CPR-series (Cricket Pitch Roller) Ride-On ROLLERS Model: CPR 120-2.5 Version: Feb. 2017 Page1
INDEX to pages SECTION 1 GETTING TO KNOW YOUR MACHINE & OPERATING INSTRUCTIONS 1. Safety 1. Foreword and Basic Overview of the machine Page 3-4 2. Basic description and intended use of the machine Page 5 3. Limitations of intended use of the machine Page 5 4. Lay-out of Controls Page 6-7 5. Safety: Basics and requirements for machine operator Page 8 6. Lifting and tying down the machine Page 9 2. Operation of the machine 1. Starting and stopping of the engine Page 10 2. Moving machine forward / backwards Page 11 3. Selecting the HIGH or LOW speed range Page 11 3. Tips for getting best compaction results 1. General Hints and Tips for the operator Page 12 2. Working on slopes and near embankments that can collapse Page 13 4. Daily Maintenance checks / actions Page 14 SECTION 2 SERVICING SCHEDULE / INSTRUCTIONS 1. Servicing General, and Servicing the Roller Page 15 19 2. Preparing the machine for being towed Page 20-21 3. Servicing KUBOTA engine Page 22-23 SECTION 3 ANNEXES Technical Data Page 24 Hydraulic Diagram Page 25 Notes Page 26 Page2
Foreword This Manual is intended to familiarize the users of STAMPEDE Ride-On Rollers with the machine, its proper and safe operation, daily maintenance requirements and will guide the customer s servicing staff through regular Servicing and adjustments as required for this machine. The information contained in this Manual is specific to current production machines at time of publication of this Manual and may be different from previous or future versions of the equipment. STAMPEDE reserves the right to make technical changes to their equipment without notice. Further details may be obtained at any time from STAMPEDE s Service Centre. Page3
Overview of the machine Protection Structure / Sunshade Forward / Reverse Control Lever HIGH / LOW range Selection Lever Control Station with Instrument Panel and Control Switches/Levers Lifting and tie-down Points Drive Motors Page4
1. Description of the machine, intended use and lay-out of the controls 1.1. Basic description of the machine The machine is a double-drum Ride-On Tandem Roller, powered by a water cooled Kubota Diesel engine. The machine s drive systems for the propulsion of the machine, as well as for its steering are hydro-static, powered by engine-mounted hydraulic pumps. Both drums are permanently driven by a hydraulic motor directly mounted on each drum. The system allows the operator to operate the machine at infinitely variable speeds in both directions. The machine s Drive system incorporates a HIGH / LOW Speed Range selection facility, which enables the machine to negotiate steep inclines and berms. The machine is equipped with an automatic Parking Brake which will mechanically prevent the machine from moving backwards or forward, as soon as the engine has stopped. As an Option the Parking Brake can also be manually engaged by depressing the red Emergency Stop Button located on the instrument panel. This procedure, however, is reserved for EMERGENCIES ONLY and must not be used for normal stopping of the engine!!! There is provision for manual release of the brake, should this be required. The machine s upper frame is isolated from the drums by Rubber Buffers. The machine is equipped with a Protection Structure / Sunroof which will protect the operator in the event of the machine falling onto its side. 1.2 Intended use of the machine The machine is intended to be used for compaction of all types of materials / surfaces occurring on Cricket Pitches. 1.3 Limitations of intended use of the machine The machine may not be used on hard surfaces such as existing asphalt, concrete, etc. Page5
1.4 Lay-out of the Controls and Instrumentation 1.4.1 Instrument Panel The steering wheel as well as all operational controls and instrumentation are located within the field of vision and within easy reach of the operator and are described below. 1 3 2 5 7 6 4 1 Hour Meter 5 Warning Light: Alternator Charging 2 EMERGENCY STOP Button (Option) 6 Warning Light: Engine Oil Pressure 3 Fuel Tank Gauge 7 Warning Light: Glow Plug active 4 Radiator Coolant Temperature gauge In an EMERGENCY the Emergency Stop Button may be activated by pressing it down this will kill the engine instantly, engage the Parking Brake and will stop all functions of the machine. This procedure is reserved for EMERGENCIES ONLY and must not be used for normal stopping of the engine!!! When any one of the Warning Lights comes on during operation, STOP machine immediately and switch off the engine report problem to Supervisor / Foreman Page6
1.4.2 Other Controls 1 2 1 Ignition / Starter Switch The switch has 4 positions: A Ignition OFF B Ignition ON C START position D GLOW PLUG (engine pre-heating) Do not engage Pre-Heat for more than 10 seconds D A B C A B 2 Battery Disconnector Switch (Master Switch) The switch has 2 positions: A (shown) ON position B OFF position (Battery is disconnected) Drive Lever Moving the Lever forward >>> machine moves FORWARD Moving the Lever backward >>> machine moves BACKWARDS Lever in neutral >>> machine STOPS 1 2 Speed range Selector Lever HIGH range setting (1) For normal operation on reasonably flat surfaces LOW range setting (2) For extra climbing power when negotiating steep inclines Page7
Articulation Lock 2 1 Transport Lock Pin Whenever the machine is loaded on a transport vehicle, insert the Locking Pin into position (1) and secure with hairpin clip pin as shown in picture When not in use store Locking Pin in position (2) Safety 2.1 Basic requirements and Do s & Don ts for the machine operator The machine must be started and operated only by suitably qualified and physically able adults who have acquainted themselves with and do understand this Manual or have been properly trained and instructed on the safe and correct operation of the machine, in line with this Manual. Operation of the machine by under aged youngsters or persons under the influence of drugs/alcohol is specifically prohibited. The operator must at all times have the Seat Belt fastened and properly tightened whenever the machine is in motion a loose Seat Belt may result in injury or death of the operator in case of an accidental fall of the machine. No passengers are allowed on the Roller at any time. Take extra care when ground conditions (condition and inclination of surface) change machine could slide unexpectedly. Be extra cautious near edges of trenches, pits or embankments, where the ground could collapse unexpectedly. Never start the engine when not seated in the driver s seat danger to be driven over by machine! Be careful when opening the bonnet there could be hot areas (exhaust, radiator, etc.) and there could be moving parts Do not leave the machine unattended with the engine running When machine needs to be parked on an incline, always place a wedge or some rocks in front of the drums Page8
2.2 Lifting the machine and tying it down for transport Lifting and tying-down not permitted at any other points on the machine! Always use suitable and adequately rated Lifting Gear when lifting the machine! Never stand below / near suspended loads! Page9
2. Operation of the machine 3.1 Starting and stopping of the engine 3.1.1 Visual checks before starting the engine Check engine oil level (on dip stick) (if necessary top up with SAE 15W40) Check the coolant level on the radiator Check hydraulic oil level Check fuel level (Fuel Gauge) Ensure that the Drive Lever is in its NEUTRAL position Ensure that the Rotating Beacon is working (check with Ignition switched ON) Ensure that the Reverse Buzzer is functioning (move Control Lever into REVERSE with Ignition ON) 3.1.2 Starting the engine 1.1. If fitted, ensure that the Emergency Stop button is in the OPERATING position (raised position) 1.2. Turn Master Switch into ON position 1.3. If engine is cold: Engage the Pre-Heat function, see below (max. 10 seconds) 1.4. Turn Ignition Key clockwise to start the engine the engine will accelerate to full throttle speed automatically 1.5. Check instruments / warning lights on the dashboard for any unusual readings or indications When the engine is cold it is good practice to pre-heat the engine (by engaging the Glow Plug for a few seconds before starting) and then letting the engine run for 2 3 minutes before engaging any load this will give the engine and the hydraulic oil a chance to warm up to reasonable operating temperature. Page10
3.1.3 Stopping the engine Turn Ignition Switch anti-clockwise to switch the engine OFF When leaving the machine or parking it, it is good practice to turn the Master Switch into the OFF position In an EMERGENCY the Emergency Stop Button may be activated by pressing it down this will kill the engine instantly, engage the Parking Brake and will stop all functions of the machine. This procedure is reserved for EMERGENCIES ONLY and must not be used for normal stopping of the engine!!! 3.2 Moving the machine forward and backwards The forward / reverse movement of the machine is controlled with the hand control lever situated on the RH side of the control station (1) 1 Pushing the lever FORWARD will make the machine move FORWARD, pushing it BACKWARDS will make the machine move BACKWARDS the further the lever is pushed, the faster the machine will move in the desired direction When changing direction, do this in a SLOW movement of the lever to allow the machine to change direction SMOOTHLY never go from fully forward into fully reverse! The Control Lever is designed as a Dead Man s Handle it will automatically return into its NEUTRAL position as soon as the operator lets go of the Lever, and the machine will automatically come to an immediate stop. 3.3 Selecting the HIGH or LOW speed range For normal operation on reasonably flat grounds, the range selector lever is to be placed in the HIGH position (1) 1 2 For negotiating of steep inclines or berms the selector lever is placed into LOW position (2). In this setting the machine will have increased (double) climbing ability but with reduced (half) propulsion speed. Page11 The selector lever should only be shifted when the machine is stationary.
4. Tips for getting best compaction results 4.1 General Hints and Tips for the operator Due to the delicacy of a perfect surface of the Cricket Pitch, the instructions given by the Captain / Umpire will always be final to the operator of the Cricket Pitch Roller. Below are a few general tips for correct operation of the STAMPEDE Cricket Pitch Roller. o To get good compaction results, you always need to run the machine SLOWLY as a rule-of-thumb this means about half of normal walking speed o When starting a run or when changing direction of the machine, do this gently, to avoid spinning of the rollers on the ground. Gentle movement of the Control Lever will give you smooth acceleration and deceleration of the machine o Never change direction of the machine by going from full speed in the one direction to full speed in the reverse direction. o Never do major articulation (steering) movements when the machine is stationary, this will result in a scuffing action of the drums on the surface. o Overlapping during the rolling process and number of passes will be determined by the Captain / Umpire but should then be done in a consistent method o Never run machine over hard materials, (e.g. concrete, hard asphalt, etc.) for travelling over such areas and for longer distances do this with care and do not exceed normal walking speed Page12
4.3 Working on slopes and near embankments that can collapse Always operate machine UP and DOWN slopes or hills never from side to side max. max. Always work your Roller TOWARDS the edge of the embankment with the operator out of the danger zone; see below Page13
4. Daily Maintenance checks / actions The listing below shows the routine Daily Maintenance items, which may be performed by the operator Clean the machine, in particular any build-up of soil or asphalt in the area of the drums Refuel the machine preferably this is done at the end of the shift to avoid entry of water into the fuel tank due to overnight condensation Check the engine oil level must be between the MIN and MAX marks of the dipstick, when machine is parked on level ground Check the hydraulic oil level at the sight glass on the hydraulic tank must be at least ¾ full when machine is cold Check the Airfilter element, and clean as required handle and re-install with absolute care! Check for any loose bolts or nuts, oil leaks and any unusual noises report any unusual findings to Supervisor / Foreman Every week: check Water Trap and drain water sediment, as required CLEAN MACHINES ALWAYS WORK BETTER Page14
1. Servicing General, and Servicing the Roller 1.1 General Due to the inherent nature of danger during the servicing / adjustments to Construction machinery, all servicing should be performed by suitably qualified persons only, and with the use of suitable tools and in appropriate locations with required facilities. Should specific details or advice be required, this should be obtained from STAMPEDE s Service Centre personnel. Service items and spare parts should always be obtained from STAMPEDE, where they are guaranteed for consistent quality and fitness for purpose. 1.2 Roller Servicing Schedule The following table lists all regular Service / Routine Adjustment items that need to be performed at the specified intervals and with the specified servicing consumables Item # Service item Service Interval Service Consumable Quantity / Spec. 1 Lubrication of the Articulation Joint 1 month EP2 grease 2 nipples 2 Lubrication of the Steering Cylinder 1 month EP2 grease 2 nipples 3 Replacement of Hydraulic Filter Element in the return-line filter 12 Part No. OMTPR100-2-GN 1 (on top of hydraulic tank) months 4 Replacement of Breather Filter Element (on top of hydraulic tank) 12 months Part No. OMTPR100-2-AB 1 5 Hydraulic oil change 24 months Hydraulic Oil grade 68-ISO *) 6 Cleaning (or replacement) of Suction 24 Part No. Strainers in hydraulic tank months RR0120550121 1 7 Water Trap / Primary Fuel Filter Part No. a) Cleaning of the Water Trap 1 month KS152143560L 1 b) replacement of filter in the bowl 3 months 8 Replacement of secondary fuel filter 3 months Pt. No. 40089401 1 9 Fine adjustment of neutral position of the Control Cable / Hydr. Pump when required 10 Preparing machine for being towed when required 75 litres *) All oils must be virgin oils from reputable manufacturers; recycled oils are not approved Page15
#1 - Lubrication of Articulation Centre Joint 2 grease nipples (1) + (2) are located on the vertical portion of the housing of the assembly Clean area of the grease nipples Apply grease pump nozzle and inject 4 5 shots into each nipple 1 2 #2 - Lubrication of Steering Cylinder Steering Cylinder is located on the LH side of the front section of the frame, just above the floor plate Clean area of the grease nipples (1) + (2) Nipple (1) is accessible from Articulation Centre Joint Apply grease pump nozzle and inject 4 5 shots to each nipple 1 2 #3 Replacement of Hydraulic Filter Element Open the Hydr. Oil Filter cap by removing the 3 screws (1) Lid is spring-loaded! Lift out Filter Element (2) and replace with new one (Part No. OMTPR100-2-GN) - avoid spillage of hydraulic oil Insert the new Filter Element (2) into place Ensure O-ring (3) is in good condition and in place Install the spring (4) on top of the element and re-install filter cap whilst holding it down Check oil level at oil sight glass on the tank - level should be near top of gauge when correct oil quantity has been filled in 3 2 1 4 Page16
#4 - Replacement of Hydraulic Tank Breather Disconnect return-line hose Remove Filter Body by undoing 2 screws (5) Screw out the now exposed Breather (6) and replace with new one (Part No. OMTPR100-2-AB) Re-assemble in reverse order, ensure O-rings are in good condition and in place 5 6 #5 Hydraulic oil change Open the Hydr. Oil Filter cap by removing the 3 screws (1) Lid is spring-loaded! Drain all the oil through the Drain Plug at the bottom of the Hydraulic Tank Perform cleaning / replacement of Suction Strainers as per item #6 below Fill in fresh oil through open top of filter housing using suitable clean funnel - for oil type and quantity ref. to table above Check oil level at oil sight glass (2) - level should be near top of gauge now 1 2 Page17 #6 Cleaning / Replacement of hydraulic oil Suction Strainers (to be done in conjunction with a hydraulic oil change, i.e. when hydraulic tank is empty) Remove the square cover/s from hydraulic tank Unscrew the suction filters by hand inside tank - they are located inside the hydraulic tank Clean out the suction element in petrol, using compressed air from inside to outside or replace if any damage is seen Re-install both suction filters, hand tight Check inside of tank for any dirt / debris and remove Re-install square covers, ensure that gasket is in tact Re-fill tank with Hydraulic Oil, see item #5 above
#7 - Cleaning the Water Trap in fuel line, and Replacement of Primary Fuel Filter Element The filter is a combined Stop Valve / Water Trap / Primary fuel filter and is located on LH side wall in engine compartment near engine fuel pump Close the Stop Valve (1) by turning it clock wise to position (A) Unscrew the transparent bowl at its ring (2) on top Drain any water / sediment and clean out the bowl properly Replace Filter Element (3) with new one (located inside bowl) Re-install the fuel bowl and open Stop Valve Air-bleed the fuel line at Fuel pump A 2 1 3 #8 Replacing the Secondary Fuel Filter 2 Close the Stop Valve (1) by turning it clock wise Open clamps on In-line Fuel Filter (2) and replace it with a new one Open Stop Valve Air-bleed the fuel line at Fuel pump 1 Page18
#9 - Fine adjustment of neutral position of the Hydraulic Drive Pump / Control Cable (only required if the machine is creeping when Forw/Rev lever is in neutral) With the engine switched OFF, check for full movement of the Control Cable 1 Ensure that the Control Cable is moving freely, if not, service the cable and/or control lever For adjustment of the neutral position of the pump actuation lever loosen both nuts (1) on the Control Cable at the mounting bracket Do adjustment by turning both nuts forward or backwards until proper neutral position is achieved, then lock both nuts again in this position Note: only small adjustments are required! Start engine and check, repeat if necessary Page19
#10 Preparing the machine for towing In the event of the machine needing to be towed, the machine s drum drive system must be set to free wheeling which consists of 2 steps as described below. 13.1 Manually releasing the Parking Brake The machine is equipped with a Parking Brake which is incorporated in the drive motor on each drum. The Parking Brake is applied automatically when the engine comes to a stand-still or when the EMERGENCY STOP Button is depressed. To manually release the brake, do the following: 1. Remove the 2 plugs (1) to get access to the release screws below 2. Insert Allan key and press and turn each release screw (2) in until its threads catch in the brake plate. Tighten each screw until the spring on each screw is fully compressed (at this point you will feel a substantial difference in the resistance to turn it) 3. Now, continue to tighten (turn clockwise) the two release screws to compress the brake plate springs. Alternate back-and-forth between the two screws, turning them approximately 45 at a time, until the drums are no longer blocked by the brake plate. The brake plate should release after having turned each screw approximately 120 in total. To test if the brake is free, manually turn the drum To undo the manual release of the Parking Brake, turn (anti clockwise) both release screws back into their original position and re-install the 2 plugs. Thereafter check for proper functioning of the Parking Brake. 2 1 See also diagram on next page Page20
1 2 13.2 Putting the hydraulic circuit into free wheeling mode Locate the By-Pass Lever (3) on the Drive pump, which you will find in position (A) Turn the Lever 90 into position (B) - the roller is now free wheeling A and can now be pushed / pulled 3 Use wheel chokes to prevent machine from rolling away! B To engage the drive again, turn the Lever back into position (A) Page21
2. Servicing KUBOTA engine The full servicing requirements and detailed information on servicing items for the engine are contained in the KUBOTA Manual supplied with the machine and can also be downloaded from http://www.manualslib.com/download/898046/kubota-d1005-e3bg.html. An extract is contained in this Manual below. Further details can at any time be obtained from STAMPEDE s Service Centre. KUBOTA Diesel model D722 Page22
When operating in areas with high dust loading, maintenance intervals should be reduced (halved), in particular Air Filter servicing/replacement and change of Engine Oil & Filter, and the replacement of the Fuel Filters. When operating in areas with high dust loading, maintenance intervals should be reduced (halved), in particular Air Filter servicing/replacement and change of Engine Oil & Filter, and the replacement of the Fuel Filters. Page23 Recommended for RSA
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Hydraulic Schematic / Diagram Page25
Notes: Page26