Dynapac CP275 Instruction Manual Download Page 39

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Machine description

4812273203.pdf

2017-08-25

Electrical system

The machine's main switchbox (fig1.) is located on

the rear of the operator platform. There is a plastic

cover over the switchbox and fuses.

On the plastic cover there is a 24V socket.

The roller is equipped with 24 V electrical system

and an AC alternator.

Connect the correct polarities (ground)

to the battery. The cable between the battery

and the alternator must not be disconnected

when the engine is running.

Fig1. Main switch box

1. Control unit (ECU)

2. Main

relay

3. Fuse

Summary of Contents for CP275

Page 1: ...ns manual Operating Maintenance 4812273203 pdf Rubber wheel roller CP275 IIIA T3 Diesel engine Cummins QSB4 5 C130 Serial number 10000509x0C003425 Original instructions Reservation for changes Printed...

Page 2: ......

Page 3: ...tructions 11 Special instructions 11 Standard lubricants and other recommended oil and fluids 11 High ambient temperatures above 40 C 104 F 11 Lower ambient temperature Freeze risk 11 Temperatures 11...

Page 4: ...panel and controls 27 Locations control cab 28 Function description of instruments and controls in the cab 29 Using the cab controls 30 Defroster 30 Heat 30 AC 30 Electrical system 31 Fuse 32 Cab fus...

Page 5: ...43 Interlock Emergency stop Parking brake Check 44 Normal braking 44 Emergency braking 45 Switching off 45 Chocking the wheels 45 Master switch 46 Long term parking 47 Miscellaneous 49 Lifting 49 Lift...

Page 6: ...eck 66 Fuel tank Refueling 67 Wheel scrapers Control 68 Removing the scrapers 68 Water tank std Filling 69 Sprinkler system Check 69 Sprinkler system 70 Cleaning of sprinkler nozzle 70 Sprinkler syste...

Page 7: ...85 Driven chain maintenance 86 Driving gear Check oil level 87 Maintenance 500h 89 Hydraulic reservoir Check 89 Maintenance 1000h 91 Air cleaner Checking Change the main air filter 91 Hydraulic filte...

Page 8: ...spray system Optional 101 Spray volume Adjustment 102 Maintenance Oil spray system Optional 102 Temporary cleaning 102 Air on the run Optional 103 Air charge and discharge 104 Maintenance Air on the...

Page 9: ...o its weight it is also suitable for soil compaction The attachment or installation of additional devices which are used to intervene in the function of the machine or with which its function are supp...

Page 10: ...ctions in this manual carefully Always follow the safety instructions Ensure that this manual is always easily accessible Read the entire manual before starting the machine and before carrying out any...

Page 11: ...ing 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 THINK ENV...

Page 12: ...Introduction 4 4812273203 pdf 2017 08 25...

Page 13: ...be used when the machine is operated on unsafe ground 7 Drive slowly in sharp bends 8 Avoid driving across slopes Drive straight up or straight down the slope 9 Make sure that there are no obstacles...

Page 14: ...been given by Dynapac 17 Avoid using the roller before the hydraulic fluid has reached its normal working temperature Braking distances can be longer than normal when the fluid is cold Refer to the o...

Page 15: ...rmal air pressure and all the tanks are full Always take into consideration that loose ground the steering of the machine different tire pressures the operating speed and that an increase in the cente...

Page 16: ...273203 pdf 2017 08 25 Driving near edges When driving close to edges or holes make sure that at least 1 4 of the outer tires are on the previously compacted material Fig Position of wheels when drivin...

Page 17: ...Work on the refrigerant circuit is only to be carried out by authorized companies The cooling system is pressurized Incorrect handling can result in serious personal injury Do not disconnect or undo t...

Page 18: ...Safety Optional 10 4812273203 pdf 2017 08 25...

Page 19: ...ver maximum 50 C 122 F the following recommendations apply The diesel engine can be run at this temperature using normal oil However the following fluids must be used for other components Hydraulic sy...

Page 20: ...of filters Fire fighting If the machine catches fire use an ABC class powder fire extinguisher A BE class carbon dioxide fire extinguisher can also be used Roll Over Protective Structure ROPS ROPS app...

Page 21: ...7 08 25 When fitting batteries always connect the positive cable first Dispose of old batteries in an environmentally friendly way Batteries contain toxic lead Do not use a quick charger for charging...

Page 22: ...battery Turn the ignition and all power consuming equipment off Switch off the engine on the machine which is providing jump start power Jump leads must have 24V First connect the plus terminal 1 on...

Page 23: ...al specifications Noise level The noise levels are measured in accordance with the operational cycle described in GB16710 with operator seat in transport position Guaranteed sound power level LwA 108d...

Page 24: ...Technical specifications 16 4812273203 pdf 2017 08 25 Technical specifications Dimensions Dimensions Dimensions mm in A 4250 167 B 2370 93 H1 3408 134 H2 3100 122 K 360 14 2 L 5310 209...

Page 25: ...condition system Coolant designation HFC R134 A Coolant weight when full 1350 gram 2 98 lbs Mixed ballast max 11 8tonnes 14 2tonnes The machine can use 4 steel blocks of 4 types of steel blocks as bal...

Page 26: ...mins QSB4 5 C130 Rated power SEA J1995 97kW 130hp Engine speed 2200 rpm Electric system Battery 24V 2x12V 74Ah Alternator 28V 70A Fuses See the Electrical system section fuses Bulbs if mounted Watt So...

Page 27: ...8 M10 40 45 56 62 68 76 M12 70 78 98 110 117 131 M14 110 123 156 174 187 208 M16 169 190 240 270 290 320 M20 30 370 470 520 560 620 M22 446 497 626 699 752 839 M24 570 640 800 900 960 1080 M30 1130 12...

Page 28: ...203 pdf 2017 08 25 ROPS bolts Bolt dimensions M22 PN 4812266655 Strength class 10 9 Tightening torque 786 Nm Hydraulic system Opening pressure Mpa Drive system 42 0 Charge system 2 5 Control system 16...

Page 29: ...me number as the machine plate s PIN serial number Machine plate The machine plate 1 is fixed on the top step on the left side of the operator platform The plate specifies the manufacturer s name and...

Page 30: ...number D E F would be useful when ordering spare parts or check the machine information Engine plate The engine s type plate is located under the engine hood and is accessible when the hood is opened...

Page 31: ...903459 15 Water tank 4700991657 6 Hoisting plate 4700904870 16 Warning high pressure fluid 4700397286 7 Tire pressure 4700374765 17 Warning starting gas 4700791642 8 Diesel fuel 4700991658 18 Emergenc...

Page 32: ...Warning Rotating engine components Keep your hands at a safe distance from the danger zone 4700903424 Warning Hot surfaces in the engine compartment Keep your hands at a safe distance from the danger...

Page 33: ...ion 25 4812273203 pdf 2017 08 25 4700904165 Warning Toxic gas Read the instruction manual 4700397286 Warning High pressure fluid Make sure to drain the pressure in the accumulators before opening the...

Page 34: ...Machine description 26 4812273203 pdf 2017 08 25...

Page 35: ...rinkler 13 Direction indicator Right 14 Hazard warning lights 15 Control indicator Right 16 Tire barometer Optional 17 Display 18 Oil filter blockage alarm indicator 20 Parking indicator 21 Centralize...

Page 36: ...Machine description 28 4812273203 pdf 2017 08 25 Location control cab...

Page 37: ...s the air damper so that fresh air comes into the cab Pressing the bottom closes the damper so that the air recirculates inside the cab 5 Front wiper switch Press to operate the front screen wiper 6 F...

Page 38: ...nd if necessary turn down the heat and fan speed AC NOTE When using AC all the windows must be closed for the system to work efficiently To quickly reduce the temperature in the cab adjust the followi...

Page 39: ...c cover over the switchbox and fuses On the plastic cover there is a 24V socket The roller is equipped with 24 V electrical system and an AC alternator Connect the correct polarities ground to the bat...

Page 40: ...FU4 Power supply ECU FU10 Seat switch High speed switch FU5 Power supply ECU FU11 Warning lighting FU6 Power supply ECU FU12 Backup alarm FU7 Pump neutral position FU13 Water pump FUSE BOX3 FU14 Oil p...

Page 41: ...tch is covered the engine hood must be unlocked driving operation to be able to reach the switch in an emergency Do not run the starter motor for too long max 30 seconds If the engine will not start w...

Page 42: ...l indicator 1 or 3 on operator side are all activated Make sure the parking brake button 7 is on pressed condition Make sure the emergency stop button is on unpressed condition Make sure the fuel gaug...

Page 43: ...ure downward to decrease pressure Or check each tire s pressure by using tire pressure gauge Test the brake valve function ensure the normalcy of this function is essential for normal operating the ma...

Page 44: ...in motion Interlock The roller is equipped with Interlock The diesel engine switches off after 7 seconds if the operator rises from the seat when going forwards backwards If the Forward Reverse lever...

Page 45: ...ake sure that the area in front of and behind the roller is clear In below there are some speed recommendation according to different working conditions First gear speed tortoise Used for variety diff...

Page 46: ...sure not to exceed the maximum speed for the roller Selecting low speed increases the efficiency of the engine brake and prolongs the brake life Low speed should always be selected when working and tr...

Page 47: ...in progress with the air pressure control on the roller The pressure is variably by adjusting the keys fig1 on the keypad Pressure adjusting interval is between maximum 780kPa 110psi and minimum 380kP...

Page 48: ...top left cover 1 rear left cover 2 top right cover 3 and the rear right cover 4 The machine can use 12 steel blocks of 6 types of steel blocks as ballast in the lower of the frame Red type blocks are...

Page 49: ...sure gives a smaller contact surface 1 Low tire pressure gives a larger contact surface 2 The total service weight divided by the number of tires give the pressure per wheel See Table The ground conta...

Page 50: ...420 445 18000 2020 357 5 381 406 430 452 5 475 22500 2500 377 5 410 437 5 462 5 487 5 510 27000 3000 405 438 468 496 520 544 30000 3300 418 455 487 5 515 542 565 Fig Low ground pressure larger area L...

Page 51: ...und pressure smaller area Normal tire pressure 510 kPa 70 psi Used for degradation session High tire pressure 780 kPa 110 psi The higher the tire pressure the greater the pressure on the contact surfa...

Page 52: ...zzer goes on and after 7 seconds the engine switches off and the brakes are activated Check the function of the emergency stop by pressing the emergency stop button when the roller is moving slowly fo...

Page 53: ...w the engine to low idle for a few minutes to cool down Switch off all lights and other electrical functions Push in the parking brake switch Turn the ignition switch to the left to the shut off posit...

Page 54: ...aster switch Before leaving the roller for the day switch the master switch 1 to the disconnected position and remove the handle This will prevent battery discharging and will also make it difficult f...

Page 55: ...reat exposed parts with anti rust agent lubricate the machine thoroughly and apply grease to unpainted surfaces Engine Refer to the manufacturer s instructions in the engine manual that is supplied wi...

Page 56: ...uppermost level mark see under the heading Every 10 hours of operation Tires Make sure that tire pressures are at least 380 kPa 55 psi Steering cylinder hinges etc Grease the steering cylinder piston...

Page 57: ...pecified on the hoisting plate 1 Refer also to the Technical specifications Lifting equipment such as chains steel wires straps and lifting hooks must be dimensioned in accordance with the relevant sa...

Page 58: ...forwards Chock the tiers 1 and secure the chocks to the transport vehicle The chock should have an angle of 37 and minimum height of 25 cm 9 9 inches The tiers should be chocked both forwards and back...

Page 59: ...en the cover you could see the propulsion multi function valve 3 turn the bypass nut on up down multi function valve 3 counterclockwise to startup the multi function bypass valve Fluctuate hand pump s...

Page 60: ...x 5 km h 3mph and only towed a short distance max 300 m 1 000ft When towing retrieving a machine the towing device must be connected to both lifting holes in the diagram Pulling forces should act para...

Page 61: ...rse lever gives the required direction of travel Use the accelerator carefully 9 Test the brakes Remember that the braking distance will be longer if the hydraulic fluid is cold 10 Check that the tire...

Page 62: ...Operating instructions summary 54 4812273203 pdf 2017 08 25...

Page 63: ...n arrival before delivery to the customer delivery inspection must be conducted as per the check list in the warranty document Any transport damage must be immediately reported to the transport compan...

Page 64: ...Preventive maintenance 56 4812273203 pdf 2017 08 25...

Page 65: ...104 F Dynapac Gear Oil 300 or equivalent FUEL See engine manual COOLANT GlycoShell or equivalent mixed 50 50 with water Prevents freezing to around 37 C BRAKE CIRCUIT OIL Mobil DOT 3 or equivalent Mai...

Page 66: ...7 08 25 Maintenance symbols Engine oil level Air filter Engine oil filter Battery Hydraulic fluid tank level Sprinkler Hydraulic fluid filter Sprinkler water Lubricating oil Recycling Coolant level Fu...

Page 67: ...wer pivot bearing 2 Oil filter 10 Refueling 18 Upper pivot bearing 3 Fuel filter 11 Scraper 19 Pivot bearing 4 Hydraulic filter 12 Water tank filling 20 Driving axle 5 Hydraulic fluid level 13 Sprinkl...

Page 68: ...the sprinkler system 13 Sprinkler system Freeze risk protection Check brake fluid level Check the tire pressure Test brake General Periodic maintenance should be carried out after the number of hours...

Page 69: ...Comment 9 Clean the air cleaner Refer to the engine manual Clean cooler Drain the fuel prefilter Refer to the engine manual 16 Inspect the air conditioning Optional Check the air conditioner compress...

Page 70: ...oints Lubricate the steering chain Pos in fig Action Comment 1 2 Change the engine oil and oil filter Refer to the engine manual 3 Change the fuel filter Refer to the engine manual Cleaner cooler Chan...

Page 71: ...air filter element Refer to the engine manual Check the engine belt drive system Refer to the engine manual 14 Check the battery condition 15 Replace the air cleaner filter in the cab 16 Inspect the a...

Page 72: ...nge hydraulic oil 12 Drain and clean the water tank 14 Check the battery condition 15 Replace the air cleaner filter in the cab 16 Inspect the air conditioning Optional Check air conditioner dry filte...

Page 73: ...if the engine is run indoors Risk of carbon monoxide poisoning Diesel engine Check oil level The dipstick is located under the engine hood Take care not to touch any hot parts of the engine or radiat...

Page 74: ...n the middle between the operator platform and the engine compartment Refilling takes place from over the black cover between the operator platform and the hood To access the expansion tank you have t...

Page 75: ...spilling fuel The filler pipe and tank cap are behind the operator platform on the left side of the frame Refuel the tank every day before starting work or fill the tank at end of work Unscrew the loc...

Page 76: ...ransportation Lift up the scraper blades 1 and make sure that they are locked in raised position by the locking hooks 2 To lower down the scrapers lift the scraper slightly while pressing in the locki...

Page 77: ...nvironment friendly antifreeze Sprinkler system Check Fill the tank with emulsion fluid e g water mixed with 2 cutting fluid Check that the sprinkler nozzles 2 are not blocked and if necessary clean t...

Page 78: ...arts and clean the blocked parts later on Nozzle Colour mm l min gal min 2 0 bar 40 psi Standard yellow 0 8 0 63 0 2 Option blue 1 1 0 31 Option red 1 2 1 25 0 39 Option brown 1 3 1 63 0 5 After inspe...

Page 79: ...ilter 3 Loosen the intake to the pump by moving the plastic clamp to the left and pulling the white plastic adapter from the pump housing Open the valves in the ends 4 of the sprinkler pipes Allow the...

Page 80: ...frame Top up with brake fluid to the max mark on the container if the level is below the min mark Tires Tire pressure Check the tire pressure with a pressure gauge Make sure that the tires have the s...

Page 81: ...osition Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Air cleaner Cleaning Wipe clean the inside of the cover 2 and the filter hou...

Page 82: ...oler grill is removed Make sure that the air flow through the cooler is unobstructed Dirty coolers are blown clean with compressed air or washed clean using a high pressure water cleaner Take care whe...

Page 83: ...omes out See Cummins service manual Tighten the drain plug as soon as uncontaminated fuel runs out Place in a suitable container and hand in to environment friendly waste disposal station The air tank...

Page 84: ...g the sight glass 1 that bubbles are not visible on the drying filter Make sure the Forward Reverse lever is always in the Neutral position The filter is located on the top of the rear part of the cab...

Page 85: ...ent 1 using compressed air Blow from above downwards The air jet can damage the element flanges if it is too powerful Wear protective goggles when working with compressed air Inspect the condenser ele...

Page 86: ...per pivot bearing 2 Lubrication nipple x 2 Lower pivot bearing 1 2 Upper Lower Pivot bearing Lubrication Lubricate nipple 1 on upper pivot bearing and nipples 2 on lower pivot bearing with five pump s...

Page 87: ...Draining decal 2 Air reservoir 3 Drainage valve Draining of air reservoir When the machine works in humid environment the air reservoirs 2 need to drain every day Press the drainage valve 3 upwards un...

Page 88: ...re with a pressure gauge Make sure that the tires have the same pressure Recommended pressure See Technical Specifications The figure shows the position of the air valve on the outer tires The figure...

Page 89: ...switch the engine off and make sure the Forward Reverse lever is in the Neutral position Ensure that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poiso...

Page 90: ...10 liters 11 qts under the drain plugs Take great care when draining engine oil Wear protective gloves and goggles Release the oil drain plug and open the filler cap allow all the oil to run out into...

Page 91: ...r is located on the left side in the engine compartment Unscrew the old one with special spanner and then replace with the new one Start the engine and check that the filter is well sealed Diesel engi...

Page 92: ...Tighten the drain plug as soon as uncontaminated fuel runs out Place in a suitable container and hand in to environment friendly waste disposal station Oil water separator Replace The oil water separ...

Page 93: ...hecking the electrolyte level Explosive gas in formed when the alternator charges the battery When disconnecting the battery always disconnect the negative cable first When connecting the battery alwa...

Page 94: ...ated completely Repeat the procedure on the other side Don t keep too much residual oil in the bottom of the chain box Water draining from chain bottom cover Unscrew the plug 4 under each chain to dra...

Page 95: ...hine so that the level plug 3 is in horizontal position Wipe clean the area around the level plug 3 and then undo the plug Ensure that the oil level reaches up to the lower edge of the plug hole Reple...

Page 96: ...Maintenance 250h 88 4812273203 pdf 2017 08 25...

Page 97: ...ion air extraction if the engine is run indoors Risk of carbon monoxide poisoning Hydraulic reservoir Check Unscrew and make sure that the reservoir cap is not clogged Air must have unobstructed passa...

Page 98: ...Maintenance 500h 90 4812273203 pdf 2017 08 25...

Page 99: ...f carbon monoxide poisoning Air cleaner Checking Change the main air filter Change the air cleaner main filter when the warning lamp on the control panel comes on when the engine is running at maximum...

Page 100: ...posable filter and cannot be cleaned Thoroughly clean the filter holder sealing surface Apply a thin coat of fresh hydraulic fluid to the rubber gasket on the new filter Screw the filter on by hand fi...

Page 101: ...filter may need to be changed more often if the machine is operated in a dusty environment Wheel gear Oil change Take great care when draining the fluid Wear protective gloves and goggles Note When f...

Page 102: ...lify filling Unscrew the filler plug 2 Unscrew the level plug 3 as well to evacuate air Oil is filled from the filler well Fill up with approx 20 l 21 qts of new oil Use transmission oil see lubricant...

Page 103: ...coolant is located at the back on the right side of the machine The drain plug can be accessed by opening the panel in front of the exhaust pipe Drain the coolant when the engine is warm Place a conta...

Page 104: ...l inside the hydraulic reservoir Place a receptacle that holds at least 80 liters 21 gal under the engine compartment Remove the plug on the end of the hose Allow all the oil to run out Reset by refit...

Page 105: ...Fig Water tank 1 Drain cock Water tank Cleaning Clean the tank with water and a suitable detergent for plastic surfaces Close the drain cock 1 fill with water and check for leaks The water tank is mad...

Page 106: ...move the protective cover Undo the screws 2 and remove the complete holder Remove the filter insert and replace with a new filter The filter may need to be changed more often if the machine is operate...

Page 107: ...the rear wheels can rotate freely Loosen the lock nuts 2 on the adjusting bolt 1 Turn the adjusting bolt 1 while rotating the wheel until the increase in tension slows the wheel down Check the distan...

Page 108: ...Maintenance 2000h 100 4812273203 pdf 2017 08 25...

Page 109: ...sily by through the fixing bolts 2 of the bracket to avoid over spraying beyond tire or missing spray CAUTION The system must keep clean use relatively high solidifying plant oil such as soybean oil I...

Page 110: ...n the tank using plant oil cleanser then wash the tank using normal plant oil Drain the water of the oil tank Spray volume Adjustment Oil spray volume can be adjusted through the valve 1 Tighten to in...

Page 111: ...e on instrument panel it should be in 380kPa 780kPa fig1 Check the air valve status In general the air valves are closed when the roller is shipped out from factory So if use the air on the run system...

Page 112: ...is air discharging The neutral position is off Fig 7 Fig 8 Before operating the system make sure the air pressure is normal and all the air valves are opened Usually keep the nine tire s pressure as t...

Page 113: ...12273203 pdf 2017 08 25 Every 3 months 250 hours Check the air pipes of the system Check the air valve Long term parking When long term parking more than one week please to close the air valve avoid l...

Page 114: ...Additional instruction 106 4812273203 pdf 2017 08 25...

Page 115: ...n withdraw from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oil greasy parts hydraulic hoses lube pipes etc...

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