DYNAPAC
CC102/102C, CC122/122C
CC132, CC142/142C
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 306000, Fax: +46 455 306030
www.dynapac.com
M102EN4
MAINTENANCE
19
ILF015WO1
1CC102/C/122/C/132/142/C M102EN4
Reservation for changes.
Printed in Sweden.
The CC102/122 and CC132 are specially designed for repair work on asphalt compounds, but can
also be used to pave small streets, sidewalks and bicycle trails. They are often utilized as a
complement to bigger rollers for compacting cross-joints and restricted spaces.
The CC102C and CC122C are small, light combo-rollers that
are used for compacting thin layers and soft asphalt compounds.
The CC142 is a typical ”town roller” for compacting asphalt compounds on streets,
parking lots and industrial sites. The capacity for this type of work is adequate for following
a smaller-size surface finisher.
The CC142C is also intended for minor paving jobs on low-traffic asphalt areas where a level and
attractive surface structure is desired. Typical workplaces—in addition to sidewalks and bicycle
trails—include parks, golf courses and sports fields.
Vibratory roller
CC102/102C, CC122/122C
CC132, CC142/142C
Maintenance
M102EN4, April 2004
Diesel engine:
CC102/C/122/C/132 Deutz F2L 2011, Isuzu 3LD1 PW-05
CC132/142/C Deutz F3L 2011
CC142/C Isuzu 3LD1 PW-05
These instructions apply from:
CC102/C/122/C
Deutz PIN (S/N) *60117500*
Isuzu PIN (S/N) *60127500*
CC132 Deutz PIN (S/N) *60232800*
CC142/C
Deutz PIN (S/N) *60212800*
Isuzu PIN (S/N) *60222800*
KEEP THIS MANUAL
AVAILABLE FOR
FUTURE USE
2 CC102/C/122/C/132/142/C M102EN4
Read the entire manual before starting any
service work.
Make sure that ventilation (extraction) is adequate if the engine is run indoors.
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 ground 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.
CONTENTS
WARNING SYMBOLS
GENERAL
Safety instructions—Personal safety.
Special caution—Machine or component
damage.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer,
birth defects, and other reproductive
harm.
Page
Lubricants and symbols ................................................... 3
Technical specifications ................................................ 4-7
Maintenance schedule ..................................................... 8
Maintenance measures .............................................. 9, 10
Every 10 hours of operation (Daily) .......................... 11-15
Every 50 hours of operation (Weekly) ..................... 16, 17
Every 250 hours of operation (Monthly) ................... 18, 19
Every 500 hours of operation (Every three months) . 20-23
Every 1000 hours of operation (Every six months) .. 24-26
Every 2000 hours of operation (Yearly) .................... 27-29
Long-term parking .......................................................... 30
Special instructions ........................................................ 31
Electrical system, fuses ................................................. 32
3CC102/C/122/C/132/142/C M102EN4
Always use high-quality lubricants in the recommended amounts. Too much grease or
oil can cause overheating and subsequent increased wear.
ENGINE OIL, Shell Rimula Super 15W/40 or equivalent
ambient temperature API CF–4/SG, (CD/CE)
-10°C to +50°C (14°F to 122°F)
HYDRAULIC FLUID,
ambient temperature
-10°C to +40°C (14°F to 104°F) Shell Tellus Oil TX68 or equivalent
ambient temperature
higher than +40°C (104°F) Shell Tellus Oil TX100 or equivalent
BIOLOGICAL Shell Naturelle HF-E46
HYDRAULIC FLUID The machine may be filled with biologically degradable
fluid from the factory. The same type of fluid must be
used when changing or topping off.
DRUM OIL,
ambient temperature
- 15 to +40°C (5°F to 104°F) Shell Spirax AX 80W/90, or equivalent
ambient temperature
higher than +40°C (104°F) Shell Spirax HD85W/140 or equivalent
API GL-5
GREASE Shell Calithia EPT2 or equivalent
Shell Retinax LX2
FUEL See engine manual
COOLANT, (Isuzu) GlycoShell or equivalent
50/50 mixture with water Anti-freeze protection down to about -37°C (-99°F).
Other lubricants are required for driving in extremely high or low ambient temperatures.
See the ”Special instructions” chapter, or consult Dynapac.
Engine, oil level Air filter
Engine, oil filter Battery
Hydraulic reservoir, level Tire pressure
Hydraulic fluid, filter Sprinkler
Drum, oil level Sprinkler water
Lubricating oil Recycling
Fuel filter Sprinkler, tires
Coolant, level
LUBRICANTS AND SYMBOLS
4 CC102/C/122/C/132/142/C M102EN4
Weight CECE,
standard equipped roller kg, Deutz(lbs) 2350(5,181)2600(5,733) 3300(7,276) 3900(8,599)
Length, standard equipped roller, mm (in) 2395(94) 2395(94) 2725(107) 2725(107)
Width, standard equipped roller, mm (in) 1150(45) 1280(50) 1350(53) 1400(55)
Height, standard equipped roller, mm (in) 1755(69) 1755(69) 1855(73) 1855(73)
Height, roller with ROPS, mm (in) 2640(103) 2640(103) 2740(108) 2740(108)
Height, roller with cab, mm (in) 2590(102) 2590(102) 2690(106) 2690(106)
Weight and sizes CC 102 122 132 142
TECHNICAL SPECIFICATIONS
Weight CECE,
standard equipped roller kg, Deutz(lbs) 2300(5,071) 2425(5,347) 3750(8,268)
Length, standard equipped roller, mm (in) 2395(94) 2395(94) 2725(107)
Width, standard equipped roller, mm (in) 1150(45) 1280(50) 1400(55)
Height, standard equipped roller, mm (in) 1755(69) 1755(69) 1855(73)
Height, roller with ROPS, mm (in) 2640(103) 2640(103) 2740(108)
Height, roller with cab, mm (in) 2590(102) 2590(102) 2690(106)
Weight and sizes CC 102C 122C 142C
5CC102/C/122/C/132/142/C M102EN4
Fluid volumes Litres (qts)
Hydraulic reservoir .................... 40 (42.2)
Fuel tank .................................... 50 (52.9)
Emulsion tank (Combo) ............. 40 (42.2)
Water tank ............................. 160 (169.1) (CC 102/102C, CC 122/122C)
Water tank ............................. 200 (211.4) (CC 132, CC 142/142C)
Diesel engine (Deutz F2L 2011F) ......... 6,5 (6.9) (CC 102/102C, CC 122/122C, CC 132)
Diesel engine (Deutz F3L 2011F) ......... 6,0 (6.3) (CC 142/142C)
Diesel engine (Isuzu 3 LD1PW-05) ...... 6,5 (6.9) (CC 102/102C, CC 122/122C, CC 142/142C)
Drum ..................................................... 4,0 (4.2) (CC 102/102C)
Drum ..................................................... 5,0 (5.3) (CC 122/122C)
Drum ..................................................... 6,0 (6.3) (CC 132, CC 142/142C)
Coolant (Isuzu 3 LD1PW-05) ............... 2,5 (2.6)
Electrical system
Battery 12 V 75 Ah
Alternator 12 V 60 A
Fuses 5, 7,5, 10, 15 A (Flat pin fuse)
Compaction data CC 102/102C CC 122/122C CC 132 CC 142/142C
Static linear load kg/cm (psi) 10,3 (57.6) 10,4 (58.2) 13,6 (76.1) 14,6 (81.7)
Amplitude mm (in) 0,50 (0,019) 0,50 (0,019) 0,53 (0,020)0,50 (0,019)
Frequency Hz (vpm) 56,0 (3,360) 56,0 (3,360) 51,0 (3,060)51,0 (3,060)
Centrifugal force kN (lb) 21,5 (4,837) 25,0 (5,625) 32,1 (7,222)32,1 (7,222)
Propulsion CC 102/122 CC 102C/122C
Deutz Isuzu Deutz Isuzu
Speed range km/h (mph) 0-8,6 (0-5,3) 0-11,8 (0-7,3) 0-6,6 (0-4,1) 0-8,9 (0-5,5)
Climbing capacity
(theoretical) % 50/45 60
Propulsion CC 132/142 CC 142C
Deutz Isuzu Deutz Isuzu
Speed range km/h (mph) 0-9,8 (0-6,0) 0-9,1 (0-5,6) 0-10,2 (0-6,3) 0-9,3 (0-5,7)
Climbing capacity
(theoretical) % 41 43
TECHNICAL SPECIFICATIONS
Tires (Combo) CC 102C/122C CC 142C
Tire size 205/60-15 7,50-16
Air pressure 170-250 kPa (1,7 - 2,5 kp/cm
2
) 240-300 kPa (2,4 - 3,0 kp/cm2)
6 CC102/C/122/C/132/142/C M102EN4
Opening pressure MPa CC 102/122 CC 132/142
Drive system 33,0 35,0
Supply system 2,0 2,0
Vibration system 20,0 20,0
Control systems 17,0 17,0
Brake release 1,4 1,4
Bolt size: M16
Strength class: 10.9
Tightening torque: 240 Nm
Tightening torque in Nm for oiled, bright galvanized
bolts tightened with a torque wrench.
Tightening torque
ROPS
Hydraulic system
TECHNICAL SPECIFICATIONS
M STRENGTH CLASS
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 –
7CC102/C/122/C/132/142/C M102EN4
TECHNICAL SPECIFICATIONS
The vibration values are measured in conformance
with the driving mode described in EU directive
2000/14/EC on EU equipped machines, on soft
polymer material with vibration switched ON and
the operator’s seat in transport mode.
Whole-body vibration is measured at less than the
action value of 0.5 m/s
2
specified in EU directive
2002/44/EC. (The limit value is 1.15 m/s
2
.)
Hand/arm vibration is measured at less than the
action value of 2.5 m/s
2
specified in the same
directive. (The limit value is 5 m/s
2
.)
Noise level can vary when driving on different
courses and with different seat positions.
Vibrations – Drivers seat
(ISO 2631)
Vibration levels may vary when driving on
different courses and with different seat
positions.
CC102 Deutz 105 – –
CC102 Isuzu 102 – –
CC102/LN Isuzu 99 – –
CC102C Deutz 105 – –
CC102C Isuzu 102 – –
CC102C/LN Isuzu 99 – –
CC122 Deutz 105 – –
CC122 Isuzu 102 – –
CC122/LN Isuzu 100 – –
CC122C Deutz 105 – –
CC122C Isuzu 102 – –
CC122C/LN Isuzu 100 – –
CC132 Deutz F2L – – –
CC132 Deutz F3L 106 – –
CC142 106 – –
CC142C 106 – –
The acoustic values are measured in conformance with EU directive
2000/14/EC on EU-equipped machines, on soft polymer material with
vibration switched ON and the operator’s seat in transport mode.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A)
Acoustic
pressure level,
operator’s ear
(platform)dB(A)
Acoustic
pressure level,
operator’s ear
(cab)dB(A)
8 CC102/C/122/C/132/142/C M102EN4
1234567
19 16 15 14 13 12 11 18 17
8
9
10
22
21
20
23
MAINTENANCE SCHEDULE
Fig. 1 Service and maintenance points
1. Fuel tank
2. Refueling
3. Radiator
4. Air cleaner
5. Battery
6. Diesel engine
7. Water tank
8. Sprinkler system/Drum
9. Scrapers/Drum
10. Rubber elements and fastening screws
11. Filling hydraulic fluid
12. Hydraulic reservoir
13. Hydraulic filter
14. Hydraulic fluid sight glass
15. Steering joint
16. Steering cylinder mounts
17. Filler plugs/Drum
18. Oil level in drum
19. Tires/Tire pressure
20. Sprinkler system/Wheels
21. Scrapers/Wheel
22. Emulsion tank
23. Reserve/parking brake control
9CC102/C/122/C/132/142/C M102EN4
Items Action See page Comments
in fig. 1
4 Check indicator on air cleaner 16
Check that pneumatic hoses are intact
and connections are tight 16
15 Grease the steering joints 17
16 Grease the steering cylinder brackets 17
19 Check the tire pressure (combo) 17
After the first 50 hours of operation, change all the oil filters and oil,
except the hydraulic fluid.
Items Action See page Comments
in fig. 1
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.
Every 50 hours of operation (Weekly)
Every 10 hours of operation (Daily)
MAINTENANCE MEASURES
Before starting up
6 Check oil level in the engine See engine instruction manual.
14 Check the hydraulic reservoir level 11
3 Check coolant level, (Isuzu) 11
3 Check for free circulation of cooling air 12
1 Refuel 12
7 Fill the water tank 12
8 Inspect the sprinkler system/Drum 13
9 Inspect the scraper setting/Drum 14
21 Inspect spring-action scrapers 14 Optional
20 Inspect the sprinkler system/Tires 14
21 Inspect the scraper setting/Tires 15
23 Test the brakes 15
10 CC102/C/122/C/132/142/C M102EN4
Items Action See page Comments
in fig. 1
3 Clean the hydraulic fluid cooler 18
5 Check electrolyte level in battery 18
6 Change the engine oil filter (Isuzu) 19 See engine instruction manual
6 Clean the engine cooling flanges See engine instruction manual
Every 250 hours of operation (Monthly)
Items Action See page Comments
in fig. 1
18 Check the oil level in the drums 20
10 Check rubber elements and bolted joints 20
11 Check the hydraulic reservoir cover/breather 21
6 Lubricate controls and pivoted joints 21
6 Change the engine oil (Deutz) 22 See engine instruction manual
6 Change the engine oil filter 22 See engine instruction manual
6 Inspect engine V belts 22 See engine instruction manual
6 Change the engine fuel filter (Isuzu) 23 See engine instruction manual
Every 500 hours of operation (Every three months)
Items Action See page Comments
in fig. 1
13 Change the hydraulic filter 24
12 Drain condensation from the hydraulic reservoir 25
4 Replace main filter in the air cleaner 25
6 Change the engine fuel filter (Deutz) 25
6 Change the engine pre-filter 26
6 Inspect engine toothed belt. See engine instruction manual
6 Check engine valve clearance See engine instruction manual
Every 1000 hours of operation (Every six months)
Items Action See page Comments
in fig. 1
12 Change the hydraulic fluid 27
18 Change oil in the drums 27
7 Empty and clean the water tank 28
22 Clean the emulsion tank 29
1 Empty and clean the fuel tank 29
Check the condition of the steering joints 29
Every 2000 hours of operation (Yearly)
MAINTENANCE MEASURES
11CC102/C/122/C/132/142/C M102EN4
ISUZU
Take great care if the radiator cap must be
opened while the engine is hot.
Risk for burns. Wear gloves and safety
goggles.
Fill with coolant consisting of 50% water and 50%
antifreeze. See the technical specifications in these
instructions and the engine manual.
Change the coolant and flush the system
every other year. Make sure that air has free
passage through the radiator.
EVERY 10 HOURS OF OPERATION (Daily)
Coolant level – Check
filling (Circulation of cooling air)
Fig. 4 Radiator
1. Radiator cap
1
Hydraulic reservoir
– Level check – Filling
1
Fig. 3 Engine compartment
1. Filling hydraulic fluid
Fully open the engine hood, unscrew the filler cap (1)
and top off with fresh oil if necessary. See page 3 for
the correct grade of hydraulic fluid.
Fig. 2 Hydraulic reservoir
1. Oil sight glass
Hydraulic reservoir
– Level check – Filling
1
Open the right door of the engine compartment.
Make sure that the oil level is between the max/min
marks. Top off with hydraulic fluid according to the
lubricant specification if the level is too low.
Place the roller on a level base. The engine
must be switched off and the reserve/parking brake knob pushed in for all checking
and adjustments on the roller unless otherwise specified.
12 CC102/C/122/C/132/142/C M102EN4
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 50 quarts of fuel.
Screw off the tank cap (1) and fill with pure
water, do not remove the strainer. See
technical specifications regarding volume of
the tank.
Sole additive: Small amount of environmentfriendly antifreeze liquid, and for combo models
possibly cutting fluid.
1
Fig. 6 Fuel tank
1. Tank cap
Fuel tank – Refueling
EVERY 10 HOURS OF OPERATION (Daily)
Fig. 5 Right roller side
1. Cooling-air grille
Air circulation – Check
1
Make sure that the engine has unimpeded circulation of
cooling air through the protective grille in the engine
compartment.
Water tank – Filling
Fig. 7 Water tank
1. Tank cap
1
13CC102/C/122/C/132/142/C M102EN4
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.
Fig. 10 Pump system
1. Water filter
2. Stopcock
3. Water pump
3
Fig. 9 Nozzle
1.Sleeve
2.Nozzle
3.Compaction
4.Strainer
1
2
3
4
When cleaning the coarse filter (1), close the stopcock
(2) and loosen the filter housing.
Clean the filter and filter housing, ensure that the rubber
gasket in the filter housing is intact.
After inspection and any cleaning, start the system and
check that it works.
A drain cock is located in the left part of the pump
system area. This facilitates draining of both tank and
pump system.
1
2
Sprinkler system/Drum
Checking – Cleaning
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, see figures below.
1
Fig. 8 Drum
1. Nozzle
EVERY 10 HOURS OF OPERATION (Daily)
14 CC102/C/122/C/132/142/C M102EN4
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.
Fill the rear tank with emulsion fluid, for example water
mixed with 2% cutting fluid. Make sure that the sprinkler nozzles (2) are not clogged. Clean them and the
filter if necessary. See under Sprinkler system/Drum;
Check—Cleaning, for detailed instructions.
Fluids that are flammable or harmful to the
environment may not be used in the emulsion tank.
Inspect the tire tread now and then to detect
asphalt compound that has fastened; this is
likely until the tires are warm enough.
Sprinkler system/Wheels
Checking—Cleaning
Fig. 13 Wheel rack
1. Filler cap
2. Nozzle (one for each tire)
1
2
EVERY 10 HOURS OF OPERATION (Daily)
Scrapers, spring-action
(Optional) – Check
Fig. 12 Spring-action scrapers
1. Spring mechanism
2. Scraper blade
1
2
Fig. 11 Drum
1. Scraper blade
2. Adjusting screws
3. Adjusting screws
1 2 3
3
2
1
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 (1) lie lightly against the drums.
The remains of asphalt can accumulate on the scraper
and thus influence the contact force.
Loosen the screws (2) to adjust the scraper blade up or
down.
Loosen the screws (3) to adjust contact pressure of the
scraper blade against the drum.
Remember to tighten all the screws after any
adjustment.
Scrapers, fixed
Checking – Setting
1-2 mm
1-2 mm
15CC102/C/122/C/132/142/C M102EN4
2 3
14
Scrapers – Checking – Setting
Fig. 15 Wheel scrapers
1. Scraper
2. Scraper beam
3. Cotter pin
4. Adjusting screws
Make sure that the scraper (1) lies against the tire
when compacting asphalt compounds.
The scrapers must hang freely from the tires during
transport driving. Lift up the scraper beam (2) by
moving up the cotter (3) to the uppermost hole.
To adjust the scraper’s angle of contact to the tire,
loosen the screws (4), set the scraper and then tighten
the screws.
Pump system/Tires
Checking – Cleaning
2
1
Fig. 14 Left step
1. Filter housing
2. Loader
When cleaning, close the stopcock (2). Release the
filter housing (1). Clean the insert and the filter housing.
Listen to or put your hand on the water pump to check
that it is working.
EVERY 10 HOURS OF OPERATION (Daily)
69
Fig. 16 Instrument panel
6. Reserve/parking brake knob
9. Brake warning lamp
Brakes – Check
Check operation of the brakes as follows:
Drive the roller slowly forward.
Push in the reserve/parking brake knob (6).
The brake warning lamp (9) on the instrument panel
should light and the roller should stop.
After testing the brakes, set the forward/reverse lever
in neutral.
Pull up the reserve/parking brake knob.
The roller is now ready for operation.
16 CC102/C/122/C/132/142/C M102EN4
Place the roller on a level base. The engine
must be switched off and the reserve/parking brake knob pushed in for all checking
and adjustments on the roller unless otherwise specified.
Change or clean the main filter of the air
cleaner (1) when the indicator (4) shows a red
sector at full engine revs.
Release the two locking catches, pull off the cover and
take out the main filter (1).
Do not remove the backup filter (2).
To clean the main filter, blow up and down along the
paper pleats with compressed air at maximum 5 bar
pressure.
Hold the nozzle at least 2–3 cm (1/8") from the paper
pleats to avoid tearing the paper.
Wear protective goggles when working
with compressed air.
Wipe the inside of the cover and filter housing (3).
Check that the hose clamps between filter
housing and suction hose are tight and that
hoses are intact. Inspect all hoses all the way
to the engine.
Change the main filter at the latest after 5
cleanings.
Air cleaner
Checking – Indicator
EVERY 50 HOURS OF OPERATION (Weekly)
Main filter
– Cleaning with compressed air
Fig. 18 Main filter
Fig. 17 Air cleaner
1. Main filter
2. Backup filter
3. Filter housing
4. Indicator
Fig. 19 Air filter
4. Backup filter
Backup filter—Replacement
Replace the backup filter with a new one after every
fifth replacement or cleaning of the main filter. The
backup filter cannot be cleaned.
To change the backup filter (4), pull the old filter out of
its holder, insert a new one and reassemble the air
cleaner in the reverse order.
1
2
3
4
4
17CC102/C/122/C/132/142/C M102EN4
Do not allow anyone near the steering joint
when the engine is running. Danger of
being crushed when steering is operated.
Push the reserve/parking brake knob before lubricating.
Turn the steering wheel fully to the left to gain access
to all four grease nipples (1) from the right side of the
machine.
Wipe the grease nipples (1). Grease each nipple with
five strokes of the hand-operated grease gun. Make
sure that grease penetrates the bearings. If grease
does not penetrate the bearings, you may need to
relieve the articulation joint with a jack while repeating
the greasing process.
Steering cylinder and steering
joint – Lubrication
1
Fig. 20 Steering joint
1. Grease nipples
1
Tires – Tire pressure
Fig. 21 Tires (Combo)
1. Air valve
Check the tire pressure with a pressure gauge.
Make sure that the tires have equal pressure.
Recommended pressure: See Technical
Specifications.
EVERY 50 HOURS OF OPERATION (Weekly)
18 CC102/C/122/C/132/142/C M102EN4
Place the roller on a level base. The engine
must be switched off and the reserve/parking brake knob pushed in for all checking
and adjustments on the roller unless otherwise specified.
Battery
Checking the electrolyte level
Never use an open flame when checking
the electrolyte level. Explosive gas is generated when the alternator is charging.
Fully open the engine hood.
Wipe the top of the battery dry.
Wear safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.
Take off the cell caps and ensure that electrolyte is
about 10 mm (3/8") above the plates. Check the level of
all cells. Top off with distilled water to the right level if
the level is low. Let the engine run for a while before
topping off with distilled water if the ambient temperature is below freezing. Otherwise 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.
Dispose of used batteries properly. 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.
Make sure that the flow of air through the cooler is
unobstructed.
Clean a dirty cooler with compressed air or highpressure water cleaning.
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 cooler.
Wear protective goggles when working
with compressed air.
Fig. 22 Engine compartment
1. Hydraulic fluid cooler
1
Hydraulic fluid cooler
Checking – Cleaning
Battery cell
1
Fig. 23 Battery shelf
1. Battery
Fig. 24 Electrolyte level in battery
1.Cell cap
2.Electrolyte level
3.Plate
EVERY 250 HOURS OF OPERATION (Monthly)
1
2
3
10 mm
19CC102/C/122/C/132/142/C M102EN4
ISUZU
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 reserve/parking brake.
Place a receptacle that holds at least 8 quarts
under the drain plug. Collect the oil and dispose of it properly.
Risk for burns when draining hot oil. Protect your hands.
Unscrew the oil drain plug (1).
Allow all of the oil to drain off and refit the plug.
Fill with fresh engine oil; see the Lubricant specification
or the engine manual for the correct grade of oil.
Check the dipstick to ensure that the engine oil level is
correct; see the engine manual for details.
Engine – Oil change
1
Fig. 25 Engine compartment, right side
1. Oil drain
EVERY 250 HOURS OF OPERATION (Monthly)
20 CC102/C/122/C/132/142/C M102EN4
Place the roller on a level base. The engine
must be switched off and the reserve/parking brake knob pushed in for all checking
and adjustments on the roller unless otherwise specified.
Drum – Oil level – Check
– Filling
This inspection applies to the CC102/122.
Drive the roller slowly until the oil plug (1) is aligned
with one of the check holes (2).
Remove the plug and check that the oil level reaches
the lower edge of the plug hole. Top off with fresh,
clean oil if necessary. Use oil according to the lubricant
specification.
Clean the magnetic oil plug (1) from any metal particles
before refitting it.
12
Fig. 26 Drum, vibration side
1. Oil plug
2. Check hole
Drum
– Checking the oil level
This inspection applies to the CC132/142.
Drive the roller slowly until the oil plug (1) is aligned
with the semicircular recess in the drum suspension.
Remove the plug and check that oil level reaches the
lower edge of the plug hole. Top off with fresh, clean oil
if necessary. Use oil according to the lubricant
specification.
Clean the magnetic oil plug (1) from any metal particles
before refitting it.
1
Fig. 27 Drum, drive side
1. Oil plug
EVERY 500 HOURS OF OPERATION (Every three months)
Fig. 28 Drum suspension
1. Rubber element
2. Fastening screws
1
2
Rubber elements and fastening
screws – Check
Check all rubber elements (1). Replace all of the
elements if more than 25% of them on one side of the
drum are cracked deeper than 10-15 mm (3/8–5/16").
Use the blade of a knife or pointed object to assist
when checking.
Make sure that the fastening screws (2) are tightened.
21CC102/C/122/C/132/142/C M102EN4
Unscrew and ensure 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.
Wear protective goggles when working
with compressed air.
1
2
Fig. 31 Operator’s station
1.Forward/reverse lever
2.Fastening screws
Lubricate the forward/reverse controls in the engine
compartment with a few drops of oil.
If the controls become sluggish after a long period of
use, remove the cover and the forward/reverse lever in
the operator’s station and lubricate the mechanism.
Lubricate the forward/reverse mechanism.
Unscrew the screws (2) in the top of the protective
cover (1), remove the cover and lubricate the
mechanism under the cover with oil.
Controls – Lubrication
Controls – Lubrication
1
Fig. 30 Engine compartment
1. Forward/reverse lever
EVERY 500 HOURS OF OPERATION (Every three months)
1
Hydraulic reservoir cap
– Check
Fig. 29 Engine compartment
1. Tank cap
22 CC102/C/122/C/132/142/C M102EN4
DEUTZ
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 parking brake.
Place a receptacle that holds at least 8 quarts
under the drain plug. Collect the oil and dispose of it properly.
Risk for burns when draining hot oil. Protect your hands.
Unscrew the oil drain plug (1).
Allow all of the oil to drain off and refit the plug.
Fill with fresh engine oil; see the Lubricant specification
or the engine manual for the correct grade of oil. Check
the dipstick to ensure that the engine oil level is correct;
see the engine manual for details.
Remove and discard the oil filter (1) and fit a new one.
Make sure that the belt (2) is free from cracks or other
damage. Replace as necessary.
Check the belt tension; if you can press it down with
your thumb more than 10 mm (3/8") half way between
the belt pulleys, it needs tightening.
See engine manual for detailed instructions on
changing oil and filters, and for belt tightening.
Start the engine and check tightness of oil filter and
drain plug.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors.
(Risk of carbon monoxide poisoning).
Refit the engine protective plate.
Engine – Oil change
1
Fig. 32 Engine compartment, right side
1. Oil drain
Oil filter – Replacement
12
Fig. 34 Diesel engine (Isuzu)
1. Oil filter
1
Fig. 33 Diesel engine (Deutz)
1. Oil filter
2. V belt
EVERY 500 HOURS OF OPERATION (Every three months)
23CC102/C/122/C/132/142/C M102EN4
ISUZU
Loosen and screw off the fuel filter (1). Discard the filter
in a safe manner, it is not reusable and cannot be
cleaned.
See the engine manual for detailed instructions
on changing the fuel filter.
Start the engine and check that the fuel filter does not
leak.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors.
(Risk of carbon monoxide poisoning).
Changing the fuel filter
Fig. 35 Engine compartment
1. Fuel filter
1
EVERY 500 HOURS OF OPERATION (Every three months)
Place a receptacle underneath to collect fuel
that runs out when removing the filter.
24 CC102/C/122/C/132/142/C M102EN4
Place the roller on a level base. The engine
must be switched off and the reserve/parking brake knob pushed in for all checking
and adjustments on the roller unless otherwise specified.
Release the filter insert (4) from the handle (5).
Discard the filter in a safe manner, it is not
reusable and cannot be cleaned.
Mount the new insert on the handle, refit the unit into
the filter holder (6), and refit the red cover.
Start the engine and let it run at full revs for half a
minute, checking that the filter cover (3) remains tight.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors.
(Risk of carbon monoxide poisoning).
Fig. 38 Hydraulic filter
3. Cover
4. Filter insert
5. Handle
6. Filter holder
6
3
5
4
Release the red cover (3) and pull up the filter insert
(4).
Refit the red cover temporarily, to prevent dust and dirt
from entering the tank.
3
Fig. 37 Hydraulic filter
3. Cover
Unscrew the six fastening screws (1).
Remove the safety plate (2).
1
2
Fig. 36 Engine compartment
1.Fastening screws
2.Safety plate
Hydraulic filter
– Replacement
EVERY 1000 HOURS OF OPERATION (Every six months)
25CC102/C/122/C/132/142/C M102EN4
DEUTZ
Loosen and screw off the fuel filter (1). Discard the filter
in a safe manner, it is not reusable and cannot be
cleaned.
See the engine manual for detailed instructions
on changing the fuel filter.
Start the engine and check that the fuel filter does not leak.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors.
(Risk of carbon monoxide poisoning).
Replace the main filter (3) of the air cleaner even if it
has not yet been cleaned five times; see under the
heading ”Every 50 hours of operation” for changing the
filter.
If the filter is not replaced when clogged, the
engine will emit smoke and lose power and
there will be serious risk of damage to the
engine.
Condensation water in the hydraulic reservoir is drained via the plug (1). Draining must be done after the
roller has stood still during a long period—for example,
after standing still overnight.
Take great care when draining. Do not drop
the plug so that all the oil runs out.
Drain as follows:
Place a receptacle under the plug.
Unscrew and allow any condensation to drain off.
Tighten the plug.
Hydraulic reservoir – Draining
Fig. 39 Left side of frame
1. Drain plug
1
Changing the air cleaner
Fig. 40 Air cleaner
1. Filter housing
2. Backup filter
3. Main filter
Changing the fuel filter
Fig. 41 Engine compartment
1. Fuel filter
1
EVERY 1000 HOURS OF OPERATION (Every six months)
Place a receptacle underneath to collect fuel
that runs out when removing the filter.
1
2
3
26 CC102/C/122/C/132/142/C M102EN4
Push the parking brake knob.
Switch off the engine and open the left door of the
engine compartment.
Release the hose clamps (2) with a screwdriver.
Discard the pre-filter (1) in a safe manner, it is
not reusable 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.
EVERY 1000 HOURS OF OPERATION (Every six months)
Changing the engine
pre-filter (Deutz)
1
2
Fig. 42 Engine compartment
1. Pre-filter
2. Hose clamps
27CC102/C/122/C/132/142/C M102EN4
These instructions apply to the CC 132/142.
Position the roller on a level surface and drive it slowly
until the oil plug (1) is straight down.
Switch off the engine and apply the reserve/parking brake.
Place a receptacle that will hold at least 7
quarts under the plug. Collect the oil and
dispose of it properly.
Remove the plug and let all the oil run out. See under
the heading ”Every 500 hours of operation” for filling oil.
These instructions apply to the CC 102/122.
Position the roller on a level surface and drive it until
the drain plug (1) is straight down.
Switch off the engine and press the parking brake knob.
Place a receptacle that will hold at least 6
quarts under the plug. Collect the oil and
dispose of it properly.
Remove the plug and let all the oil run out. See under
the heading ”Every 500 hours of operation” for filling oil.
Place the roller on a level base. The engine
must be switched off and the reserve/
parking brake knob pushed in for all checking and adjustments on the roller unless
otherwise specified.
Risk for burns when draining hot oil. Protect your hands.
Place a receptacle that will hold at least 40
quarts under the plug. Collect the oil and
dispose of it properly.
Remove the drain plug (1) and let all the oil run out,
wipe and refit the drain plug.
Fill with fresh hydraulic fluid of the grade
indicated in the Lubricant specification.
Replace the hydraulic filter as described under the
heading ”Every 1000 hours of operation”.
Start the engine and operate the various hydraulic
functions. Check the level in the reservoir and top off
as necessary.
Make sure that ventilation (extraction) is
adequate if the engine is run indoors. Risk
of carbon monoxide poisoning.
Hydraulic reservoir
– Changing the fluid
1
Fig. 43 Left side of roller
1. Drain plug
Fig. 45 Drum, drive side
1. Oil plug
Drum – Changing the oil
Fig. 44 Drum, vibration side
1. Oil plug
1
1
Drum – Changing the oil
EVERY 2000 HOURS OF OPERATION (Yearly)
28 CC102/C/122/C/132/142/C M102EN4
Water tank – Draining
1
Fig. 46 Pump system
1. Water filter
Water pump – Draining
Fig. 47 Pump system
1. Water pump
2. Drain cock
Open the drain cock (2) to empty the water pump (1).
Water tank – Cleaning
Fig. 48 Water tank
1. Drain plug
1
EVERY 2000 HOURS OF OPERATION (Yearly)
Clean the tanks with water and a suitable detergent for
plastic surfaces.
Refit the filter housing or the drain plug (1), fill with
water and check for tightness.
The water tanks are made of recyclable
plastic (polyethylene).
1
2
Remember the risk of freezing during the
winter period and drain the tank, pump and
leads.
The easiest way to empty the water tank is to open the
drain cock on the water filter (1).
(There is also a drain plug underneath the water tank).
29CC102/C/122/C/132/142/C M102EN4
It is easiest to clean the tank when it is almost empty.
Pump out any bottom sediment with a suitable
pump, such as an oil emptying pump. Save
the oil in a can and deposit it in an approved
manner.
Remember the danger of fire when handling fuel.
The fuel tank is made of recyclable plastic
(polyethylene).
Open the cock (1) and the drain cock (2), which is
located in the left step. The hose (3) facilitates draining
the emulsion fluid into a suitable receptacle.
For cleaning the tank, see Water tank – Cleaning.
The emulsion tank is made of recyclable
plastic (polyethylene).
Fig. 50 Fuel tank
1. Oil emptying pump
Fig. 49 Pump system
1. Stopcock
2. Drain cock
3. Drain hose
3
1
2
1
Fuel tank – Cleaning
Emulsion tank
– Draining
EVERY 2000 HOURS OF OPERATION (Yearly)
Steering joint – Check
Inspect the steering joint to detect any damage or
cracks.
Check and correct any loose bolts.
Check also for any stiffness and play.
Fig. 51 Steering joint
30 CC102/C/122/C/132/142/C M102EN4
The following instructions should be followed
for parking longer than one month:
The measures apply for a period of up to 6
months.
The items marked * must be restored before
using the roller.
Fig. 52 Roller protected against the weather
LONG-TERM PARKING
Battery
Diesel engine
Air cleaner, exhaust pipe
Fuel tank
Hydraulic reservoir
Sprinkler system
Steering cylinder, hinges, etc.
Tires (combo)
Hoods, tarpaulin
*
See manufacturer’s instructions in the engine manual that accompanies the roller.
*
Remove the battery from the roller, clean it, check
that the electrolyte level is correct (see under the
heading ”Every 50 hours of operation”) and trickle
charge the battery once a month.
*
Cover the air cleaner (see under the headings
”Every 50 hours of operation” and ”Every 1000
hours of operation”) or its intake opening with plastic
or tape. Cover the exhaust pipe opening. This is
necessary to prevent moisture from entering the
engine.
Fill the fuel tank completely to prevent condensation.
Fill the hydraulic reservoir to the uppermost level mark;
see under the heading ”Every 10 hours of operation”.
*
Empty the water tank completely (see under the
heading ”Every 10 hours of operation”), and also
hoses, filter housing and the water pump. Remove
all the sprinkler nozzles (see under the heading
”Every 10 hours of operation”). Also drain the emulsion tank (see under the heading ”Every 2000 hours
of operation”).
Lubricate bearings of the steering joint and both
bearings of the steering cylinder with grease (see
under the heading ”Every 50 hours of operation”).
Grease the piston rod of the steering cylinder with
inhibitor grease. Grease the hinges on doors to the
engine compartment and the cab, and also grease
both ends of the forward/reverse control (bright
parts) (see under the heading ”Every 500 hours of
operation”).
Make sure that tire pressure is at least 200 kPa (2.0
kp/cm
2
) psi.
*
Lower the instrument shield plate on the steering
column. Cover the entire roller with a tarpaulin. The
tarpaulin must be free from the ground. Store the
roller indoors if possible, preferably on premises with
an even temperature.
31CC102/C/122/C/132/142/C M102EN4
Never aim a water jet directly at the cap of the
fuel tank or hydraulic reservoir. This is
especially important when using a highpressure jet.
Do not spray water directly on electric components or
the instrument panel. Put a plastic bag over the filler
cap of the fuel tank and secure with an elastic band.
This will prevent water from entering the venting hole in
the filler cap. This could otherwise cause operational
disturbance, such as a clogged filter.
On leaving the factory, the various systems and
components are filled with oil or fluid as indicated in the
Lubrication specification and are thus suitable for
operation in ambient temperatures between -10°C and
+40°C (14°F-104°F)
A maximum temperature of +35°C (95°F)
applies for biological hydraulic fluid.
The following recommendations apply for operation in
higher ambient temperatures, up to a maximum of
+50°C (122°F):
The diesel engine can be run at this temperature using
the normal oil, but for other components the following
fluids must be used: Hydraulic system using mineral
fluid Shell Tellus TX100 or equivalent. Other
components using transmission oil: Shell Spirax AX
85W/140, or equivalent.
Do not connect the negative cable to the
negative pole of the discharged battery,
because in the event of a spark, the oxyhydrogen gas that is emitted around the battery could explode.
Always ensure that voltage of the jump-start
battery is the same as that of the discharged
battery.
Switch off the ignition and all power consuming items.
Switch off the engine in the assisting machine. First
connect the positive pole of the jump-start battery to the
positive pole of the discharged battery and then connect
the negative pole of the jump-start battery to a bolt or the
engine lifting lug in the machine to the discharged
battery. Start the engine of the assisting machine and let
it run for a while. Attempt to start the other machine.
Disconnect the cables in the reverse order.
SPECIAL INSTRUCTIONS
Standard oils and other
recommended fluids
Higher ambient temperature
max. +50°C (122°F)
The temperature limits apply to standard versions of the roller.
Rollers that are fitted with additional equipment, such as
noise suppression, etc, may require extra observation in
the higher temperature ranges.
Temperature
High-pressure washing
In the event of fire in the machine, use an ABE powder
fire extinguisher if possible. A BE-type carbon dioxide
fire extinguisher may also be used.
If the roller is equipped with a protective structure
(ROPS, Roll Over Protective Structure), or protective
cab, the structure or cab must on no account be
subjected to welding or the drilling of holes. Never
attempt to repair a damaged structure or cab; they
must be replaced with new ones.
Fire fighting
Protective structure (ROPS)
Starting aid
Fig. 53 Starting aid
32 CC102/C/122/C/132/142/C M102EN4
The machine is equipped with a 12 V electrical system
and an alternator.
Connect the battery to the correct polarity (- to
ground). The cable between battery and
alternator must not be disconnected while the
engine is running.
Before doing any electric welding on the
machine, disconnect the battery ground cable
and then all electrical connections to the
alternator.
Flat pin fuses located in the fuse boxes protect the
electrical regulating and control system. The fuse
boxes indicated by the figures are located in the
steering column.
Fuses
Fig. 54 Left fuse box (standard)
10 A 1. Brake valve, warning panel,
hourmeter
7.5 A 2. Vibration relay
10 A 3. Water pump, neutral relay
7.5 A 4. Horn, fuel gauge
7.5 A 5. Water pump (combo),
speedometer
7.5 A 6. Reversing signal, flow manifold,
frequency meter
Fig. 55 Right fuse box (accessories)
15 A 1. Front headlight, L position lights,
R taillight
15 A 2. Rear headlight, R position lights,
L taillight, license plate lighting
5 A 3. Direction indicator, right
5 A 4. Direction indicator, left
10 A 5. Hazard beacon
10 A 6. Flasher relay
The figure shows the ampere rating and function of the
different fuses.
The left fuse box is found in all machines.
The right fuse box is provided only in machines
equipped with electric accessories. The figures show
the fuse boxes located in the cab, if fitted.
Fig. 56 Fuse boxes in cab (accessories)
10A 1. Front working lights
15A 2. Front wiper
3A 3. Front washer
15A 4. Fan
10A 5. Rear working lights
15A 6. Rear wiper
7.5A 7. Hazard beacon
3A 8. Interior lighting
5A 9. Radio connection
10. –
11. –
25 A 12. Radio memory, heater
1 2 3 4 5 6
7 8 9 10 11 12
1
2
3
4
5
6
1
2
3
4
5
6
ELECTRICAL SYSTEM, FUSES
19
ILF015WO1
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