Dynapac CP2700 Instruction Manual Download Page 1

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Instruction Manual

4812325557EN

Operation and Maintenance

Pneumatic Tire Roller

CP2700

Diesel Engine

Cummins QSB 4.5

– Tier III

Cummins QSF 3.8 - Tier IV

Serial number

100005x2xxB005423

It is reserved the right to make any changes

Printed in Brazil

Summary of Contents for CP2700

Page 1: ...2325557EN Operation and Maintenance Pneumatic Tire Roller CP2700 Diesel Engine Cummins QSB 4 5 Tier III Cummins QSF 3 8 Tier IV Serial number 100005x2xxB005423 It is reserved the right to make any cha...

Page 2: ......

Page 3: ...ergency Stop Parking Brake 50 Long term storage 53 Lifting 55 Towing 56 Transport 59 Operation instructions Overview 60 Preventive maintenance 61 Preventive maintenance Symbols and lubricants 62 Speci...

Page 4: ...4812325557EN 2018 02 19...

Page 5: ...hine or its parts CAUTION Risk of death or injures Safety information The Safety Manual delivered with the machine shall be read by the operator Always follows the safety instructions and keep the Man...

Page 6: ...pose oil fuel or other hazard substances to the environment Always dispose correctly used filters draining oil and fuel residues This manual contains instructions for periodic maintenance which is usu...

Page 7: ...during the travel Always look up and down during the travel Make sure there are no obstacles in the direction of travel on the ground in front or behind the roller 11 Drive particularly carefully on...

Page 8: ...N 2018 02 19 19 For your own protection always wear Helmet Working boots with steel toecaps Ear protectors Reflecting clothing Working gloves 20 If there is a cab in the machine operate it always with...

Page 9: ...ionary position The steering angle is zero the tires pressure is normal and all the tanks are full Always remember that loosen ground the steering of the machine different tire pressures the operation...

Page 10: ...steep ground Always drive the machine in slow speed when operating or during transport on steep ground 15 To drive or stop the machine the rear wheels shall always be towards the slope that is the rol...

Page 11: ...loose or disconnect hoses and connections with the system loaded The system must be refilled with approved coolant when necessary Refer to the safety decal next to the replacement and filling place E...

Page 12: ...ce on the lighting system shall be performed by authorized technicians and the main power source shall be off CAUTION Environmentally hazardous waste The xenon lamps of the working lights contain merc...

Page 13: ...2 5 m s action value as specified in the same abovementioned directive the limit is 5 m s Noise level The sound levels are measured according to the operational cycle described in the EU directive 200...

Page 14: ...Technical specifications Dimensions Dimensions Dimensions mm inches A Between axles 4 300 169 B Total width 2 360 93 H1 Height with attachment 3 344 132 H2 Total height 2 990 118 K Height from the gr...

Page 15: ...ion items 2018 02 19 4812325557EN 11 Dimensions Millimeter Inch R Outer radius 9045 356 r Inner radius 5711 225 x Tire width 300 11 8 Dimensions Degree O Vertical oscillation 4 5 D Direction angle 33...

Page 16: ...decals description and location 12 4812325557EN 2018 02 19 Safety decals description and location 10 13 15 16 1 23 15 15 8 7 12 13 2 3 17 18 9 14 17 18 24 20 4 6 15 21 5 22 15 1 13 15 16 23 10 11 12...

Page 17: ...components be careful Keep your hands off the danger zone 3 NOTICE Hot surface Keep your hands off the surface 4 NOTICE Read carefully the towing chapter before releasing the brakes Crushing injury da...

Page 18: ...4812325557EN 2018 02 19 Safety decals Description and location cont 10 Emergency exit Cab 11 Fire extinguisher 12 Hoisting plate 13 Tire pressure 14 Diesel oil 15 Securing point 16 Lifting point 17 H...

Page 19: ...description and location 2018 02 19 4812325557EN 15 Safety decals Description and location cont 19 Handbook compartment 20 Master switch 21 Battery voltage 22 Sound power level 23 Water tank 24 Hydrau...

Page 20: ...power and the manufacturing year machines delivered outside EU do not present CE marking and in some cases they also do not present the manufacturing year NOTE State the machine plate s serial number...

Page 21: ...code B Sorocaba Brazil F Serial number from 000001 to 999999 Engine plate The engine plate 1 is on the cylinder head cover 1 and it can be accessible when the hood is open The plate is also on the top...

Page 22: ...atic sprinkler OPTION 12 increase of the sprinkler interval timer OPTION 13 decrease of the sprinkler interval timer OPTION 14 Working lights OPTION 15 Horn 16 Emergency stop button 17 Eco mode 18 Ena...

Page 23: ...2325557EN 19 Pedals The roller has two pedals 1 Throttle pedal 2 Brake pedal Steering column multiple switch option Switch functions 1 Forward reverse lever 2 Central warning lights 3 Direction lights...

Page 24: ...entral warning lights Appoints general fault See the control panel 22 for the description of the fault 6 High beam lights It shows that the high beam lights are on via switch at the steering column 7...

Page 25: ...itch Press to sound the horn 16 Emergency stop button Press it to turn off the machine and the engine All the power supply is also turned off 17 Eco mode When activated maintain speed reducing the eng...

Page 26: ...ting 23 Function buttons 5 24 Brake test pedal Press it to test the brakes 25 Parking brake When it is pressed the parking brake is activated To turn it off slide the red part backwards towards you an...

Page 27: ...fied in percentage The screen remains visible until the Diesel engine is turned on or if one of the function buttons below the screen is pressed If the engine starts before you choose the screen it wi...

Page 28: ...rm log button to show the alarms of the engine and machine Settings menu selection button which opens the main menu Settings can be changed in the main menu Exit return button returns 1 step at once P...

Page 29: ...value shown in the top of the main screen starts to flash The temperature value is continuously on when it is in the right limit When an engine motor alarm is activated it is shown in the screen The...

Page 30: ...ning symbol engine temperature If this symbol appears the engine is too hot Stop immediately the engine and find the fault Refer also to the engine manual Warning symbol hydraulic oil temperature This...

Page 31: ...or Feedback Resistance Valve out of range Limited Mode 12 3 2 Error in the Motor Control Valve Error Feedback Resistance Valve out of range Limited Mode 13 3 3 Hydraulic motor valve BPD Error Feedback...

Page 32: ...018 02 19 Control panel Alarms cont Alarms received are stored logged and can be seen by selecting Display Alarms ENGINE ALARM Stored logged engine alarms MACHINE ALARM Stored logged machine alarms Th...

Page 33: ...12325557EN 29 USER SETTINGS Users can change lighting settings choose between Metric or Imperial system and set warning sounds on off Adjustment of light and contrast settings on the display including...

Page 34: ...e low speed low slow speed not all the models refer to the manual to know if your model fits in this condition Operator help when activating When trying to activate the edge cutter option with the mac...

Page 35: ...very low level Operator should refill the DEF tank with DEF DEF Lamp With Check Engine Lamp Illuminates when the DEF level is critically low If the tank is not refilled immediately power will be reduc...

Page 36: ...ed in a timely manner after the Exhaust System Cleaning Lamp is illuminated the Check Engine Lamp will illuminate and engine power will be significantly reduced Park the equipment when safe to do so a...

Page 37: ...ded when the Exhaust System Cleaning Lamp illuminates When the Start Switch is pressed cleaning begins and this is confirmed by the Exhaust System Cleaning Lamp flashing The HEST lamp may illuminate d...

Page 38: ...Instruments Controls 34 4812325557EN 2018 02 19 Instruments and Controls Cab Radio CD player option 9 3 10 1 4 5 6 7 3 2 8 9 Radio Option 11...

Page 39: ...op to activate the front washers Press the bottom to activate the rear washers 6 Asymmetric front wiper switch Press to operate the front side windshield wiper 7 Asymmetric rear wiper switch Press to...

Page 40: ...r The set point temperature will flash on the display press until reaches desired temperature Display The display shows set point value bar graph evaporator speed active function and other information...

Page 41: ...ual ventilation The manual ventilation has three speeds When some function cooling heating or automatic mode is active the ventilation function is always on To change the fan speed press the key Venti...

Page 42: ...inner lever 1 The transverse travel brake will be released For rotation raise the outer lever 2 Make sure the control unit is in the correct position before operating the machine For steering column a...

Page 43: ...e sure the seat is locked before starting the operation Always use the seat belt 4 Comfort operator s seat option adjustment Adjust the operator s seat so all the controls are within easy reach and th...

Page 44: ...and lock the railings in the desired position Make sure the anti slip protections 4 of the platform are in good condition and replace them for new ones if they are worn If the machine is fitted with a...

Page 45: ...ngine cannot be started if the lever is not in this position When sitting on the operator s seat turn the ignition key 3 to the right the first position I and then to the start position Release the sw...

Page 46: ...t with the engine in maximum rpm it shall be necessary to replace the hydraulic oil filter Warning lamp air filter If the lamp is lit with the engine in maximum rpm it shall be necessary to clean or r...

Page 47: ...asphalts do not forget to activate the sprinkler system 1 or 2 Release the parking brake button 5 by sliding the red lock on the button backwards and changing the lever position Remember that the mac...

Page 48: ...n the main tank and it is the same used in the standard sprinkler system Tire pressure adjustment option The operator can vary the pressure during the operation with the tire air pressure control It c...

Page 49: ...der 2 Make sure the lock pin 4 releases properly from the locking hook 3 and allow the scraper to rest against the tires in the working position To release the coconut mats Hold and lift the handle in...

Page 50: ...water may leak when the ballast is filled with it Fill the ballast box when necessary with gravel sand and steel The water shall be added when it is filled with sand so it can fill all the spaces betw...

Page 51: ...in the steel ballasts Remove the bedplate 4 off the ballasts assembly 3 Install or remove the ballasts according to the necessity using the forks from a standard forklift The ballasts grooves 5 were p...

Page 52: ...g to the following table Ground pressure TIRE PRESSURE kPa 240 350 480 620 720 830 LOAD ON THE WHEEL kgf GROUND PRESSURE kPa 1 125 200 240 270 300 330 340 1 375 220 260 300 330 350 380 1 825 240 280 3...

Page 53: ...the larger surface area Normal tire pressure 480 kPa 69 6 PSI Used for degradation session High tire pressure 830 kPa 120 4 PSI The higher the tires pressure the higher the pressure on the contact sur...

Page 54: ...nds the engine will turn off and the brakes will be activated To check if the emergency stop works correctly the operator shall press the corresponding button with the roller moving forwards and backw...

Page 55: ...ward lever shall be in the neutral position and the parking brake shall be on Turning off the engine Allow the engine to cool down in low idle for a few minutes Check if the Display 1 shows any indica...

Page 56: ...In extremely cold weather some components may freeze Drain the water tanks and pipings Master switch At the end of the working shift turn off the battery master switch 1 and remove the handle This wil...

Page 57: ...struction manual supplied with the roller Battery Remove the batteries from the roller clean their outside parts and recharge them once a month Air cleaner exhaust pipe Close the air tube refer to the...

Page 58: ...over the instrument panel Cover the entire roller with a tarpaulin It shall have a gap between it and the ground If possible store the machine indoors and preferably in a place with regular temperatur...

Page 59: ...ck the machine gross weight and the compatibility of the lifting equipment Lifting the roller with a jack The machine s gross weight is specified in the hoisting plate 1 Refer also to the Technical Sp...

Page 60: ...he pump are freely connected to the pressure side This function allows the machine to be moved without the drive shaft rotating 4 Start the Diesel engine and run it in idle 5 Move the forward backward...

Page 61: ...hine to be moved without the drive shaft rotating 4 The brake release pump is at the right side of the engine compartment 5 Pump with the arm 3 until the brakes are released 6 So the brake release pre...

Page 62: ...meters During the roller towing its devices shall be connected in both lifting holes The pulling forces shall act to the machine s longitudinal axis as illustrated in the figure Refer to the table be...

Page 63: ...Chock under the frame 2 to ensure that the chains remain tensioned if the air goes out of the tires Block up the machine according to the figure Secure the roller with chains in all four corners The...

Page 64: ...engine and warm it Always check the brakes Before starting the working shift carry out a test in the system and remember that if the hydraulic oil is cold the brake distance will be longer When opera...

Page 65: ...eaving the plant The inspection shall happen in the moment it arrives to the client following the list in the warranty document Any transport damage shall be immediately reported to the carrier compan...

Page 66: ...C Shell Tellus V68 or equivalent Shell Tellus V100 or equivalent BIOLOGICAL HYDRAULIC OIL When leaving the plant the machine may be filled with biologically degradable oil When replacing or filling w...

Page 67: ...maintenance Symbols and lubricants 2018 02 19 4812325557EN 63 Engine oil level Engine oil filter Hydraulic fluid level Air filter Hydraulic fluid filter Transmission oil level Fuel filter Battery Coo...

Page 68: ...Preventive maintenance Symbols and lubricants 64 4812325557EN 2018 02 19 Lubricating oil Air pressure Sprinkler Sprinkler water Recycling...

Page 69: ...on to obtain the maximum of the ballast The roller working weight consists of the machine weight and the ballast weight Thicker layers demand a heavier machine for compacting and thinner layers do not...

Page 70: ...50 1 lb ft 76 N m 56 05 lb ft M12 70 N m 51 6 lb ft 78 N m 57 5 lb ft 98 N m 72 2 lb ft 110 N m 81 1 lb ft 117 N m 86 3 lb ft 131 N m 96 6 lb ft M14 110 N m 81 1 lb ft 123 N m 90 7 lb ft 156 N m 115...

Page 71: ...m 172 5 lb ft M16 240 N m 177 lb ft 304 N m 224 2 lb ft 290 N m 213 9 lb ft 360 N m 265 5 lb ft M20 470 N m 346 6 lb ft 585 N m 431 4 lb ft 560 N m 413 03 lb ft 698 N m 514 8 lb ft M22 626 N m 461 7 l...

Page 72: ...ed Coolant designation HFC R134 A Coolant weight when full 1 000 g 2 2 lb Engines ENGINE Manufacturer and model Cummins QSB 4 5 TIER III and QSF 3 8 TIER IV Power SAE J1995 110 130 HP 82 97 kW 2 200 r...

Page 73: ...nd lubrication points 1 Engine oil 9 Coolant 17 Cab air filter 2 Oil filter 10 Engine air filter 18 Cab air conditioning 3 Fuel filter 11 Fuel supply 19 Edge cutter 4 Hydraulic oil filter 12 Scrapers...

Page 74: ...anufacturer instructions For further information refer to the Engine Manual DAILY Every 10 hours of operation POSITION IN THE FIGURE ACTION NOTES Before starting the engine 1 Check the Diesel engine o...

Page 75: ...ce the hydraulic oil filters 20 Lubricate the lower pivot bearing 21 Lubricate the upper pivot bearing 23 Replace the wheel gear oil WEEKLY Every 50 hours of operation POSITION IN THE FIGURE ACTION NO...

Page 76: ...ngs 20 Lubricate the lower pivot bearing 21 Lubricate the upper pivot bearing Replace air dryer filter Machine equipped with AOR EVERY THREE MONTHS Every 500 hours of operation POSITION IN THE FIGURE...

Page 77: ...h AOR 4 Replace the hydraulic oil filters 17 Replace the cab air filter 20 Lubricate the lower pivot bearing 21 Lubricate the upper pivot bearing 23 Replace the wheel gear oil 23 Check the wheel gear...

Page 78: ...the upper and lower parts For further information refer to the Engine Manual instructions Check the engine coolant The expansion tank is placed in the center between the operator platform and the engi...

Page 79: ...rting the operation or fuel the tank when the work is done Unscrew the tank cap 1 and check up to the lower edge of the filler pipe The tank capacity is of 58 gal 220 liters of fuel For further inform...

Page 80: ...re is excessive wear on the roller tires Do not add flammable fluids or those which are hazardous to the environment in the emulsion tank Clean the sprinkler injector Dismantle the blocked nozzle by h...

Page 81: ...craper blade 1 firmly while pressing the locking hook 2 The scrapers can be easily removed for cleaning and inspection 1 First fix the scraper in the locking hook 3 at the scraper attachment 4 to prev...

Page 82: ...k 3 and clean the filter and its housing Check if the rubber gasket of the filter housing is in intact After the cleaning and inspection put again all the components on their right places and start th...

Page 83: ...m allowed value for used belts Drain the fuel filter To drain the fuel filter follow the instructions below 1 Unscrew the drain plug 1 in the bottom of the filter 2 With the hand operated secondary pu...

Page 84: ...d protective goggles to prevent the hot oil getting in contact with the skin which can cause burns 1 Remove the hexagon nut 1 take off the hose 2 and loose the oil drain plug 3 2 Let all the oil come...

Page 85: ...lter 4 2 If necessary clean the air filter according to this page instructions 3 When replacing the main filter 3 put a new one in its place and fit back all the air filter components in the reverse o...

Page 86: ...lder install a new on and fit the components back in the reverse order 2 Clean the main filter if necessary Replace the engine fuel filter The fuel filter is located in front of the accumulators on th...

Page 87: ...er 4 Fit manually the filter first until the filter gasket manages to reach the holder Next tighten it with one more turn 5 Check the hydraulic oil level on the sight glass 2 and adjust if necessary R...

Page 88: ...to prevent the hot oil getting in contact with the skin which can cause burns 1 Unscrew the drain plug 1 2 Put a container with 5 28 gal 20 liters of capacity under the drain plug 3 Unscrew the drain...

Page 89: ...es that the coolant level is too low Turn off the air conditioning to prevent damages and fill it with coolant Clean the air conditioning If there is a significant loss of cooling capacity clean the c...

Page 90: ...nd protective goggles to prevent the hot oil getting in contact with the skin which can cause burns 1 Remove the hexagon nut 1 take off the hose 2 and loose the oil drain plug 3 2 Let all the oil come...

Page 91: ...oolers is unobstructed If the cores are dirty wash them with flowing water with the engine cold and blow them with compressed air When using compressed air always use protective goggles Whenever possi...

Page 92: ...e batteries When working with batteries protect your face and eyes using the proper equipment for individual protection and always provide the proper ventilation as well 3 Take off the cell caps and c...

Page 93: ...ting of the upper pivot bearing 1 and the grease fitting of the lower pivot bearing 2 operating the grease gun manually with five pump strokes 2 Use the grease according to the lubricant specification...

Page 94: ...fuel filter is located in front of the accumulators on the left side of the engine compartment 1 Unscrew the bottom of the filter and drain the water Next screw the unit back in its place 2 Fit the fu...

Page 95: ...tation bearing with three strokes of a hand operated grease gun 2 Clean and lubricate the chain 3 with grease between the seat and the steering column 3 Also lubricate the slide rails 4 of the seat wi...

Page 96: ...1 Lubricate each grease fitting 1 with five hand operated strokes 2 Use the grease according to the lubricant specifications recommended by DYNAPAC Replace the air dryer filter To replace the filter e...

Page 97: ...is obstructed the engine will lose power and the exhaust will let the smoke black besides the risks of damaging the engine Replace the secondary air filter Replace the secondary air filter for a new...

Page 98: ...er 4 Fit manually the filter first until the filter gasket manages to reach the holder Next tighten it with one more turn 5 Check the hydraulic oil level on the sight glass 2 and adjust if necessary R...

Page 99: ...to prevent the hot oil getting in contact with the skin which can cause burns 1 Unscrew the drain plug 1 2 Put a container with 5 28 gal 20 liters of capacity under the drain plug 3 Unscrew the drain...

Page 100: ...the manufacturer specifications Drive the machine until the level plug 2 is in the horizontal position Check if the oil level reaches the bottom of the plug opening Clean and fix the plugs again Chec...

Page 101: ...draulic tank oil follow the instructions below 1 Park the roller on a level surface and turn off the engine 2 Use a container with the proper capacity to drain the hydraulic circuit tank 13 20 gal or...

Page 102: ...f the machine in a proper compartment 3 Unscrew the drain plug 2 and drain the remaining fuel inside the tank 4 Refit the drain plug and tighten it Using adulterated contaminated dirty or bad quality...

Page 103: ...ther Empty the tanks compartments filters and tubes during such period or mixed fluid with water and antifreeze The coarse filter is inside the frame s upper compartment on the right side of the machi...

Page 104: ...iner to collect the coolant with 3 69 gal or 14 liters of capacity Be careful when draining the product Use gloves and protective goggles TAKE CARE OF THE ENVIRONMENT All used coolant shall be properl...

Page 105: ...d Also check if the system hoses are not in contact with other components Check if there are no draining obstructions on the coolant unit There is a risk of condensation being accumulated inside the u...

Page 106: ...tting of the upper pivot bearing 1 and the grease fitting of the lower pivot bearing 2 operating the grease gun manually with five pump strokes 2 Use the grease according to the lubricant specificatio...

Page 107: ...applied Temperatures The limit temperatures are valid for series rollers The rollers with additional equipment like noise level diminution equipment may need special attention when they are operated...

Page 108: ...ormed around the battery Check if the battery used for the jumper starting and the dead battery have the same tension Turn off the ignition key and all the power consuming equipment Turn off the rolle...

Page 109: ...nside the engine compartment are located alongside the battery master switch The roller is equipped with a 24V electrical system supplied by an AC alternator Connect the batteries to the correct polar...

Page 110: ...reen 5A 3 Main ECU PWR 1 10A 4 Main ECU PWR 2 10A option 5 Main ECU PWR 3 20A 6 Main ECU PWR 4 20A 7 Jack 24V 10A 8 Transmission ECU 10A F2 fuse box 1 Air during the operation 5A 2 Asphalt 10A 3 Backu...

Page 111: ...screen wiper washers right 10A 7 Empty 8 Empty Main fuses panel The main fuses panel is behind the battery master switch on the battery compartment 1 General key 2 Pre heating relay 120A 3 F20 fuse pr...

Page 112: ...108 4812325557EN 2018 02 19...

Page 113: ...Dynapac do Brasil Industria e Comercio de Maquinas Ltda Rua Georg Schaeffler 430 Sorocaba SP Brasil Tel 55 15 3412 7500 Fax 55 15 3412 7522 www dynapac com...

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