Dynapac CP2100, CP2100W, CP2700 Instruction Manual

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Instruction Manual

4812325555EN

Operation and Maintenance

Pneumatic Tire Roller

CP2100 / CP2100W

Diesel Engine

Cummins QSB 3.3 – Tier III

Cummins QSF 3.8 - Tier IV

Serial number

100005x1xxB005446

It is reserved the right to make any changes

Printed in Brazil

2018-02-08 4812325555EN

TABLE OF CONTENTS

OPERATION Page

Introduction .............................................................................................................................. 1

Safety - General instructions .................................................................................................... 3

Safety - When operating .......................................................................................................... 5

Safety – Option items ............................................................................................................... 7

Technical Specifications .......................................................................................................... 9

Technical specifications -Dimensions .................................................................................... 10

Safety decals - description and location ................................................................................. 12

Identification plates ................................................................ ................................................ 16

Instruments/controls............................................................................................................... 18

Instruments and Controls - Cab ............................................................................................. 30

Operation - Before starting ..................................................................................................... 37

Operating the roller ................................................................ ................................................ 43

Interlock/Emergency Stop/Parking Brake ............................................................................... 50

Long-term storage ................................................................................................................. 53

Lifting ..................................................................................................................................... 55

Towing ................................................................................................................................... 56

Transport ............................................................................................................................... 59

Operation instructions - Overview .......................................................................................... 60

MAINTENANCE ............................................................................................................... Page

Preventive maintenance ........................................................................................................ 61

Preventive maintenance - Symbols and lubricants ................................................................. 62

Specifications ........................................................................................................................ 65

Maintenance and lubrication points ........................................................................................ 69

Scheduled maintenance and lubrication................................................................................. 70

Maintenance and lubrication procedures................................................................................ 70

Daily (Every 10 hours of operation) ........................................................................................ 74

Weekly (Every 50 hours of operation) .................................................................................... 80

Monthly (Every 250 hours of operation) ................................................................................. 86

Quarterly (Every 500 hours of operation) ............................................................................... 90

Semiannually (Every 1,000 hours of operation)...................................................................... 93

Annually (Every 2,000 hours of operation) ............................................................................. 97

Special instructions .............................................................................................................. 103

Electrical system .................................................................................................................. 105

2018-02-08 4812325555EN

Introduction

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Introduction

Dynapac CP2100 / CP2100W

Dynapac CP2100 is a 21 tones rubber wheel roller, with 5,905 ft (1,800 m) width. CP2100 is also available on the wide base version (CP2100W), with larger tires and 7,480 ft (2,280 m) width.

It has three direction front wheels and four back wheels. The hydrostatic drivers, the flexible ballast solution and a wide range of option equipment indicate that the machine has different settings available. CP2100 is mainly used together with other asphalt rollers to seal surfaces. Thanks to its weight, it also serves as a roller for other types 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. Always follows the safety instructions and keep the Manual inside the machine.

It is recommended to at least train the operators on daily handling and maintenance of the machine, according to the Instruction Manual. Passengers are not allowed on the machine, and the operator must be on the seat whenever he operates the equipment.

Read throughout the manual before starting the machine and before performing any maintenance.

Request immediately new manuals if the old ones are lost damaged or become illegible.

Make sure there is a good vent (air exhaust) when the engine is turned on in closed facilities.

Introduction

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General Information

This manual contains instructions to operate and perform the maintenance of the machine.

The machine's maintenance shall be made correctly in order to obtain the maximum performance and the equipment shall also be kept clean, so leakage, loosen bolts and connections can be found as soon as possible.

Perform a daily inspection in the machine before starting, so you can find possible leakage or other failures.

Verify the machine's floor. Leakages are easier detected on the floor than on the equipment itself.

THINK ABOUT THE ENVIRONMENT! Do not dispose 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 usually performed by the operator.

Other engine instructions can be found at the manufacturer's manual.

CE Marking and Statement of Compliance

(APPLIED TO MACHINES SOLD WITHIN THE EUROPEAN COMMUNITY)

This machine has a CE Marking. It shows that at its delivery, it meets all the applicable health and safety basic directives, according to 2006/42/EC Machinery Directive, besides attending other directives applicable on machinery.

Following the machine there is a "Statement of Compliance" specifying the directive and supplement applicable, as well as the harmonized norms and other regulations relevant to the case.

Safety - General instructions

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Safety - General instructions

(you must also read the Safety Manual)

1. Read and understand this Manual before starting and operating the machine. The operator must be familiar with the equipment contents before operating it.

2. Observe and follow all the Maintenance Section instructions.

3. Only experienced/trained operators are allowed to operate the machine. NEVER allow the presence of passengers and ALWAYS remain seated while operating the equipment.

4. Do not operate the equipment if adjustment or repairs are necessary.

5. Use ladders and rails to enter and leave the cab. NEVER enter or leave the machine while it is moving.

6. The ROPS (Roll Over Protective Structure) should always be used when the machine is operated on unsafe ground. Always use the seat belt when the ROPS is on.

7. Use the first gear on sharp turns.

8. Avoid driving close to cliffs or sharp side slopes. Operate the machine on first gear and always check the brakes.

9. When driving close to edges or holes, make sure at least 2/3 of the wheels are on the previously compacted materials.

10. Make sure there are no obstacles over your head 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 uneven ground.

12. Follow all the safety rules and use the protection equipment proper to the work to be performed.

13. Keep the roller clean. Clean immediately dirt, oil and grease accumulated on the operator platform. Keep all the signs, lanterns, headlights and decals clean, visible and legible.

14. Observe the following safety measures before refueling:

- Turn off the engine;

- Do not smoke;

- Do not allow sparks or flame next to the equipment;

- To avoid sparks, ground the filling nozzle.

15. Before performing any maintenance operation, chock the roller wheels and apply the emergency/parking brakes.

16. Hearing protection is recommended if the machine's noise level exceeds 85 dB (A). The noise level can vary depending on the work the machine performs.

17. Do not make any changes on the machine, under the risk of affecting the personal safety as well the equipment's. Any change on the machine demands a previous written approval by DYNAPAC.

18. Avoid using the machine before the hydraulic oil reaches the normal operating temperature. The braking distance may be longer than normal if the oil is cold. Refer to the operation instructions on "Stop", in the "Operation" section.

Safety - General instructions

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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 the doors closed and with the seat belt.

Safety

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Safety - When operating

Avoid people entering at the danger area, that is, at a distance of at least 23 ft (7 m) in all the directions from the machine operating. The operator can allow one person to be at the danger area, but in this case, care must be taken and the machine can only be operated when this person is in a visible place or with clear indication of where he/she is.

Operating on slopes

The machine must never be operated from the outside of the cab. The operator shall be seated when operating.

Slopes

This angle was measured on a flat, hard surface and with the machine in a stationary position.

The steering angle is zero, the tires pressure is normal and all the tanks are full.

Always remember that loosen ground, the steering of the machine, different tire pressures, the operation speed and the gravity center raising may cause the machine to turn, even on slopes smaller than the ones stated here.

If you need to leave the cab in emergency situations, take off the hammer at the rear pillar on the right and break the opening windows that are also on the right.

It is recommended that ROPS (Roll Over Protective Structure) is always used when driving on slopes or unsafe ground.

Whenever possible, avoid driving across slopes. On slopes, drive straight up and down.

The speed must always be slow when operating on slopes.

Always operate the machine with the doors closed and with the seat belt.

Max. 20º

or 36%

Safety

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Transport on steep ground

During the transport on steep ground (slope >5%), be careful to not exceed the roller's maximum speed.

Take your foot off the throttle pedal and use the engine brake system. Also use the main brake if the speed keeps increasing.

Selecting the low speed will increase the engine brake system efficacy and also the life of the braking system.

Operation and transport on 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 roller shall go up normally and shall go down in reverse.

Make sure there are no obstacles both in front or behind your work area.

Driving near edges

When driving close to edges or holes, make sure that at least ¼ of the tires is on the compacted ground.

>15% (8.5°)

Fig.: Steep slope Low speed (up to 4.7 mph or 7.5 km/h)

>5% (2.8°)

Fig.: Steep ground v < max. speed. (9.3 mph or 15 km/h).

At least 1/4

Fig.: Position of wheel when driving near edges.

Safety - Option items

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Safety – Option items

Air conditioning

The system contains pressurized refrigerant. It is forbidden to release refrigerant to the atmosphere.

The maintenance of the air conditioning system shall be carried out only by trained people and with the proper tools and equipment.

The air conditioning system is pressurized. The incorrect handling can result in serious personal injury. Do not loose or disconnect hoses and connections with the system loaded.

The system must be refilled with approved coolant when necessary. Refer to the safety decal next to the replacement and filling place.

Edge cutter

The operator must make sure that nobody is in the work place when the machine is operating.

The edge cutter has rotating components which may cause crushing.

Immediately after use, the tool shall always be put back on the transport position (1) that is, on the raised position.

If the edge cutter and its components are dismounted, make sure that it is made with the machine in a safe position and that it is on the ground.

Fig. Air conditioning

Fig. Edge cutter

1. Transport position

2. Work position

Safety - Option items

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Working lights - Xenon

CAUTION! High voltage!

The working lights are Xenon type and have a high voltage auxiliary source of power.

Any maintenance 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 mercury (Hg). A defective lamp is considered a hazardous waste and shall be

disposed of properly, according to the applicable local directives.

Contact an DYNAPAC dealer!

Fig. Xenon working lights

Technical specifications

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Technical Specifications

Vibrations – Operator station (ISO 2631)

The vibration levels are measured according to the operational cycle described in the EU

directive 2000/14/EC on machines equipped for the EU market with the operator’s seat in the

transport position.

The measured vibrations on the whole body are below the 0.5 m/s² action value, as specified in the directive 2002/44/CE (the limit is 1.15 m/s²).

The measured vibrations on the hand/arm are also below the 2.5 m/s² action value, as specified in the same abovementioned directive (the limit is 5 m/s²).

Noise level

The sound levels are measured according to the operational cycle described in the EU directive

2000/14/EC on machines equipped for the EU market with the operator’s seat in the transport

position.

Guaranteed sound power level, LwA

103 dB (A)

Sound pressure level at the operator's ear (platform), LpA

85 ±3 dB (A)

Sound pressure level at the operator's ear (cab), LpA

80 ±3 dB (A)

During normal operations, the values abovementioned may differ, depending on the work specific conditions.

Electrical system

The machines were tested for electromagnetic compatibility (EMC) in accordance with EN 13309:2000: "Construction machinery".

Technical specifications

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Technical specifications -Dimensions

Dimensions

inches

A – Between axles

4.000

157

B – Total width

2.032

H1 – Height with attachment

3.344

132

H2 – Total height

2.990

118

K – Height from the ground

250

9,8

L – Total length

5.180

204

H1 B K

Technical specifications

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CP2100

Dimension

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

Dimension

Degree

O – Vertical oscillation

4,5

D – Direction angle

R r D

Safety decals - description and location

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Safety decals - description and location

15, 16

15 8 7

2, 3

17,

17, 18,

20 4 6

21 5 22

15 1 13

15, 16

Safety decals - description and location

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Safety decals - Description and location (cont.)

Always make sure that all the safety decals are completely legible and remove the dirt or request for new ones if they are illegible. Use the part number indicated on each decal.

WARNING: Crush zone, wheel. Keep a safe distance from the crush zone.

WARNING: Rotating engine components, be careful! Keep your hands off the danger zone.

WARNING: Hot surface! Keep your hands off the surface.

WARNING: Read carefully the towing chapter before releasing the brakes. Crushing injury danger.

WARNING: The operator must read the Safety and Engine Manuals, as well as the Operation and Maintenance instructions.

WARNING: High pressure fluid. Make sure to release the pressure from the accumulators before opening the hydraulic system.

WARNING: Gas shall not be use to start the machine.

WARNING: Edge cutter (option).

WARNING: Toxic gas danger. Refer to the Instruction Manual.

Safety decals - description and location

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Safety decals - Description and location (cont.)

Emergency exit - Cab.

Fire extinguisher

Hoisting plate

Tire pressure

Diesel oil

Securing point

Lifting point

Hydraulic oil

Bio-hydraulic oil (option)

Safety decals - description and location

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Safety decals - Description and location (cont.)

Handbook compartment

Master switch

Battery voltage

Sound power level

Water tank

Hydraulic oil level

Identification plates

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Identification plates

Machine plate.

The machine plate (1) is on the top step, on the left side of the operator's platform.

It specifies the manufacturer's name, the type of the machine, the serial number, the service weight, the engine 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 when ordering spare parts.

PIN (Product Identification Number) at the frame

The PIN - product identification number (1) is punched on the right side of the right frame. It is the same number of the machine plate (serial number).

Fig.: Frame 1 – Machine plate 2 – Engine plate

Fig. Frame 1 – PIN

Identification plates

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Explanation of the 17PIN (Product Identification Number)

A – Manufacturer's code (100 = Dynapac) B – Family/model code (00501 = CP2100) C – Check code D – Year of manufacturing (E=2014, F=2015...) E – Production's unit code (B = Sorocaba, Brazil) F – Serial number (from 000001 to 999999)

Engine plate

The engine plate (1) is on the cylinder head cover (1), and it can be accessible when the hood is open.

The plate is also on the top step of the operator's platform. It contains information like the serial number and the engine

specifications.

NOTE: State the engine plate's serial number when ordering

spare parts.

100

00123

V E A

123456

A B C D E

Fig. Engine

1. Engine plate

Identification plates

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Instruments/controls

Control panel, side panel and command keyboard.

1. Ignition key

2. Forward/reverse lever

3. Command keyboard

4. Direction lights (OPTION)

5. Warning lights

6. High beam lights (OPTION)

7. "+" increase in the tire pressure (OPTION)

8. "-" decrease in the tire pressure (OPTION)

9. High/low speed

10. "MAN" manual sprinkler (OPTION)

11. "AWC" automatic 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. Enable regeneration (Tier iV engine)

19. Disable regeneration (Tier iV engine)

20. Hazard warning lights (OPTION)

21. Rotating beacon (OPTION)

22. Control panel

23. Function buttons (5)

24. Brake test pedal

25. Parking brake

26. Edge cutter (OPTION)

27. Edge cutter sprinkler(OPTION)

Fig. Control panel, side panel and command keyboard.

2 3 4

7 8 10

Instrument/controls - Description and function

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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. - Steering column multiple switch (option)

Fig. – Pedals

Instrument/controls - Description and function

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Instrument/controls - Description and function

No.

DESIGNATION

SYMBOL

FUNCTION

Ignition key

The electric circuit is off.

All instruments and electric controls are on.

The starter is activated.

Forward/reverse lever

To start the machine, the lever shall be in the "neutral" position. Move the lever forward and step on the throttle to drive forwards; move the lever back and step on the throttle to drive backwards.

Command keyboard

Direction lights

It shows that the direction lights are activated (activation via switch at the steering column).

Central warning lights

Appoints general fault. See the control panel (22) for the description of the fault.

High beam lights

It shows that the high beam lights are on (via switch at the steering column).

"+" increase in the tire pressure

When activated, it increases the tires pressure.

"-" decrease in the tire pressure

When activated, it decreases the tires pressure.

High/low speed

The roller starts always in the high speed mode. The low speed mode is obtained when activated.

Manual sprinkler

Gives continuous sprinkling of water on the wheels.

Automatic sprinkler

When activated, sprinkling is automatically turned on/off when the forward/reverse lever is in the "neutral" position.

"+" increase of the sprinkler interval (timer)

The sprinkling frequency increases each time the water volume on the wheels is also increased.

Instrument/controls - Description and function

2018-02-08 4812325555EN 21

Instrument/controls - Description and function (cont.)

No.

DESIGNATION

SYMBOL

FUNCTION

"-" decrease of the sprinkler interval (timer)

The sprinkling frequency decreases each time the water volume on the wheels is also decreased.

Working lights

Press to turn on/off all the working lights.

Horn switch

Press to sound the horn.

Emergency stop button

Press it to turn off the machine and the engine. All the power supply is also turned off.

Eco-mode

When activated, maintain speed reducing the engine rotation, thus saving fuel (up to 30% economy)

Button to enable the regeneration (Tier IV Engine)

Press to execute the regeneration

Button to disable the regeneration (Tier IV Engine)

Press to disable regeneration.

Hazard warning lights

Press the switch to activate the hazard warning lights.

Rotating beacon

Press the switch to activate the rotating beacon.

Instrument/controls - Description and function

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Instrument/controls - Description and function (cont.)

No.

DESIGNATION

SYMBOL

FUNCTION

Control panel

It shows the engine and transmission functions. Refer to the Section: "Before Starting".

Function buttons (5)

Brake test pedal

Press it to test the brakes.

Parking brake

When it is pressed, the parking brake is activated. To turn it off, slide the red part backwards (towards you) and change the switch position.

NOTE: to start the machine, the parking brake shall be activated.

Edge cutter

The edge cutter can be moved up and down when machine is in work postion.

Edge cutter sprinkler

Press to activate the edge cutter sprinkler.

Instrument/controls - Description and function

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Control panel – General description

When the ignition key is in the position "I", the start screen is visible on the display. It remains activated for a few seconds then it switches to the status screen.

The status screen provides information about the fuel level, the sprinkler tank water level, the working hours and the voltage level. The water and fuel levels are specified 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 will switch to the main screen.

This screen provides an overview and it remains on during the operation:

- The speed is shown in the middle of the screen.

- The high/low speed mode is shown with a symbol in the middle of the screen.

- The engine rpm, the asphalt temperature (option) and the tires pressure (option) are shown in the upper left corner and in the lower left corner, respectively.

Fig. – Start screen

Fig. – Status screen

Fig. – Main working screen

Instrument/controls - Description and function

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Control panel – General description (cont.)

A menu field is shown by pressing one of the selection buttons. It is visible for a short time, then it fades out if any selection is made. A menu field appears again by pressing one of the selection buttons (1).

Scroll/selection buttons to choose the available functions.

Alarm 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. Pressing the button for approximately 2 seconds displays the main menu again.

The temperature screen shows the engine oil (top of the screen) and hydraulic oil temperature (bottom of the screen). The values are shown in Celsius or Fahrenheit, according to the choice of unit system.

Fig. – Main working screen with the menu

selection buttons

Fig. – Temperature screen

Example of the menu field:

Instrument/controls - Description and function

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Control panel - Alarms

It is also possible to refer to a menu with the asphalt temperature when the asphalt temperature gauge (option) is installed. Set the upper and lower temperature limits with the function keys.

If the asphalt effective temperature is outside the limits, the 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 alarm is sent from the engine's ECM, which tracks its functions.

The message displays SPN and FMI codes and can be read via the engine supplier error code list. To erase the message, press "OK".

When a machine's alarm is activated, it is shown in the screen with a warning text describing it.

To erase the message, press "OK".

Fig.: Asphalt temperature screen

Instrument/controls - Description and function

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Control panel – Alarms (cont.)

SYMBOL

DESCRIPTION

FUNCTION

Warning symbol, hydraulic oil filter.

If the symbol appears with the engine in maximum rpm, it shall be necessary to replace the hydraulic oil.

Warning symbol, air filter.

If the symbol appears with the engine in maximum rpm, it shall be necessary to clean or replace the air filter.

Warning symbol, battery charging.

If the symbol appears with the engine running, the alternator is not charging. Stop the engine and find the fault.

Warning 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 symbol appears when the hydraulic oil is too hot. Do not drive the roller, put the engine on idle, wait until the oil cools down and find the fault.

Warning symbol, low fuel level.

This symbol appears when the fuel level is 10%.

Warning symbol, low sprinkler water level.

This symbol appears when the sprinkler water level is 10% in the main tank.

Warning symbol, low braking capacity.

This symbol appears when the oil level and/or pressure for the brakes are low. If this alarm appears and remains with the machine working, stop it immediately and contact DYNAPAC.

Instrument/controls - Description and function

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Fail list

Byte . Bit

Description

Action

0.0

Hydraulic Filter

LED

0.1

Air Filter

LED

0.2

No Charging

LED 4 0.3

Low Fuel

LED

0.4

Low Spr. Water

LED

0.5

Engine Temp

LED 7 0.6

Hydraulic Temp (Temperatura hidráulica)

LED

1.0

Battery tension will be monitored.

< 9 V ou > 36V = SAFE MODE

< 18V ou > 32V = LIMITED MODE

Safe Mode

1.4

Sensor tension error. 5V.

<4,875V or >5,125V out of range of work

Safe Mode

3.1

Error in the hydraulic pump front valve

Error Feedback / Resistance Valve out of range.

Limited Mode

3.0

Error in reverse of the valve of hydraulic pump

Error Feedback / Resistance Valve out of range.

Limited Mode

3.2

Error in the Motor Control Valve

Error Feedback / Resistance Valve out of range.

Limited Mode

3.3

Hydraulic motor valve BPD.

Error Feedback

Limited Mode

2.3

Error in the rotation of the pump / diesel engine / Input

Frequency >10.000 Hz

Limited Mode

2.0

Short circuit on FNR

Safe Mode

2.1

Inch sensor error

Limited Mode

2.2

Throttle pedal sensor error

Limited Mode

2.6

Error in rotation motor H1/ Frequency >8.000 Hz

Limited Mode

1.1

Error in direction motor (sensor x joystick)

Limited Mode

1.2

Error in J1939

Limited Mode

4.0

Coolant Level

LED

4.1

Oil Pressure

LED

4.2

Water in Fuel

LED

LIMITED Mode

Limits the speed to 50%. This mode is active as long as the fault remains.

SAFE Mode

The machine stops and cannot be used before the fault is corrected.

Instruments/controls - Cab

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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. They come from other systems on the machine.

Instrument/controls - Description and function

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“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 brightness of the panel light.

Operator help when starting

Emergency procedures

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When trying to turn on the machine without having set up to three necessary conditions to do so, the missing ones are shown in the display. The missing conditions must be set before turning on the machine.

Conditions that must be set:

- The parking brake shall be activated.

- The forward/reverse lever shall be in the neutral position.

- The Diesel engine rpm shall be in the 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 machine in high speed, the display will show the slow speed mode for a few seconds.

To activate the previous function, make sure the low speed mode is activated.

Eco-mode

This equipment has a new fuel economy system. When activated the Eco-mode maintain work speed decreasing

the engine rotation (≈1700 rpm), so the fuel economy can reach

30% depending on work (slopes, ballast, etc).

Don´t use Eco-mode on slopes higher that 15%.

Emergency procedures

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Regeneration system (Emission Control)

This equipment has a system of emission control and need

special care during the operation. This system has a particulate filter (DPF) which accumulates pollutants throughout the operation and must go through a regeneration process that happens automatically, to eliminate the accumulated material. When the machine is stationary with the engine running, if necessary, the regeneration system will start. ! During regeneration, the engine increases its operation speed. ! Whenever regeneration is 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 accumulation in the DPF reaches the low level (Low) contamination, the alert will be shown regeneration, indicating that the machine will trigger automatic regeneration if the machine is stopped.

When the accumulation in DPF reach the average level (Medium) of contamination, the alert ‘regeneration’ flashes and yellow alert ‘engine’ is activated. In this condition, it is recommended to stop the machine at the first opportunity to perform regeneration.

Fig. – The level of accumulation in the DPF is indicated on the display.

Fig. – Low accumulation level

Fig. – Medium accumulation level

Emergency procedures

32 4812325555EN 2018-02-08

When the high level (High) contamination is achieved, the

equipment will be turned off and the engine red alert will be triggered. Under these conditions, we recommend stop the machine immediately and let it perform the regeneration completely.

Attention! If the accumulation 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 technician Cummins.

Attention! Inhibition should only be used in exceptional cases, when the machine has to be stopped and there is still a small part of work to be completed.

Instruments and Controls - Cab

Fig. – High accumulation level

Fig. – Maximum accumulation level

Fig. – The button disables the inhibition of regeneration. .

Instruments/controls - Cab

2018-02-08 4812325555EN 33

Radio/CD player (option)

1 4 5 6 7

8 9

Radio/ Option

Instruments/controls - Cab

34 4812325555EN 2018-02-08

Instruments and controls - Cab

No.

DESIGNATION

SYMBOL

FUNCTION

Automatic Climate Control

Air conditioning automatic control (see A/C operation for detail).

Front wiper, intermittent

Intermittent function for front wiper. 3

Front wiper switch

Press to operate the front windshield wiper.

Rear wiper switch

Press to operate the rear windshield wiper.

Front and rear windshield washers switch

Press the top to activate the front washers. Press the bottom to activate the rear washers.

Asymmetric front wiper switch

Press to operate the front side windshield wiper.

Asymmetric rear wiper switch

Press to operate the rear side windshield wiper.

Asymmetric side windshield washers switch

Press the top to activate the front side washers. Press the bottom to activate the rear side washers.

Fuse box

Contains fuses from the electric system in the cab.

Hammer for emergency exit

If it is necessary to leave the cab during an emergency, release the hammer and break the right side windows.

Defroster nozzle

Turn the defroster nozzle to direct the air flow.

Instruments/controls - Cab

2018-02-08 4812325555EN 35

A/C – System operation

Power/Enter

By feeding the panel with 24VDC, the screen will be on, indicating that the product is in standby mode. Press to turn on the A/C, it will show the software version and then the temperature. To return to standby mode you must press the button for 3s.

Set point Up/Down

Set point is the desired temperature inside the vehicle. To set it up press or . 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. It also serves to allow the operator to view the coil and return temperature, as well as the parameters. It also serves to alert when there is some system flaws.

Operation Mode

To change the operation mode, press the button (operation mode), select the desired mode:

The controller has 4 operation modes that are:

- Only ventilation

- Only cooling

- Only heating

- Automatic mode

Press the button to confirm or wait a few seconds to cancel.









Instruments/controls - Cab

36 4812325555EN 2018-02-08

Ventilation

The controller has two ventilation modes: manual and automatic ventilation.

Manual 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

(Ventilation mode) and after set the desired speed with the

keys or . After press the key to confirm or wait a few

seconds and the speed will be saved.

Operation - Before starting

2018-02-08 4812325555EN 37

Operation - Before starting

Daily maintenance

Before starting your work shift and operating the equipment, make sure the daily maintenance was carried out. For further information, refer to the maintenance section in this manual.

Master switch

Check if the master switch is on. The master switch is located in the electric device compartment (1) on the right side of the machine.

If the main battery switch is closed, the engine hood shall be opened during the operation to make it possible to reach in an emergency.

The control and operation unit

The control and operation unit has three adjustment options: transverse travel, rotation and steering column angle.

For transverse travel, raise 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 column angle, release the locking lever (3). Fix it again in the new position.

To adjust the operator's seat, refer to the next section.

Perform all the control and operation unit adjustments when the machine is stationary.

Before starting your work shift and operating the machine, make sure the seat and the steering column are locked and never release the side travel if you are on a slope.

After the daily use of the roller, the master switch shall be turned off. It prevents the machine to be turned on accidentally and protects the electronic devices.

Fig. – Engine compartment.

1. Battery switch

Fig. - The control and operation unit

1. Locking lever – transverse travel

2. Locking lever - rotation

3. Locking lever - steering column angle

Operation - Before starting

38 4812325555EN 2018-02-08

Standard operator's seat - adjustment

Adjust the operator's seat so all the controls are within easy reach and the machine operation is comfortable.

(1) Length adjustment. (2) Weight adjustment. (3) Back support adjustment. (4) Seat belt.

ALWAYS 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 and the machine operation is comfortable.

(1) Length adjustment. (2) Height adjustment. (3) Seat-cushion inclination. (4) Back support inclination. (5) Armrest inclination. (6) Lumbar support adjustment. (7) Seat belt.

Fig. - Operator's seat

Fig. - Operator's seat (option adjustment)

6 7 3 2 1 5 4

Operation - Before starting

2018-02-08 4812325555EN 39

View

Before starting the engine, make sure that the view around the machine is unobstructed.

All the cab windows shall be clean and the rear view mirrors adjusted for a good rear view.

Operator position

If a ROPS (Roll Over Protective Structure) or a cab is fitted to the roller, always use the seat belt (1) and wear a protective helmet.

Always replace the seat belt for a new one if the previous show signs of wear or has been subjected to a huge impact.

The safety railings (2) around the operator's station are adjustable both in the inner and outer positions. Retract them when driving close to walls or other side obstacles.

Release the locking knob (3) and 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 fitted with a cab, make sure the door is always closed when in motion.

Interlock

The roller is equipped with Interlock. The Diesel engine turns off after 4 seconds if the operator

leaves the seat when the machine is moving forward/backward. If the machine is in neutral position when the operator leaves the seat, a horn is sound until the parking brake is activated.

If the parking brake is activated, the Diesel engine will not stop, but the engine will be automatically turned off if, by any reasons, the transmission is not in the neutral position when the operator is not seated in his place.

Sit down for all operations!

Fig. - Operator's seat

1. Seat belt

2. Safety railings

3. Locking knob

4. Anti-slip protections

Operation

40 4812325555EN 2018-02-08

Starting Screen - Control

Sit down for all operations. Turn the ignition key (1) to the position I and the initial screen

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 the engine working hours.

Fig.– Side panel

1. Ignition key

2. Control Panel

6 4 5

Fig.– Status screen

3. Voltmeter

4. Fuel level

5. Water level

6. Hourmeter

Operation

2018-02-08 4812325555EN 41

Starting the engine

Make sure the emergency stop system (2) is off (upper position) and the parking brake is on.

The forward/reverse lever (1) shall be in the neutral position. The Diesel engine cannot be started if the lever is not in this position.

When sitting on the operator's seat, turn the ignition key (3) to the right (the first position I) and then to the start position. Release the switch as soon as the engine starts.

Do not try to run the start engine for too long (max. 30 seconds). If it does not work, wait 60 seconds to try again.

Let the engine idle for a few minutes or more if the environment temperature is below 50 F (10º C).

When the engine is running indoors, make sure if there is proper ventilation to extract the exhaust gases.

Fig. - Control panel

1. Forward/reverse lever

2. Emergency stop button

3. Ignition key

Operation

42 4812325555EN 2018-02-08

Display and button set

The parking brake symbol is shown when the parking brake is activated.

= Low speed.

= Automatic water control (AWC). The sprinkling is activated when the forward/backward lever is in the neutral position.

= Tire pressure.

= Sprinkler activation for edge cutter.

= High/low speed mode (in the center of the screen).

= Alarm display, see the table below for information.

Alarm descriptions

SYMBOL

DESCRIPTION

FUNCTION

Warning lamp, hydraulic oil filter

If the lamp is lit 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 replace the air filter.

Warning lamp, battery charging

If the lamp is lit with the engine running, the alternator is not charging. Stop the engine and find the fault.

Warning lamp, engine temperature

If the lamp is lit it means the engine is too hot. Stop IMMEDIATELY the engine and find the fault. Refer to the engine manual.

Warning lamp, hydraulic oil temperature

If the lamp is lit it means the hydraulic oil is too hot. Do not operate the roller. Cool the oil making the engine run in idle and locate the fault.

Operation

2018-02-08 4812325555EN 43

Operating the roller

Under no circumstances the machine shall be operated away from the ground. The operator shall be seated inside the machine during the operation.

Make sure the areas at the front and behind the machine are free.

1. Select the maximum gear the machine will operate. To activate the operation speed, use the throttle on the right side of the steering column.

2. Make sure the steering is working normally by turning the steering wheel to the left and to the right once with the roller stationary.

3. When compacting 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 machine can roll if you are on a slope.

4. Activate the low speed (3).

5. Move the forward/backward lever (4) carefully to any direction you desire.

6. Increase or decrease the machine speed using the throttle control.

Make sure the parking brake (5) is working correctly by activating it and moving the forward/backward lever (4) to the F or R position. Keep the brake test button pressed. This way, when you throttle the machine, it will not move.

Fig.– Side panel

1. Manual sprinkler

2. Automatic sprinkler

5 3 4

Fig.– Side panel

3. Low speed

4. Forward/reverse lever

5. Parking brake

Operation

44 4812325555EN 2018-02-08

Edge cutter (option)

To activate the edge cutter, the machine must be in low speed. When the side panel button (1) is pressed with the machine in

low speed, a hydraulic piston lowers down the edge cutter to the ground.

The tool can also be lifted if the machine is in the transport position.

A bypass valve prevents the hydraulic system being overloaded. To prevent asphalt sticking to the edge cutter, the operator shall

use a separate sprinkler system. It is operated by a switch (2). The water is supplied on 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 can be variable adjusted with the keys (2) and (3) on the keypad, within the interval from 240 kPa to 830 kPa (35 to 120 PSI) and can be reduced with the key (3). The tire pressure level is shown in the lower left corner, on the Display (1).

When the tire pressure is at the maximum level (830 kPa) or at the minimum level (240 kPa), it will not be possible to increase/decrease the pressure.

Fig.– Side panel

1. Edge cutter, up and down

2. Edge cutter, sprinkler

Fig.– Side panel

1. Display

2. Increase in the tire pressure

3. Decrease in the tire pressure

Operation

2018-02-08 4812325555EN 45

Coconut mats (option)

To apply the coconut mats (1) on the wheels, follow the instructions below:

- Hold and lift the handle in the middle of the scraper holder (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 the middle of the scraper holder (2).

- Make sure the lock pin (4) fits well in the locking hook (3).

1 2 3

Fig. – Scraper bars adjustment

1. Coconut mats

2. Scraper holder

3. Locking hook

4. Lock pin

Operation

46 4812325555EN 2018-02-08

Ballast box

Water and wet sand ballast

Remove the top covers (1) and side upper covers (3) and fill with water and sand through this opening.

Keep the side lower covers (2) closed during the water filling. Do not remove the draining plugs (4) because the 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 between the ballast.

When using the roller with mixed ballast, start using the steel objects available, and then add the requisite amount of sand and water.

Distribute the ballast evenly.

Fig.– Ballast box cover

1. Top covers

2. Side lower covers

3. Side upper covers

4. Draining plugs

Operation

2018-02-08 4812325555EN 47

Removable steel ballasts

The CP2100/CP2100W roller uses an innovative and patented system of steel ballasts, which can be removed and installed easily and quickly:

1. With the ballast box drained (without water and/or sand), remove four side covers (1) from the ballast box.

2. Unscrew the nuts and counternuts (2) and four lower bolts (3) of the bedplate 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 projected so the forklift forks fit perfectly and to easy their removal, installation and transport.

4. After installing or removing the ballasts in the box, mount the bedplate, performing the reversal steps used to remove them.

Distribute the steel ballast evenly in the box. 1

4 3 5

Fig. - Removable steel ballasts

1. Side covers

2. Nut and counternut

3. Bolts

4. Bedplate

5. Ballast grooves

Operation

48 4812325555EN 2018-02-08

Ground pressure (driving)

The tire contact surface can be changed by means of tire pressure.

The high pressure on the tires provides a smaller contact surface (1) and the low pressure on the tire provides a larger contact surface (2).

The contact surface with the ground is very important for the compaction result. The total weight divided by the quantity of tires provides the correct pressure for the wheel, according to the following table.

Ground pressure

CP2100

CP2100W

Tire

TIRE PRESSURE (kPa)

Tire

TIRE PRESSURE (kPa)

11/20-18

240

350

480

620

720

830 14/70-20

240

350

480

620

720

830

LOAD ON

THE WHEEL

(kgf)

GROUND PRESSURE (kPa)

LOAD ON

THE WHEEL

(kgf)

GROUND PRESSURE (kPa)

1.125

200

240

270

300

330

340 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

280

326

370

2.750

260

320

390

440

480

520 2.750

231

248

256

303

356

408

3.000

270

330

410

460

490

540 3.000

242

257

267

315

373

430

Tire

TIRE PRESSURE (psi)

Tire

TIRE PRESSURE (psi)

11/20-18

105

120 14/70-20

105

120

LOAD ON

THE WHEEL

(lbs)

GROUND PRESSURE (psi)

LOAD ON

THE WHEEL

(lbs)

GROUND PRESSURE (psi)

2.500

49 2.500

3.000

55 3.000

4.000

62 4.000

5.000

69 5.000

6.000

75 6.000

6.500

78 6.600

Fig. - Ground contact surface

1. Contact surface with the tire (high pressure)

2. Contact surface with the tire (low pressure)

Operation

2018-02-08 4812325555EN 49

Low tire pressure – 240 kPa (34,8 PSI)

The lower the tires pressure, the lower the pressure on the contact surface, due to 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 surface, due to the smaller surface area.

Fig. - Low ground pressure, larger contact area

Fig. - Normal ground pressure

Fig. - High ground pressure, smaller contact area

Operation

50 4812325555EN 2018-02-08

Interlock/Emergency Stop/Parking Brake

The interlock, emergency stop and parking brake shall be checked daily before starting the machine. To check if the emergency stop and interlock are working correctly, it is necessary to turn on and off the machine.

To check if the Interlock works correctly, the operator shall rise from the seat with the roller moving forwards and backwards (perform the test in both ways). The operator must hold the steering wheel firmly and be ready for a sudden stop. The alarm will be activated and after 4 seconds 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 backwards (perform the test in both ways). Next, the operator must hold the steering wheel firmly and be ready for a sudden stop. The engine will be turned off and the brakes will be activated.

To check if the parking brake works correctly, it shall be activated with the roller moving forwards and backwards (perform the test in both ways). The operator shall hold the steering wheel and be ready for a sudden stop when it is activated. The engine does not turn off.

Normal braking

Release the throttle control (1) and press the brake pedal (2).

Fig. – Pedals

1. Throttle control

2. Brake pedal

Operation

2018-02-08 4812325555EN 51

Emergency braking

The brake pedal is normally used to brake.

For emergency braking, press the emergency stop button (1), hold the steering wheel and be ready for a sudden stop. The engine stops.

The Diesel engine will be turned off and it must be turned on again, if necessary.

When starting the engine after an emergency stop, the forward/backward 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 indication of faults. Turn off

all the lights and other electric functions. Press the parking brake switch (3). Turn the ignition key (2) to the left to turn it off. Fit and fix the cover of the instruments panel over the screen

and the upper part of the control box (on rollers without cab).

Fig. – Side panel

1. Emergency stop

Fig. – Side panel

1. Display

2. Ignition key

3. Parking brake

2 1 3

Operation

52 4812325555EN 2018-02-08

Chocking the wheels

Never leave the roller and let it with the engine running unless the parking brake is activated.

Make sure the machine is parked in a safe area, without traffic. Chock the wheels when parking on slopes.

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 will prevent the battery discharging and will also make it difficult to start and drive the machine if unauthorized people try to use it. Close and lock the maintenance covers and doors.

Fig. - Choking the wheels

1. Chocks

Fig. – Engine compartment

1. Master switch

Long-term storage

2018-02-08 4812325555EN 53

Long-term storage

For long-term storage (more than a month) follow the instructions below:

These measures are valid for storage for a period of up to 6 months.

Before starting the machine again, the points stated below shall be performed before parking and store the roller.

Wash the machine and touch up the painting finishing to prevent rusting. Use anti-rust agents on the exposed parts and lubricate carefully the machine, besides applying grease to unpainted surfaces.

Engine

Refer to the manufacturer information in the engine instruction 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 sections "Every 50 Hours of Operation" and "Every 1,000 Hours of Operation") or the respective intake opening with plastic or tape. Also cover the exhaust pipe opening with sealing material to avoid moisture entering in the engine.

Water distribution system

Drain all the water in the water tank and all the hoses. Also drain the filter housing and the water pump and remove all the sprinkler nozzles.

Refer to the Maintenance section to obtain further information about water draining.

Fuel tank

Fill the fuel tank completely to prevent condensation.

Fig. - Roller weather protection

Long-term storage

54 4812325555EN 2018-02-08

Hydraulic oil reservoir

Fill the hydraulic reservoir until the uppermost level mark (refer to the section "Every 10 Hours of Operation").

Tires

Make sure the tires pressure is at least 200 kPa (29 PSI).

Steering cylinder, hinges, etc.

Grease the steering cylinder plunger spindle to preserve it. Also lubricate the hingers on the engine compartment and cab

doors.

Hoods, tarpaulin

Lower 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 place with regular temperature.

When stopping and parking the equipment, always apply the parking brake.

As a precaution measure, chock the roller tires when parking on slopes and turn off the engine.

To prevent accidents, when parking on slopes, stop transversally to the road towards the slope.

Never leave the roller with the engine running. Before leaving it, apply the emergency/parking brake.

Make sure the roller is parked in a safe place and that it is not obstructing the traffic.

Lifting

2018-02-08 4812325555EN 55

Lifting

Lifting the roller

Make sure the front wheels are parallel with the frame before lifting the roller.

Make sure the hooks are safely placed in the lifting eyes. The equipment shall only be lifted by the proper lifting eyes.

Always use cables and steel chains according to the safety norms and make sure there are no worn components and that parts are not damaged during the lifting.

The machine's gross weight is specified in the hoisting plate (1). Refer also to the Technical Specifications.

Do not go under or next to the machine when it is being lifted.

Make sure the lifting hooks are safely connected to the machine. Check 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 Specifications.

Lifting devices such as a jack (2) or equivalents must be dimensioned according to the safety regulations for lifting devices.

Do not go under or next to the machine when it is being lifted. Also check if the lifting device is fixed and secure in its position, and at a steady level and surface.

The roller shall only be lifted with a jack or similar if it is correctly fitted in the lifting eyes. The frame is reinforced in these points to support the tension. Lifting at any other place can result in damage to the machine or personal injury to the operator.

Fig. - Roller prepared for lifting.

Fig. - Roller lifted with the jack

1. Hoisting plate

2. Jack

Lifting

56 4812325555EN 2018-02-08

Towing

Short distance towing with the engine running

The roller can be moved up to 984 feet (300 meters), according to the following instructions:

To tow the machine, use the same lifting points.

1. Park the roller on a flat and safe place. If necessary, chock the tires.

2. Open the hood and check if the propulsion pump is

accessible.

3. On the pump, there are two by-pass valves (1) (hexagonal

bolts) which should be turned three turns anticlockwise to put the whole system in the by-pass mode, which means that the A and B sides of the 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 lever in one of the two

positions. If it is in a neutral position, the hydraulic engine brakes are activated.

6. The roller can be towed and even steered now, if the

steering system is working.

7. To leave the by-pass mode, turn both valves (1) three times

to the right.

The machine must not be moved in a speed higher than 5 km/h and over 984 feet (300 meters). If it happens, there are risks of damage in the transmission system. Make sure the towing valves are reseted (turning them three times to the right) after the towing.

Fig. - Transmission pump

1. By-pass valves

Towing

2018-02-08 4812325555EN 57

Short distance towing with the engine inoperative

As a safety measure, chock the wheels to prevent the machine to move when the brakes are hydraulically disengaged.

The roller can be moved up to 984 feet (300 meters), according to the following instructions:

1. Park the roller on a flat and safe place.

2. Open the hood and check if the propulsion pump is accessible.

3. On the pump, there are two by-pass valves (1) (hexagonal bolts) which should be turned three turns anticlockwise to put the whole system in the by-pass mode, which means that the A and B sides of the pump are freely connected to the pressure side. This function allows the machine 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 pressure is quickly drained, turn on the start engine for a few seconds.

7. If you cannot start it, turn the towing valve four times to the left (remember always to turn it four times later to the right).

8. To disconnect the by-pass mode, loose the hexagon bolts turning them three times to the right.

9. This way the roller can be towed.

Fig. - Transmission pump

1. By-pass valves

Fig. - Brake release valve 2 - Valve 3 - Pump arm

Towing

58 4812325555EN 2018-02-08

Towing the roller

When towing, the roller shall be braked by the towing vehicle. Always use a towing bar, because the machine cannot brake.

The roller must be towed slowly and must not be moved in a speed higher than 5 km/h and over 984 feet (300 meters).

During the roller towing, its devices shall be connected in both lifting holes.

The pulling forces shall act to the machine's longitudinal axis, as illustrated in the figure. Refer to the table below to know the maximum pulling force allowed for this machine model:

MODEL

Lbf

CP2100/CP2100W

324

72,900

Trailer eye (option)

The roller can be equipped with a trailer eye. It shall only be used for towing objects weighing no more than 4,000 kg.

Fig. - Towing direction

Fig. - Trailer eyes

Transport

2018-02-08 4812325555EN 59

Transport

Preparing the roller for transport

Apply the parking brake and make sure the machine is in the neutral position, that is, that the tires are pointing forwards.

Chock (1) the tires in an angle of 37º and at a minimum height of 9,9 inches (25 cm). They should be chocked both forwards and backwards.

Chock under the frame (2) to ensure that the chains remain tensioned if the air goes out of the tires. Block up the machine according to the figure.

Secure the roller with chains in all four corners. The attachment points are shown in the safety decals. Put the chains in symmetrical pairs, crossing each other.

Make sure the chains, supports and attachments of the transport vehicle are approved and have the proper tension to perform the fitting and locking. Check regularly if the chains are not slack.

Fig. - Positioning

1. Chocks

2. Supports

3. Straps

2 2 3 3 3

Operation instructions - Overview

60 4812325555EN 2018-02-08

Operation instructions - Overview

Follow the safety instructions specified in the Safety Manual.

● Make sure all the MAINTENANCE INSTRUCTIONS were carried out. For further information, refer to the Maintenance section in this manual.

● Turn on the battery switch.

● Move the forward/backward lever to the "P" position.

● Apply the emergency stop. The roller will always start in the

High speed.

● Keep the ignition key in the "O" position.

● Start the 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 operating the roller, use carefully the forward/backward lever.

● Make sure the tires are well sprinkled, when necessary.

In an emergency, apply the emergency stop, hold well the steering wheel and be ready for a sudden stop.

● When parking: stop the engine, apply the parking brake and chock the roller tires.

● When towing: refer to the towing instructions in this manual.

● When lifting: refer to the lifting instructions in this manual.

● When transporting: refer to the transport instructions in this

manual.

Preventive maintenance

2018-02-08 4812325555EN 61

Preventive maintenance

Introduction

It is necessary to carry out a complete maintenance so the machine can work satisfactorily and at the lowest possible costs.

The Maintenance section includes the periodic maintenance that shall be carried out on the machine.

The recommended maintenance intervals assume that the machine is being used in a normal environment and working conditions.

Delivery

The machine is tested and adjusted before 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 company.

Warranty

The warranty is only valid if the inspections were carried out at the time of the delivery, as well as the maintenance inspections according to the warranty.

The warranty is not valid if there are damages due improper assistance, misuse of the machine, use of lubricants and hydraulic oils not specified in the manual or if other adjustments were made without the proper authorization.

Warning symbols

WARNING! Damage to the machine or its parts.

CAUTION! Risk of death or injures.

Preventive maintenance - Symbols and

lubricants

62 4812325555EN 2018-02-08

Preventive maintenance - Symbols and lubricants

Always use high quality lubricants and in the amounts required. Too much grease or lubricant oil can cause overheating and premature wear.

ENGINE OIL

Room temperature: 5 F to 122 F (-15ºC to 50ºC)

Shell Rimula R4 L 15W-40 or equivalent.

HYDRAULIC OIL

Room temperature: 5 F to 122 F (-15ºC to 50ºC)

Room temperature: above 122 F (50ºC)

Shell Tellus V68 or equivalent.

Shell Tellus V100 or equivalent.

BIOLOGICAL HYDRAULIC OIL When leaving the plant, the machine may be

filled with biologically degradable oil. When replacing or filling with oil, use the same type of oil used previously.

PANOLIN HLP Synth 46 (www.panolin.com) GREASE

Shell Retinax LX2 or equivalent.

FUEL

Refer to the engine manual instructions.

COOLANT

Antifreeze protection effective down to -34.6 F (-37ºC). 50/50 mixed (clean water + coolant additive).

GlycoShell/Carcoolant 774C or equivalent.

TRANSMISSION OIL

Shell Spirax ST 85W-140 or equivalent.

For room temperatures extremely high or low, other lubricants shall be applied. Refer to the chapter "Special Instructions" or contact DYNAPAC.

Preventive maintenance - Symbols and lubricants

2018-02-08 4812325555EN 63

Engine, oil level

Engine, oil filter

Hydraulic fluid, level

Air filter

Hydraulic fluid, filter

Transmission, oil level

Fuel filter

Battery

Coolant level

Preventive maintenance - Symbols and

lubricants

64 4812325555EN 2018-02-08

Lubricating oil

Air pressure

Sprinkler

Sprinkler water

Recycling

Specifications

2018-02-08 4812325555EN 65

Specifications

WEIGHTS

Operational weight with ROPS and series equipment

9,450 kg

(20,828 lb)

Weight without ballast

9,050 kg

(19,947 lb)

Weight with ballast, wet sand

15,810 kg

(34,846 lb)

Weight with maximum ballast

21,000 kg

(46,285 lb)

The roller can use 16 ballast blocks inside the frame. Each block is 1,102 lb (500 kg) and is used individually. Eight of them are in the front part and eight are in the rear part, so use a proper 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 layers do not need a machine that heavy.

FILLING VOLUMES

Hydraulic oil reservoir

95 L (25.09 gal.)

Hydraulic oil system

35 L (9.24 gal.)

T engine lubricant oil

2x8 L (0.5x2.11 gal)

Diesel engine lubricating oil

7.4 L (1.95 gal.)

Diesel engine coolant

14.6 L (3.85 gal.)

Fuel tank

210 L (55.47 gal.)

Water tank

415 L (109.63 gal.)

Sand ballast box volume (total)

3.38 m³

ELECTRICAL SYSTEM

Battery

2 x 12 V / 74 Ah (24V)

Alternator

24 V 60A

Fuses

Refer to "Fuses" in the

"Electrical System"

section

Specifications

66 4812325555EN 2018-02-08

Specifications (cont.) – Working capacity

COMPACTION DATA

Load on the tires:

- Without ballast

1,400 kg

- With wet sand ballast

2,100 kg

- With the ballast at its max.

3,000 kg

Torque

Torque for oiled bolts tightened with a torque wrench.

METRIC

COARSE

SCREW

THREAD,

BRIGHT

GALVANIZED

(fzb)

STRENGTH CLASS

8.8, oiled

8.8

dry

10.9, oiled

10.9 dry

12.9, oiled

12.9

dry

8.4 N.m

(6.2 lb.ft)

9.4 N.m

(6.9 lb.ft)

12 N.m

(8.8 lb.ft)

13.4 N.m (9.9 lb.ft)

14.6 N.m

(10.7 lb.ft)

16.3 N.m

(12.02lb.ft)

21 N.m

(15.5 lb.ft)

23 N.m

(16.9 lb.ft)

28 N.m

(20.6 lb.ft)

32 N.m

(23.6 lb.ft)

34 N.m

(25.07 lb.ft)

38 N.m

(28.02lb.ft)

M10

40 N.m

(29.5 lb.ft)

45 N.m

(33.1 lb.ft)

56 N.m

(41.3 lb.ft)

62 N.m

(45.7 lb.ft)

68 N.m

(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 lb.ft)

174 N.m

(128.3 lb.ft)

187 N.m

(138 lb.ft)

208 N.m

(153.4 lb.ft)

M16

169 N.m

(124.6 lb.ft)

190 N.m

(140.1 lb.ft)

240 N.m

(177 lb.ft)

270 N.m

(200 lb.ft)

290 N.m

(213.9 lb.ft)

320 N.m

(236.01

lb.ft)

M20

330 N.m

(243.4 lb.ft)

370 N.m

(272.9 lb.ft)

470 N.m

(346.6 lb.ft)

520 N.m

(383.5 lb.ft)

560 N.m

(413.03 lb.ft)

620 N.m

(457.28

lb.ft)

M22

446 N.m

(329 lb.ft)

497 N.m

(366.5 lb.ft)

626 N.m

(461.7 lb.ft)

699 N.m

(515.5 lb.ft)

752 N.m

(554.6 lb.ft)

839 N.m

(618.8 lb.ft)

M24

570 N.m

(420.4 lb.ft)

640 N.m

(472 lb.ft)

800 N.m

(590 lb.ft)

900 N.m

(663.8 lb.ft)

960 N.m

(708.05 lb.ft)

1,080 N.m

(796.5 lb.ft)

M30

1,130 N.m

(833.5 lb.ft)

1,260 N.m

(929.3 lb.ft)

1,580 N.m

(1,165.3

lb.ft)

1,770 N.m

(1,305.5

lb.ft)

1,900 N.m

(1,401.3

lb.ft)

2,100 N.m

(1548.8

lb.ft)

Specifications

2018-02-08 4812325555EN 67

Torque (cont.)

METRIC COARSE

THREAD, ZINC-

TREATED

(Dacromet/GEOMET)

STRENGTH CLASS

10.9

oiled

10.9 dry

12.9

oiled

12.9 dry

12 N.m

(8.8 lb.ft)

15 N.m

(11.06 lb.ft)

14.6 N.m

(10.7 lb.ft)

18.3 N.m

(13.4 lb.ft)

28 N.m

(20.6 lb.ft)

36 N.m

(26.5 lb.ft)

34 N.m

(25.07 lb.ft)

43 N.m

(31.7 lb.ft)

M10

56 N.m

(41.3 lb.ft)

70 N.m

(51.6 lb.ft)

68 N.m

(50.1 lb.ft)

86 N.m

(63.4 lb.ft)

M12

98 N.m

(72.2 lb.ft)

124 N.m

(91.4 lb.ft)

117 N.m

(86.3 lb.ft)

147 N.m

(108.4 lb.ft)

M14

156 N.m

(115 lb.ft)

196 N.m

(144.5 lb.ft)

187 N.m

(138 lb.ft)

234 N.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 lb.ft)

786 N.m

(579.7 lb.ft)

752 N.m

(554.6 lb.ft)

944 N.m

(696.2 lb.ft)

M24

800 N.m

(590 lb.ft)

1,010 N.m

(744.9 lb.ft)

960 N.m

(708.05 lb.ft)

1,215 N.m

(896.1 lb.ft)

M30

1,580 N.m

(1,165.3 lb.ft)

1,990 N.m

(1,467, 7 lb.ft)

1,900 N.m

(1,401.3 lb.ft)

2,360 N.m

(1,740.6 lb.ft)

Wheel bolts

Bolt dimensions

M20 (PN 4700792683)

Strength class

10.9

Torque

Oiled: 494 N.m (364.5 lb.ft)

Dry: 620 N.m (457.2 lb.ft)

Hydraulic system

OPENING PRESSURE

Steering system

160 BAR

2,320 PSI

Transmission system

330 BAR

4,786 PSI

Supply system

2 BAR

29 PSI

Brake release

19 BAR

275 PSI

Specifications

68 4812325555EN 2018-02-08

Specifications (cont.) Air conditioning (option)

The system described in this manual is the ACC (Automatic Climate Control), that is, a system which maintains the set temperature in the cab provided that all the windows and doors are kept closed.

Coolant designation: 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

Power (SAE J1995)

121 HP (89 kW) @ 2,200 rpm

Lamps (when installed)

LAMPS

Drive lights, front

75/70 W - P43t (H4)

Front lights

21 W - BA9s

Side lights

5 W – SV8.5

Brake-position lights

21/5 W – BAY15d

Rear lights

21 W – BA15s

License plate lights

5 W – SV8.5

Working lights

70 W – PK22s (H3)

35 W – Xenon

Cab lights

10 W – SV8.5

Maintenance and lubrication points

2018-02-08 4812325555EN 69

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

Scheduled maintenance and lubrication

70 4812325555EN 2018-02-08

Scheduled maintenance and lubrication

Maintenance and lubrication procedures

The maintenance and lubrication shall be carried out first based on the working hours. When they cannot be considered, use the periods, like daily, weekly, etc.

Always clean around the covers, plugs, grease nipples or hoods before open or apply grease to them.

Respect and follow the engine manufacturer 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

Check the Diesel engine oil level

Refer to the engine

manual instructions.

Check engine coolant level

Check the hydraulic oil level

Fill the fuel tank

Fill the water tanks

Check the sprinkler system

Clean the sprinkler injector

Adjust the scrapers

Check the brakes oil level

Clean the pre-filter

Check the alternator belt tension

Refer to the engine

manual instructions.

Drain the fuel filter

Refer to the engine

manual instructions.

Scheduled maintenance and lubrication

2018-02-08 4812325555EN 71

WEEKLY (after the first 50 hours of operation)

POSITION

IN THE

FIGURE

ACTION

NOTES

1, 2

Replace the Diesel engine oil and the oil filter

Refer to the engine

manual instructions.

Check and replace the main air filter

Refer to the engine

manual instructions.

Check and replace the secondary air filter

Refer to the engine

manual instructions.

Replace the engine fuel filter

Refer to the engine

manual instructions.

Replace the hydraulic oil filters

Lubricate the lower pivot bearing

Lubricate the upper pivot bearing

Replace the wheel gear oil

WEEKLY (Every 50 hours of operation)

POSITION

IN THE

FIGURE

ACTION

NOTES

Check the engine air intake system

Refer to the engine

manual instructions.

Check the tires air pressure

Retighten the wheel nuts

Check and clean the engine air filter elements

Replace them, if

necessary

Drain the fuel pre-filter

Refer to the engine

manual instructions.

Check the air conditioning

When equipped (option)

Clean the air conditioning

Check and lubricate the edge cutter

When equipped (option)

Lubricate the lower pivot bearing

Lubricate the upper pivot bearing

Scheduled maintenance and lubrication

72 4812325555EN 2018-02-08

MONTHLY (Every 250 hours of operation)

POSITION

IN THE

FIGURE

ACTION

NOTES

1, 2

Replace the Diesel engine oil and the oil filter

Refer to the engine

manual instructions.

Check and clean the hydraulic water and Diesel engine water coolers.

If necessary

Check the air conditioning

When equipped (option)

Check the batteries

Lubricate the pilot and link bearings

Lubricate the lower pivot bearing

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

FIGURE

ACTION

NOTES

Replace the Diesel engine fuel filter

Refer to the engine

manual instructions.

Replace the Diesel engine pre-filter

Refer to the engine

manual instructions.

Check the bolted joints

Check the hydraulic oil tank cover

Lubricate the seat bearing

Lubricate the lower pivot bearing

Lubricate the upper pivot bearing

Lubricate the pivot bearing

Replace the air dryer filter

Machine equipped with

AOR

Scheduled maintenance and lubrication

2018-02-08 4812325555EN 73

EVERY SIX MONTHS (Every 1,000 hours of operation)

POSITION

IN THE

FIGURE

ACTION

NOTES

Check the Diesel engine valve clearances

Refer to the engine

manual instructions.

Check the engine propulsion system

Refer to the engine

manual instructions.

Replace the main and the secondary air filters

Replace the air dryer filter

Machine equipped with

AOR

Replace the hydraulic oil filters

Replace the cab air filter

Lubricate the lower pivot bearing

Lubricate the upper pivot bearing

Replace the wheel gear oil

Check the wheel gear oil level

ANNUALLY (Every 2,000 hours of operation)

POSITION

IN THE

FIGURE

ACTION

NOTES

Replace the hydraulic oil

Clean the fuel tank

Clean the water tank

Clean the sprinkler system

Check the pilot bearings

Replace the coolant

Refer to the engine

manual instructions.

Check the air conditioning

When equipped (option)

Lubricate the lower pivot bearing

Lubricate the upper pivot bearing

Maintenance - Every 10 hours

74 4812325555EN 2018-02-08

Daily (Every 10 hours of operation)

Park the roller on a level surface.

When checking and adjusting the machine, always turn off the engine and make sure the forward/backward lever is in the neutral position.

When the engine is off in enclosed places, make sure there is a good ventilation, to prevent carbon monoxide poisoning.

Check the Diesel engine oil level

The oil dipstick is under the oil filling plug (1), on the left side of the engine.

Be careful with hot engine parts and also with the cooler when removing the oil dipstick. There is risk of burns.

1. Remove the dipstick (2) and check if the oil level is between 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 engine compartment. To access the expansion tank (3), remove both retaining bolts (1) and also the protective plate (2).

Check if the coolant level is between the MAX and MIN marks in the expansion tank (3). If necessary, remove the tank hood and fill the level.

NEVER open the expansion tank cap if the engine is still hot and always use protective gloves and goggles.

When filling with coolant, always use a mixed solution with 50% of water and 50% of additive. Refer to the lubricant specifications in this manual and in the engine instructions manual.

Fig. – Engine compartment

1. Oil filling plug

2. Oil dipstick

Fig. - Expansion tank

1. Bolts

2. Protective plate

3. Expansion tank

Maintenance - Every 10 hours

2018-02-08 4812325555EN 75

Check the hydraulic oil level

1. Park the roller on a level ground and turn off the engine.

2. Check the hydraulic oil reservoir sight glass (1) located on the right side of the machine.

3. If the oil level is 2 cm below the glass upper line, fill with the recommended hydraulic oil.

Use only hydraulic oil recommended by DYNAPAC.

Filling the fuel tank

Never fill the engine when it is working. Do not smoke and avoid spilling fuel.

The filling nozzle and the tank cap are in the front of the operator platform, in the left side of the machine.

Check the fuel tank daily before starting 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 information about the fuel grade, refer to the Engine Manual.

Before filling, stop the machine on a safe place with level surface, turn off the engine and ground the filling pipe, putting it in contact with the frame in a non-insulated place.

When filling, keep the pump nozzle in contact with the filling pipe. Always use fuel recommended by DYNAPAC.

Using adulterated, contaminated, dirty or bad quality fuel damages the injection system and engine components. The repairs due to the conditions above are NOT covered by the warranty.

Fig. - Hydraulic oil reservoir

1. Oil sight glass

2. Filling plug

Fig. – Fuel tank

1. Tank cap

2. Filling pipe

Maintenance - Every 10 hours

76 4812325555EN 2018-02-08

Fill the water tanks

There are two filling caps above the water tank (1).

Unscrew the tank cap and fill with clean water. Do not replace the filter.

1. Fill the tank; it holds 110 gal. (415 liters).

Only recommended additive: small quantity of environmentally-friendly antifreeze.

Check the sprinkler system

Fill the tank with emulsion fluid, e.g. water mixed with 2% of cutting fluid.

Check if the sprinkler injectors (3) are not blocked, and if necessary, clean them, as well as the filter.

Check periodically if there 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 hand (1). Use compressed air to clean the nozzle (1) and the strainer (2).

It is also possible to use the spare parts and to clean the blocked ones later on.

NOZZLE

COLOR

Ø (mm)

l/min

(2.0 bar)

gal./min

(40 PSI)

Standard

Yellow

0.8

0.63

0.20

Option

Blue 1 1

0.31

Option

Red

1.2

1.25

0.39

Option

Brown

1.3

1.63

0.50

After checking and cleaning, turn on the system and inspect if it is working correctly.

Use protective goggles when working with compressed air.

Fig.– Sprinkler injector

1. Nozzle

2. Strainer

3. Sprinkler injector assembly

Fig. - Filling the water tanks

1. Caps

Maintenance - Every 10 hours

2018-02-08 4812325555EN 77

Adjust the scrapers

Make sure the scrapers and tires are in good operation conditions, otherwise, replace them.

If the scraper's wear is uneven, unscrew the adjusting bolt (3) in the back of the scraper attachment.

Pull down the blade (1) until it is leveled with the tire. After the adjustment, tighten the screws again (3).

The scrapers shall be adjusted on the tires during the transport. To do it, lift up the scraper blades (1) and make sure they are

fixed at this position by the locking hooks (2). To lower down the scrapers, raise the scraper 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 prevent the scraper to fall onto the ground.

2. Remove the pin (1) on the hook axle removing the hairpins

(2) on both sides of the pin. Grip the hook axle up and pull it straight out.

To put the scraper back after the inspection, it shall be initially fit on the locking hook before the up hook is fitted in the right position.

Refit the pin (3) in the right position and make sure it is well secured by the attachment (4).

Fig. - Tire scrapers

1. Scraper blade

2. Locking hook

Fig. - Tire scrapers

1. Scraper blade

2. Scraper holder

3. Bolts

Fig. - Tire scrapers

1. Pin

2. Hairpins

3. Locking hook

4. Attachment

Maintenance - Every 10 hours

78 4812325555EN 2018-02-08

Check the brakes oil level

Check daily if the oil level is within the max. and min. marks. Open the brake oil tank (1) under the plastic cap, on the right

side of the steering column. Next, fill with hydraulic oil up to the tank's maximum level, if it is

under the min. mark.

Clean the coarse filter

The coarse filter is inside the frame' upper compartment, on the right side of the machine.

To clean the coarse filter (1), open the drain cock (2) of the filter and let the dirt run out.

If necessary, close the cock (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 the system to check if it works correctly.

Another drain cock (5) is under the water tank, on the left side of the front of the frame. It can be used to drain the water tank and the pumping system.

It is also possible to install an extra pump if the standard fails to work.

To drain the complete sprinkler system, refer to "Draining the sprinkler system", in the section "Maintenance - Every 2,000 hours".

Fig. – Pump system, front frame, right side

1. Coarse filter

2. Drain cock

3. Cock

4. Water pump

5. Extra cock

Fig. - Brakes oil tank

1. Oil tank

2. Filling plug

Maintenance - Every 10 hours

2018-02-08 4812325555EN 79

Check the alternator belt tension

Use the pressure or Burroughs type gauge to check the belt tension.

 The new belt tension shall be 200 lb (890 N).  The old belt tension shall be 80 – 160 lb (360 – 710 N).

NOTE: The belt is considered used after 10 or more minutes of

use.

NOTE: This procedure is not applied in belt automatic

tensioners.

If the used belt tension is under the minimum value, tighten it to the maximum 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 pump (2), make sure all

the sediments were removed. For further information, refer to the Engine Manual instructions.

3. When only clean fuel is coming out of the filter, close the

drain plug.

TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment.

Fig. - Alternator belt tension

Fig. – Fuel tank

1. Drain plug

2. Hand-operated pump

Maintenance - Every 50 hours

80 4812325555EN 2018-02-08

Weekly (Every 50 hours of operation)

Park the roller on a level surface.

When checking and adjusting the machine, always turn off the engine and make sure the forward/backward lever is in the neutral position.

When the engine is off in enclosed places, make sure there is a good ventilation, to prevent carbon monoxide poisoning.

Replace the Diesel engine oil

The engine oil drain plug is on the rear of the machine, on the right side. Its access can be found when opening the panel in front of the exhaustion duct.

Drain the oil when the engine is still hot and put a container with minimum capacity of 3.69 gal (14 liters) under the plug.

Be extremely careful when draining the oil. Use gloves 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 come out to the container and when the operation is done, fix the drain plug (3) back to its place and fit the hose (2) back again.

3. Next, tighten the hexagon nut.

TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment.

Always fill with new oil. For correct grade oil information, refer to the Lubricant specifications or the Engine Manual Instructions. Fill according to the oil volume necessary to the engine. Check the dipstick to know if the volume is correct and before carrying out the operation, let the engine in idle for a few minutes and turn it off.

1 3

Fig. - Drain plugs

1. Hexagon nut

2. Hose

3. Drain plug

Maintenance - Every 50 hours

2018-02-08 4812325555EN 81

Replace the Diesel engine oil filter

Never perform any maintenance work under the machine while the engine is still operating. Always park the roller on a flat and safe place and chock the tires.

The oil filter (1) is on the right side of the engine compartment. Refer to the Engine Instructions Manual to obtain information

about the oil filter replacement.

Check and replace the main air filter

Replace the main filter element when the corresponding warning light on the instrument panel comes on and the engine is in the maximum speed.

1. Release the clamps (1), take off the cap (2) and the main filter (3). Do not take off the backup filter (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 order.

4. Check if the dust valve (6) is in good conditions and replace it, if necessary.

5. When fitting the cap, make sure the dust valve is positioned downwards.

To clean the air filter, follow the instructions below:

1. Wipe inside the cap and the filter housing.

2. Wipe also both outlet pipe surfaces, as shown in figure.

Check if the hoses clamps between the filter housing and the intake hose are tighten and if the hoses are intact. Check the entire hose system, all the way to the engine.

Fig. – Air filter

1. Clamps

2. Locking hook

3. Main filter

4. Backup filter

5. Filter housing

6. Dust valve

Fig. Inside the Outside the outlet pipe outlet pipe

5 4 1

Fig. – Engine compartment

1. Oil filter

Maintenance - Every 50 hours

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Check and replace the secondary air filter

Replace the backup filter when the main air filter is replaced for the third time.

To replace the backup filter for a new one, follow the instructions below:

1. Remove the old backup filter (1) from the holder, 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 the left side of the engine compartment.

1. Unscrew the bottom of the filter and drain the water. Next, screw the unit back in its place.

2. Fit the fuel filter in the correct place, turn on the engine and check if the filter is well sealed.

Fig. – Air filter

1. Backup filter Fig. – Engine compartment

1. Filter

Maintenance - Every 50 hours

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Replace the hydraulic oil filters

The hydraulic filters are located on the left side of the engine compartment, behind the battery disconnected.

TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment. The filter is disposable and cannot be cleaned.

1. Open the hydraulic oil tank cap (1).

2. Clean carefully the sealed surface on the filter holder.

3. Apply a thin layer of clean hydraulic oil on the rubber gasket of the new filter.

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. Refer to the section "Every 10 Hours" to obtain further information.

6. Turn on the engine and check if the filter is well sealed.

Check the tires air pressure

To check the pressure, use an air pressure gauge. The pressure in all the tires must be the same.

To know the recommended pressure values, refer to the "Technical Specifications" section.

When replacing the tires, it is important that all of them have the same original diameter and width, otherwise they can slide into the wheel or make their installation impossible.

Fig. - External/internal wheels

1. Air valve

Fig. - Hydraulic oil tank

1. Tank cap

2. Sight glass

Maintenance - Every 50 hours

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Lubricate the upper/lower pivot bearing

1. Lubricate the grease fitting of the upper pivot bearing (1) and the grease fitting of the lower pivot bearing (2) by operating the grease gun manually with five pump strokes.

2. Use the grease according to the lubricant specifications recommended by DYNAPAC.

Replace the wheel gear oil

Be extremely careful when draining the oil. Use gloves and protective goggles 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 plug (1) and the filling plug (2) to evacuate the air. Allow all the oil to drain out to the container and refit the plugs.

TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment.

Fig. - Pivot bearings

1. Upper pivot bearing grease fitting

2. Lower pivot bearing grease fitting

Fig. - Wheel gear

1. Drain plug

2. Filling plug

Maintenance - Every 50 hours

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Check the air conditioning (if equipped)

Park the roller on a level surface.

When checking and adjusting the machine, always turn off the engine and make sure the forward/backward lever is in the "P" position.

With the machine working and with the aid of the sight glass (1), check if there are no visible bubbles on the drying filter.

The filter is located on the upper rear part, on the cab's roof. If there are visible bubbles, it indicates 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 condenser element (3), located on the rear of the cab's roof.

Check and lubricate the edge cutter (if equipped)

Refer to the Operation section to obtain more information about how to work with an edge cutter.

Lubricate both points indicated in the figure. Recommended grease shall be used to lubricate it. Lubricate all the pivot points, with 5 grease gun applications

each.

Fig. - Edge cutter

1. Lubricating point

2. Lubricating point

Fig. – Drying filter

1. Sight glass

2. Filter holder

3. Condenser

Maintenance - Every 50 hours

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Monthly (Every 250 hours of operation)

Park the roller on a level surface.

When checking and adjusting the machine, always turn off the engine and make sure the forward/backward lever is in the neutral position.

When the engine is off in enclosed places, make sure there is a good ventilation, to prevent carbon monoxide poisoning.

Replace the Diesel engine oil

The engine oil drain plug is on the rear of the machine, in the right side. Its access can be found when opening the panel in front of the exhaustion duct.

Drain the oil when the engine is still hot and put a container with minimum capacity of 3.69 gal (14 liters) under the plug.

Be extremely careful when draining the oil. Use gloves 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 come out to the container and when the operation is done, fix the drain plug (3) back to its place and fit the hose (2) back again.

3. Next, tighten the hexagon nut.

TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment.

1 3

Fig. - Drain plugs

1. Hexagon nut

2. Hose

3. Drain plug

Maintenance - Every 250 hours

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Replace the Diesel engine oil filter

Never perform any maintenance work under the machine while the engine is still operating. Always park the roller on a flat and safe place and chock the tires.

The oil filter (1) is on the right side of the engine compartment. Refer to the Engine Instructions Manual to obtain information

about the oil filter replacement.

Check and clean the hydraulic water and Diesel engine water coolers.

1. Make sure the air flow through the 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 possible, clean the cores on the opposite direction to the fan air flow. Every time you clean the core, cover the electric and electronic components.

Check the air conditioning (if equipped)

Check the coolant hoses and connections and make sure there is no sign of oil. If there is oil, maybe there is a possible leakage as well.

Fig. - Air conditioning

1. Coolant hoses

2. Condenser element

Fig. - Coolers

1. Recharge air cooler

2. Water cooler

3. Hydraulic oil cooler

4. Cooler grid

Fig. – Engine compartment

1. Oil filter

Maintenance - Every 250 hours

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Check the batteries

When checking the batteries, never smoke or allow sparks or flame next to them. Usually the batteries produce explosive gases which can cause severe injuries.

The batteries are sealed and maintenance-free.

Never use open flames when checking the electrolyte level. When the alternator is being charged, an explosive gas is formed in the battery.

When removing the battery, first remove the negative pole (-). But when installing it, connect first the positive pole (+). Avoid the contact of both battery posts with metallic tools or the accidental contact between the positive post with the machine's frame, otherwise short circuits can happen.

1. Open the right cap of the equipment, where the batteries are located.

2. Clean the external caps of the 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 check the electrolyte level, which

must be at least 10mm above the plates. If necessary, fill the level with the battery fluid solution. If the operation room temperature is below 32 F (0ºC), allow the engine to work for a few minutes after the level is filled, otherwise the solution may freeze.

4. Check if the cell cap breather is not obstructed, and clean it,

if necessary.

5. The battery posts must be kept clean and the contacts must

have their cables tightened. If they are oxidized, clean them with a solution of water and sodium bicarbonate and apply a layer of petroleum jelly to prevent a new corrosion process.

TAKE CARE OF THE ENVIRONMENT: Return the used battery, according to the CONAMA 257/99 (06/30/1999) resolution. Every client or final user has the obligation to return the used battery to a sales point.

Maintenance - Every 250 hours

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Lubricate the upper/lower pivot bearing

1. Lubricate the grease fitting 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 specifications recommended by DYNAPAC.

Replace the air dryer filter

To replace the filter, empty the compressed air and unscrew the cartridge with suitable tool. Clean and grease the sealing surfaces and the fixing screw. Manually screw the cartridge until there is resistance, and tighten half turn.

Fig. – Air dryer filter

1. Cartridge

Fig. - Pivot bearings

1. Upper pivot bearing grease fitting

2. Lower pivot bearing grease fitting

Maintenance - Every 500 hours

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Quarterly (Every 500 hours of operation)

Park the roller on a level surface.

When checking and adjusting the machine, always turn off the engine and make sure the forward/backward lever is in the neutral position.

When the engine is off in enclosed places, make sure there is a good ventilation, to prevent carbon monoxide poisoning.

Replace the engine fuel filter

The 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 fuel filter in the correct place, turn on the engine and check if the filter is well sealed.

Replace the air dryer filter

Fig. – Air dryer filter

1. Cartridge

Fig. – Engine compartment

1. Filter

Maintenance - Every 1,000 hours

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Check the hydraulic oil tank cover

To check the hydraulic oil tank cap:

1. Unscrew the tank cap and check if it’s obstructed. The air must flow freely throughout the cap in both ways.

2. If one way is obstructed, wash the filter with a small portion of Diesel oil and use compressed air until the obstruction is eliminated or replace the cap for a new one.

Always use protective goggles when working with compressed air.

Lubricate the seat bearing

Keep in mind that the chain is a vital part of the steering mechanism.

To lubricate the seat bearing:

1. Remove the cap (2) to access the grease fitting (2). Lubricate the operator's seat rotation 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 with grease.

4. If the chain gap is next to the sprocket wheel (5), loose the

bolts (6) and move the steering column forward. Tighten the bolts and check if the chain is with the proper gap.

5. Do not tension the chain too tightly. It should be possible to

move the chain about 0.4 inches (10 mm) to the side with a forefinger/thumb at the marking (7) in the seat frame. Fit the chain lock at the bottom.

If it is hard to move the seat, lubricate it more frequently than the instructions specified in this manual.

2 3 4 5 6

Fig. - Seat bearing

1. Locking hook

2. Grease fitting

3. Steering column chain

4. Slide rails

5. Sprocket wheel

6. Adjusting bolt

7. Marking

Fig. - Left side of the frame

1. Tank cap

Maintenance - Every 1,000 hours

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Lubricate the upper/lower pivot bearing

1. Lubricate the grease fitting 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 specifications recommended by DYNAPAC.

Lubricate the pivot bearing

1. Lubricate each grease fitting (1) with five hand-operated strokes.

2. Use the grease according to the lubricant specifications recommended by DYNAPAC.

Fig. - Rear cylinder

1. Grease fittings

Fig. - Pivot bearings

1. Upper pivot bearing grease fitting

2. Lower pivot bearing grease fitting

Maintenance - Every 1,000 hours

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Semiannually (Every 1,000 hours of operation)

Park the roller on a level surface.

When checking and adjusting the machine, always turn off the engine and make sure the forward/backward lever is in the neutral position.

When the engine is off in enclosed places, make sure there is a good ventilation, to prevent carbon monoxide poisoning.

Replace the main air filter

Replace the air filter (1) every 1,000 hours of operation, even if it was not cleaned 5 times. For further information about the filter's replacement, refer to the "Maintenance - Every 50 Hours of Operation" section.

If the filter is not replaced when 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 new one when you clean or replace the main filter for the fifth time. The secondary air filter shall not be cleaned.

To replace it for a new one, follow the instructions below:

1. Remove the old backup filter (1) from the holder, install a new one and fix the components in the reverse order used to remove them.

Replace the air dryer filter

Fig. – Air filter

1. Main filter

Fig. – Air filter

1. Secondary filter

Fig. – Air dryer filter

1. Cartridge

Maintenance - Every 1,000 hours

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Replace the hydraulic oil filters

The hydraulic filters are located on the left side of the engine compartment, behind the battery switch.

1. Open the hydraulic oil tank cap (1).

2. Clean carefully the sealed surface on the filter holder.

3. Apply a thin layer of clean hydraulic oil on the rubber gasket of the new filter.

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. Refer to the section "Every 10 Hours" to obtain further information.

6. Turn on the engine and check if the filter is well sealed.

Replace the cab air filter

There is an air filter (1) on the left side of the cab. To replace it, follow the instructions below:

1. Open the protective cap.

2. Unscrew the bolts (2) and remove the entire holder. Remove the filter element and replace the filter for the new one.

3. If the machine works in places with excessive dust, it may be necessary to replace the filter more frequently.

Fig. - Hydraulic oil tank

1. Tank cap

2. Sight glass

Fig. - Front of the cab.

1. Air filter (1x)

2. Bolt (2x)

1 2 2

Maintenance - Every 1,000 hours

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Lubricate the upper/lower pivot bearing

1. Lubricate the grease fitting 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 specifications recommended by DYNAPAC.

Replace the wheel gear oil

Be extremely careful when draining the oil. Use gloves and protective goggles 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 plug (1) and the filling plug (2) to evacuate the air. Allow all the oil to drain out to the container and refit the plugs.

TAKE CARE OF THE ENVIRONMENT: All the used oil shall be properly stored for subsequent disposal. Do not dispose of oil on the ground, sewage system or other place which can harm the environment.

Fig. - Wheel gear

1. Drain plug

2. Filling plug

2 1 2

Fig. - Pivot bearings

1. Upper pivot bearing grease fitting

2. Lower pivot bearing grease fitting

Maintenance - Every 1,000 hours

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Refill the wheel gear oil

Drive the machine until the filling plug is in the right position. The opening must be a little above the horizontal position in order to make the filling easier.

Unscrew the filling plug (1) and also the level plug (2), so the air can be released. Apply the oil only from the external part of the gears.

Fill with 2.11 gal (8 liters) of new transmission oil. Refer to 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.

Check the wheel gear oil level

Drive the machine until the level plug (2) is in the horizontal position.

Clean the place around the level plug (2) and then unscrew it. Check if the oil level reaches the bottom of the plug opening. If the level is low, fill with new transmission oil until it reaches

the correct level. Refer to the lubricant specifications. Clean and fix the plugs again.

Fig. - Refilling the wheel gear oil

1. Filling plug

2. Level plug

Dynapac CP2100, CP2100W, CP2700 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual