Fayat Group Dynapac CP2100 Instruction Manual Download Page 87

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Maintenance and lubrication points

2020-01-06

4812314580EN

Maintenance and lubrication points

Read carefully this manual section before carrying out
any maintenance or lubrication on the machine.

Always check the areas around and under the
equipment. It is an easy way to detect earlier leakages
and possible damages.

Fig. Service and 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

20. Lower pivot bearing

5. Hydraulic oil level

13. Water supply system

21. Upper pivot bearing

6. Hydraulic oil supply

14. Sprinkling system

22. Pivot bearing

7. Hydraulic oil reservoir

15. Seat bearing

23. Wheel gear

8. Hydraulic oil cooler

16. Battery

5, 6, 7

8, 9

1, 2, 3, 10

17, 18

Summary of Contents for Dynapac CP2100

Page 1: ...ration and Maintenance Pneumatic Tire Roller CP2100 CP2100W Diesel Engine Cummins QSB 3 3 Tier III Cummins QSF 3 8 Tier IV Serial number It is reserved the right to make any changes Printed in Brazil...

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Page 4: ...rt 68 Operation instructions Overview 70 Preventive maintenance 72 Preventive maintenance Symbols and lubricants 74 Specifications 77 Maintenance and lubrication points 81 Scheduled maintenance and lu...

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Page 7: ...pes of ground Warning symbols WARNING Damage to the machine or its parts CAUTION Risk of death or injures Safety information The Safety Manual delivered with the machine shall be read by the operator...

Page 8: ...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 9: ...Introduction 2020 01 06 4812314580EN 3...

Page 10: ...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 11: ...12314580EN 5 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 12: ...n 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 speed and the...

Page 13: ...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 14: ...tions 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 Edge cutter The operator must make sur...

Page 15: ...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 16: ...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 17: ...Technical specifications 2020 01 06 4812314580EN 11...

Page 18: ...Technical specifications Dimensions Dimensions Dimensions mm inches A Between axles 4 000 157 B Total width 2 032 80 H1 Height with attachment 3 344 132 H2 Total height 2 990 118 K Height from the gr...

Page 19: ...n Millimeter Inch R Outer radius 7994 315 r Inner radius 5249 207 x Tire width 300 11 8 CP2100W Dimensions Millimeter Inch R Outer radius 8164 321 r Inner radius 5022 198 x Tire width 360 14 1 Dimensi...

Page 20: ...decals description and location 14 4812314580EN 2020 01 06 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 21: ...mponents be careful Keep your hands off the danger zone 3 WARNING Hot surface Keep your hands off the surface 4 WARNING Read carefully the towing chapter before releasing the brakes Crushing injury da...

Page 22: ...4812314580EN 2020 01 06 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 23: ...description and location 2020 01 06 4812314580EN 17 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 24: ...Safety decals description and location 18 4812314580EN 2020 01 06...

Page 25: ...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 26: ...ode 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 27: ...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 28: ...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 Fig Steerin...

Page 29: ...Instrument controls Description and function 2020 01 06 4812314580EN 23...

Page 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...Instrument controls Description and function 30 4812314580EN 2020 01 06...

Page 37: ...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 38: ...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 39: ...Instrument controls Description and function 2020 01 06 4812314580EN 33...

Page 40: ...020 01 06 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 41: ...12314580EN 35 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 42: ...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 43: ...s initiated it is advisable to wait with the equipment on and stopped to completion The equipment controls the level of contamination of the DPF in 5 stages Empty Low Medium High and Service When the...

Page 44: ...ion of the DPF reaches maximum level Service equipment is locked and the system is unable to regenerate itself Under these conditions cleaning the filter can only be performed manually by a skilled te...

Page 45: ...Instruments controls Cab 2020 01 06 4812314580EN 39 Radio CD player option 9 3 10 1 4 5 6 7 3 2 8 9 Radio Option 11...

Page 46: ...Emergency procedures 40 4812314580EN 2020 01 06...

Page 47: ...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 48: ...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 49: ...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 50: ...Instruments controls Cab 44 4812314580EN 2020 01 06...

Page 51: ...aise the 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...

Page 52: ...S make 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 a...

Page 53: ...adjust 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 fitte...

Page 54: ...is shown in the Control panel 2 Check if the voltmeter 3 appoints at least 24 volt and if the fuel 4 and water 5 levels show a percentage value The hourmeter 6 records and shows the total quantity of...

Page 55: ...nition key 3 to the right the first position I and then to the start position Release the switch as soon as the engine starts Do not try to run the start engine for too long max 30 seconds If it does...

Page 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...0 1 125 163 181 188 228 261 290 1 375 220 260 300 330 350 380 1 375 175 193 199 240 276 308 1 825 240 280 340 380 400 430 1 825 194 212 219 261 301 339 2 250 250 310 360 410 440 480 2 250 211 229 236...

Page 63: ...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 64: ...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 65: ...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 66: ...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 67: ...Operation 2020 01 06 4812314580EN 61...

Page 68: ...tion 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 sect...

Page 69: ...the instruments hood covering 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...

Page 70: ...k 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 Spe...

Page 71: ...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 72: ...chine 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 pr...

Page 73: ...ers 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 below...

Page 74: ...r 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 attachment...

Page 75: ...Transport 2020 01 06 4812314580EN 69...

Page 76: ...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 77: ...Operation instructions Overview 2020 01 06 4812314580EN 71...

Page 78: ...ore leaving 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 c...

Page 79: ...Preventive maintenance 2020 01 06 4812314580EN 73...

Page 80: ...ll 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 with oi...

Page 81: ...maintenance Symbols and lubricants 2020 01 06 4812314580EN 75 Engine oil level Engine oil filter Hydraulic fluid level Air filter Hydraulic fluid filter Transmission oil level Fuel filter Battery Coo...

Page 82: ...Preventive maintenance Symbols and lubricants 76 4812314580EN 2020 01 06 Lubricating oil Air pressure Sprinkler Sprinkler water Recycling...

Page 83: ...r combination 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 la...

Page 84: ...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 85: ...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 86: ...R134a Coolant weight when full 1 000 g 2 20 lbs Engines ENGINE Manufacturer and model Cummins QSB 3 3 TIER 3 Power SAE J1995 99 HP 74 kW 2 200 rpm ENGINE Manufacturer and model Cummins QSB 3 8 TIER 4...

Page 87: ...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 88: ...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 89: ...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 90: ...gs 20 Lubricate the lower pivot bearing 21 Lubricate the upper pivot bearing Replace the air dryer filter Machine equipped with AOR EVERY THREE MONTHS Every 500 hours of operation POSITION IN THE FIGU...

Page 91: ...Scheduled maintenance and lubrication 2020 01 06 4812314580EN 85...

Page 92: ...ith 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 gea...

Page 93: ...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 eng...

Page 94: ...ting 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 55 4 gal 210 liters of fuel For further infor...

Page 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...and 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 com...

Page 106: ...Maintenance Every 50 hours 100 4812314580EN 2020 01 06...

Page 107: ...e coolers 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 po...

Page 108: ...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 109: ...se the grease according to the lubricant specifications recommended by DYNAPAC Replace the air dryer filter To replace the filter empty the compressed air and unscrew the cartridge with suitable tool...

Page 110: ...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 in its place again 2 Fit the...

Page 111: ...otation 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 w...

Page 112: ...gun manually with five pump strokes 2 Use the grease according to the lubricant specifications recommended by DYNAPAC Lubricate the pivot bearing 1 Lubricate each grease fitting 1 with five hand oper...

Page 113: ...it 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 ne...

Page 114: ...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 115: ...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 plu...

Page 116: ...o 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 Che...

Page 117: ...ydraulic 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 118: ...of 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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...Revision History 122 4812314580EN 2020 01 06 Revision DATA VERS O MODIFICA O 19 02 2018 0 General 06 11 2019 1 Correction of applicable oils in equipment...

Page 129: ......

Page 130: ...2014 MSV TECH DO BRASIL LTDA Dynapac China Compaction Paving Equipment Co Ltd No 38 Quanwang Road WuQing High Tech Industrial Park 301700 Tianjin China www dynapac com...

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Fayat Group Dynapac CP2100, Instruction Manual

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