibration – Operator’s station
(ISO 2631)
TECHNICAL SPECIFICATIONS
Tightening torque Tightening torque in Nm (lbf.ft) for oiled, bright
galvanized bolts tightened with a torque wrench.
Bolt size : M22 (P/N 19 50 96 - 19 50 97)
Strength class: 10.9
Tightening torque: 520 Nm (Dacromet treated)
ROPS ROPS -bolts are always to be torque tighte-
ned dry.
M STRENGTH CATEGORY
thread 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 –
* Total acceleration in the driver’s seat.
CAUTION

6CS 141 M141EN4
MAINTENANCE SCHEDULE
Fig.1 Service and maintenance points
9
1. Engine oil
2. Radiator
3. Drum nuts
4. Refueling
5. Air cleaner
6. Scrapers
7. Water tanks, filling
8. Sprinkler system
9. Battery
10. Articulation joint
11. Steering cylinder
12. Hydraulic filter
13. Hydraulic fluid level
14. Hydraulic fluid, filling
15. Hydraulic reservoir
16. Diesel engine
17. Hinges
18. ROPS
19. Fuel tank
20. Fresh air filter
38
66
8
5119162
13
18 7
10
6 6
20
4
17
17
11
12
17
14 15

7
CS 141 M141EN4
MAINTENANCE MEASURES
Items Action See page Comments
in fig. 1
Before starting each day
2 Check coolant level 9
1 Check level of engine oil 9 See engine manual
13 Check level in hydraulic reservoir 10
4 Refuel 10
7 Fill the water tank 10
8 Check sprinkler system 11
Test the brakes 11
6 Check setting of scrapers 12
Inspect spring-action scrapers 12 Optional
Every 10 hours of operation (Daily)
Items Action See page Comments
in fig. 1
Check/clean the filter element in the air cleaner 13
10 Lubricate the articulation 14
11 Lubricate the steering cylinder mounts 14
15 Check tightening of drum nuts 15
After the first 50 hours of operation, change all oil and hydraulic fluid filters and the
lubricating oil, but not the hydraulic fluid.
Every 50 hours of operation (Weekly)
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.
CAUTION
CAUTION
CAUTION

8CS 141 M141EN4
MAINTENANCE MEASURES
Items Action See page Comments
in fig. 1
Check the engine V belt tension See engine manual
16 Check engine valve clearance See engine manual
12 Change the hydraulic filter 19
5 Change main filter in the air cleaner 19
20 Change air cleaner filter in cab 19
19 Drain the fuel tank 20
15 Drain condensation from the hydraulic reservoir 20
Every 1000 hours of operation (Every six months)
Items Action See page Comments
in fig. 1
15 Change the hydraulic fluid 21
19 Empty and clean the fuel tank 21
7 Empty and clean the water tanks 21
10 Check the condition of the articulation 22
Every 2000 hours of operation (Yearly)
Items Action See page Comments
in fig. 1
19 Replace engine fuel filter See engine manual
16 Replace engine fuel pre-filter 18
Lubricate hinges and controls 18
14 Check breather filter on the hydraulic reservoir 18
Every 500 hours of operation (Every three months)
Items Action See page Comments
in fig. 1
9 Check electrolyte level in battery 16
16 Drain the fuel filters 16
2 Clean the radiator elements 17 Or when required
1 Change the engine oil and oil filter 17 See engine manual
Every 250 hours of operation (Monthly)

9
CS 141 M141EN4
EVERY 10 HOURS OF OPERATION (Daily)
Coolant level – Check
Check the level with the engine stopped and cold.
Coolant should reach the top level mark (1) in the
radiator expansion vessel.
The coolant is hot and under pressure and
the escaping steam can cause serious
scalding. Open the filler cap carefully to
release the pressure. Wear protective
goggles and protective gloves.
Make sure that cooling air flows freely through the
protective grille to the engine.
Fig.3 Radiator filler hole
1. Level mark in expansion vessel
(max./min.)
1
Engine hood support 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.
Ensure that the engine hood support is
securely in position for all work in the
engine compartment.
Fig.2 Engine compartment
1. Engine hood support
1
Diesel engine
– Checking the oil level Beware of hot parts of the engine and hot
radiator when taking out the oil dipstick.
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.
1
Fig.4 Engine compartment
1. Dipstick
WARNING
WARNING
WARNING
WARNING

10 CS 141 M141EN4
Fig.6 Fuel tank
1. Filler pipe
EVERY 10 HOURS OF OPERATION (Daily)
Fuel tank – Refueling
Refuel every day before starting operation. Screw off
the lockable tank cap (1) and fill diesel fuel to the lower
edge of the filler pipe.
Never refuel while the engine is running,
do not smoke, and avoid spilling fuel.
See the engine handbook for the grade of diesel fuel.
The tank holds 110 l (29 gallons) of fuel.
1
Water tanks – Filling
Fig.7 Water tanks
1. Strainers
1
Screw off the tank cap and fill with pure water,
do not remove the strainer (1).
Fill both water tanks; they hold a total of 550 liters (145
gallons).
Sole additive: Small amount of environment-
friendly antifreeze liquid.
Hydraulic reservoir
– Level check/Filling
1
Fig.5 Right step up
1. Sight glass
Check that the fluid level is between the min. and max.
marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.
WARNING
CAUTION

11
CS 141 M141EN4
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.
Wear protective goggles when working
with compressed air.
Sprinkler system
– Checking / Cleaning
Fig.8 Sprinkler ramp
1. Water nozzles
Start the sprinkler system and make sure that no
nozzle (1) is clogged. If necessary, clean clogged
nozzles and the coarse filter located adjacent to the
water pump (2), see figures below.
1
EVERY 10 HOURS OF OPERATION (Daily)
Inspect the intake water filters of the pumps every day.
The water filter housing (2) can be removed.
Flush the housing and the filter clean with water and
then put them back into place.
Use only clean water in the water tank.
The water system must completely drained if
the roller is to be left unused for a longer
period or if temperatures below zero can be
expected. Remove the bottom plug to drain the
tank.
There are two strainers located behind the fuel tank.
Fig.10 Water system (basic setting)
1. Water pump
2. Water strainer housing
2
1
12
4
3
2
1
Fig.9 Nozzle
1.Sleeve
2.Nozzle
3.Compaction
4.Strainer
WARNING
CAUTION
CAUTION

12 CS 141 M141EN4
Scrapers, fixed
– Checking / Setting
Fig.12 Drum scrapers
1. Locking screws
2. Scraper
Make sure that the scrapers are undamaged. Adjust
the scrapers so that they lie 1–2 mm from the drum.
For special asphalt compounds it may be better if the
scraper blades (2) lie lightly against the drums.
The remains of asphalt can accumulate on the scraper
and thus influence the contact force.
Loosen the screws (1) to adjust contact pressure of the
scraper blade against the drum.
Remember to tighten all the screws after any
adjustment.
EVERY 10 HOURS OF OPERATION (Daily)
2
1
Scrapers, spring-action
(Optional) – Check
Fig.13 Spring-action scrapers
Make sure that the scrapers are undamaged. The
spring-action scrapers require no adjustment because
the spring force provides the correct contact force.
Asphalt remnants can accumulate on the scraper and
influence the contact force. Clean as necessary.
Make sure the scrapers are retracted from the
drum during transport driving.
Fig.11 Instrument panel
2. Forward/reverse lever
12. Reserve/Parking brake knob
29. Control lamp, brakes
2
29
12
Brakes – Check Check operation of the brakes as follows:
Drive the roller slowly
forward.
Press down the reserve brake knob (12). The brake
warning lamp (29) should light and the roller should
stop.
After checking the brakes, put the forward/reverse
lever (2) in neutral before resetting the reserve brake
knob.
Pull out the reserve brake knob.
WARNING
CAUTION

13
CS 141 M141EN4
EVERY 50 HOURS OF OPERATION (Weekly)
Air cleaner
– Check/Cleaning
Main filter – Cleaning with
compressed air
Fig.15 Main filter
23
Fig.14 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).
1 4 5
Fig.16 Air filter
4. Backup filter
Backup filter
– Replacement
4
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.
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.
WARNING
CAUTION
WARNING
CAUTION
CAUTION

14 CS 141 M141EN4
Fig.18 Lubricantnipple
1. Lubricant nipple, steering
cylinder
Fig.17 Lubricantnipples
1. Lubricant nipples, articulation
2. Lubricant nipples, steering
cylinders
Articulation steering and
steering cylinder bushings
– Lubrication
1
1
2
1
EVERY 50 HOURS OF OPERATION (Weekly)
Nobody must be allowed near the steering
joint when the engine is running. Danger of
being crushed when steering is operated.
Push the reserve/parking brake knob befo-
re lubricating.
Turn the steering wheel fully to the left to gain access
to all seven grease nipples (1 and 2) from the right side
of the machine.
Wipe the grease nipples. Lubricate the articulation
nipples (1) with five strokes of the hand grease gun,
and the steering cylinder bearings (2) with three
strokes in each bearing. Make sure that grease
penetrates the bearings. If grease does not penetrate
the bearings, it may be necessary to relieve the
articulation joint with a jack while repeating the greasing
process.
Turn the machine back for driving straight ahead. This
makes the rear bearing (1) of the left steering cylinder
accessible from the left side of the machine.
Wipe the nipple and grease with three strokes of the
hand grease gun.
21
WARNING

15
CS 141 M141EN4
EVERY 50 HOURS OF OPERATION (Weekly)
Fig.19 Drum
1. Drum nut
Tightening the drum nuts
– Check
1
Ensure that all nuts are properly tightened. Tightening
torque is 500 Nm (369 lbf.ft).
Check all the nuts on all three drums.
(Applies only on new machine or newly fitted wheels.)

16 CS 141 M141EN4
Place the roller on a level base. The engine
must be switched off and the reserve/par-
king brake knob pushed in for all checking
and adjustments on the roller unless other-
wise specified.
Never use a naked flame when checking the
battery. The electrolyte emits explosive gas
while the alternator is charging.
The battery is located in the front beam, underneath the
cover.
Wear safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.
Take off the cell caps and make sure that electrolyte is
about 10 mm above the plates. Check the level of all
cells. Top off with distilled water to the right level if the
level is low. If the ambient temperature is below
freezing, run the engine for a while before topping off
with distilled water. Otherwise the electrolyte might
freeze.
Make sure that ventilation holes in the cell cover are not
clogged. Then put the cover back on.
The cable shoes should be clean and well tightened.
Clean corroded cable shoes and grease them with acid-
free Vaseline.
When disconnecting the battery, always
disconnect the negative cable first. When
connecting the battery, always connect the
positive cable first.
Discard used batteries wisely. Batteries
contain lead, which is harmful to the
environment.
Before doing any electric welding on the
machine, disconnect the battery ground
cable and then all electrical connections to
the alternator.
EVERY 250 HOURS OF OPERATION (Monthly)
Fig.20 Location of battery
1. Battery
2. Battery disconnector
Electrolyte level in battery
– Check
Fig.21 Electrolyte level in battery
1. Cell cap
2. Electrolyte level
3. Plates
1
2
3
Battery cell
1
2
10 mm
Fig.22 Fuelfilter
Fuel filter – Draining
Unscrew the drain plug at the bottom of the filter.
Make certain, with the aid of the secondary hand-
operated pump, that all sediment comes out. See
Cummins service manual.
Tighten the drain plug as soon as uncontaminated fuel
runs out.
WARNING
WARNING
WARNING
WARNING
CAUTION

17
CS 141 M141EN4
EVERY 250 HOURS OF OPERATION (Monthly)
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 cooler 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 radiator.
Wear protective goggles when working
with compressed air or a high-pressure
water jet.
Fig.23 Engine compartment
1. Radiator
1
Radiator – Check/Cleaning
Fig.24 Drainplug
Engine – Oil change
Run the engine warm before draining the oil.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors (risk
of carbon monoxide poisoning).
Switch off the engine and apply the par-
king brake.
Place a receptacle that holds at least 15 liters
(4 gallons) under the drain plug. Save the oil
and dispose of it properly.
Risk for burns when draining hot oil. Pro-
tect your hands.
Unscrew the oil drain plug (1). Allow all of the oil to
drain off and refit the plug.
Change the engine oil filter at the same time. See
engine instruction manual.
Fill with fresh engine oil; see Lubricant specification or
the engine manual for the correct grade of oil.
Check the dipstick to ensure that the engine oil level is
correct; for details see the engine manual.
WARNING
CAUTION
WARNING
WARNING
WARNING

18 CS 141 M141EN4
EVERY 500 HOURS OF OPERATION (Every three months)
Fuelpre-filter
– Replacement Place the roller on a level surface. Switch
the engine off and push in the reserve/parking-
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Loosen the hose clips (2) and remove the filter (1). Fit
the new fuel filter and make certain the direction of flow
is correct. The arrow should point from the tank.
Discard the pre-filter (1) in a safe manner, it is
of the expendable type and cannot be cleaned.
Fit a new pre-filter and tighten the hose clamps again.
Start the engine and check that the pre-filter does not
leak.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors. Risk
of carbon monoxide poisoning.
Fig.25 Diesel engine
1. Fuel pre-filter
2. Hose clamps
2
1
2
Fig.27 Fuel tank
1. Tank cap
Hydraulic reservoir cap
– Check
1
Unscrew and make sure that the reservoir cap is not
clogged, air must have unobstructed passage through
the cap in both directions.
If clogged in either direction, clean with a little diesel oil
and blow with compressed air until free passage is
assured or replace the cap with a new one.
Use protective goggles when working with
compressed air.
Lubricate both hinges (1) on the engine compartment
doors until grease penetrates through.
Grease the hinges of the cab door in the same way.
Lubricate the hinges of the front and rear spotlight
covers with a few drops of oil.
Lubricate the forward/reverse control wires by the
control arm of the hydraulic pump. Apply a few drops of
oil to the mouth of the control sleeve.
Fig.26 Enginehood
1. Hinge
1
Hinges, controls
– Lubrication
WARNING
WARNING
WARNING