Atlas Copco CC424HF Instruction Manual
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Atlas Copco CC424HF Instruction Manual

Engine cummins qsb 4.5 iiia/t3
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Instruction manual
Instruction manual
Operating & Maintenance
Operating & Maintenance
4812273394.pdf
4812273394.pdf
Vibratory roller
Vibratory roller
CC424/524/624HF
CC424/524/624HF
CC4200/5200/6200
CC4200/5200/6200
Cummins QSB 4.5 (IIIA/T3)
Cummins QSB 4.5 (IIIA/T3)
Serial number
Serial number
10000320x0C002131 -
10000320x0C002131 -
10000322x0C000254 -
10000322x0C000254 -
10000324x0C000247 -
10000324x0C000247 -
Translation of original instruction
Translation of original instruction
Reservation for changes
Reservation for changes
Printed in China
Printed in China
Engine
Engine

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Summary of Contents for Atlas Copco CC424HF

  • Page 1 Instruction manual Instruction manual Operating & Maintenance Operating & Maintenance 4812273394.pdf 4812273394.pdf Vibratory roller Vibratory roller CC424/524/624HF CC424/524/624HF CC4200/5200/6200 CC4200/5200/6200 Engine Engine Cummins QSB 4.5 (IIIA/T3) Cummins QSB 4.5 (IIIA/T3) Serial number Serial number 10000320x0C002131 - 10000320x0C002131 - 10000322x0C000254 - 10000322x0C000254 - 10000324x0C000247 - 10000324x0C000247 -...

  • Page 3: Table Of Contents

    Table of Contents Introduction ..........................1 The machine ....................1 Intended use ....................1 Warning symbols..................1 Safety information ..................1 General ....................... 2 Safety - General instructions....................3 Safety - when operating ......................5 Slopes ......................5 Driving near edges ..................6 Safety (Optional) ........................
  • Page 4 Weights and volumes................16 Working capacity..................16 General ..................... 17 Hydraulic system..................18 Automatic Climate Control (ACC) (Optional)..........18 Tightening torque ..................19 Machine description ....................... 21 Diesel engine .................... 21 Electrical system ..................21 Propulsion system..................21 Brake system .................... 21 Steering system ..................
  • Page 5 "MAIN MENU" ................... 38 "USER SETTINGS" ..............39 "MACHINE SETTINGS".............. 40 "SERVICE MENU" ..............40 "ABOUT"..................42 Operator help when starting..............42 Operator help Workmode................42 Instruments and controls, cab ..............43 Function description of instruments and controls in the cab ..... 44 Using the cab controls................
  • Page 6 Starting the engine ..................54 Display when activating choice via the button set........55 Alarm descriptions..................56 Driving ........................57 Operating the roller ................... 57 Machine with gear change in separate spring-return switch (gear position switch)..............57 Interlock/Emergency stop/Parking brake - Check ........59 Pivotal steering (Optional).................
  • Page 7 Miscellaneous ........................67 Lifting ........................67 Locking the articulation ................67 Lifting the roller..................68 Lifting the roller with jack:................68 Unlocking the articulation ................69 Towing/Recovering....................69 Short distance towing with the engine running.......... 70 Short distance towing when the engine is inoperative......70 Towing the roller..................
  • Page 8 Diesel engine - Check oil level ..............87 Coolant level - Check ................88 Fuel tank - Refueling ................. 88 Hydraulic reservoir - Check fluid level............89 Water tank, Std - Filling................89 Sprinkler system/Drum Check ......................90 Cleaning the coarse filter ................90 Sprinkler system/Drum Cleaning of sprinkler nozzle ..............
  • Page 9 Air cleaner Checking - Change the main air filter............101 Backup filter - Change................102 Air cleaner - Cleaning....................103 Diesel engine Oil change ....................103 Engine Replacing oil filter..................104 The engine fuel filter - replacement/cleaning .......... 105 Drum - oil level Inspection - filling ..................
  • Page 10 Hydraulic reservoir cap - Check .............. 115 Rubber elements and attachment screws Check ...................... 116 Seat bearing - Lubrication ............... 116 Steering axle - Lubrication ..............117 Pivot bearing (Optional) - Lubrication............117 Fresh air filter - Replacing ............... 118 Air conditioning (Optional) - Overhaul ....................
  • Page 11 Hydraulic reservoir Fluid change.................... 128 Rubber elements and attachment screws Check ...................... 128 Seat bearing - Lubrication ............... 129 Steering axle - Lubrication ..............129 Watering system - Draining....................130 Water tank - Cleaning ................130 Steering joint - Check................131 Steering hitch - Tightening ..............
  • Page 12 2015-12-20 4812273394.pdf...

  • Page 13: Introduction

    Introduction Introduction The machine Dynapac CC424/524/624HF, CC4200/5200/6200 is a self-propelled vibratory tandem roller in the 10/12/13 tonnes class with 1730/1950/2130 mm (68/77/84 in) wide drums. It features power drive, brakes, vibration and timer controlled water sprinklers on both drums. A variety of different engine power settings, operator platforms, control possibilities and options makes the machine available in a lot of different configurations.

  • Page 14: General

    Introduction We recommend that the operator reads the We recommend that the operator reads the safety instructions in this manual carefully. safety instructions in this manual carefully. Always follow the safety instructions. Ensure Always follow the safety instructions. Ensure that this manual is always easily accessible. that this manual is always easily accessible.

  • Page 15: Safety - General Instructions

    Safety - General instructions Safety - General instructions (Also read the safety manual) The operator must be familiar with the contents of the OPERATION section The operator must be familiar with the contents of the OPERATION section before starting the roller. before starting the roller.
  • Page 16 Safety - General instructions 16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The 16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The noise level can vary depending on the equipment on the machine and the noise level can vary depending on the equipment on the machine and the surface the machine is being used on.

  • Page 17: Safety - When Operating

    Safety - when operating Safety - when operating Prevent persons from entering or remaining in Prevent persons from entering or remaining in the danger area, i.e. a distance of at least 7 m the danger area, i.e. a distance of at least 7 m (23 ft) in all directions from operating machines.

  • Page 18: Driving Near Edges

    Safety - when operating Driving near edges When driving near an edge, minimum 2/3 of the drum width must be on solid ground. When using pivotal steering, only one drum When using pivotal steering, only one drum should be allowed to move into the position should be allowed to move into the position shown in the picture.

  • Page 19: Safety (Optional)

    Safety (Optional) Safety (Optional) Air conditioning The system contains pressurized refrigerant. It is The system contains pressurized refrigerant. It is forbidden to release refrigerants into the forbidden to release refrigerants into the atmosphere. atmosphere. Work on the refrigerant circuit is only to be carried Work on the refrigerant circuit is only to be carried out by authorized companies.

  • Page 20: Working Lights - Xenon

    Safety (Optional) Working lights - Xenon Warning, high voltage! Warning, high voltage! The working lights of the Xenon type have a secondary high-voltage source. Work on the lighting should only be conducted by an authorized electrician and with the primary voltage disconnected.

  • Page 21: Special Instructions

    Special instructions Special instructions Standard lubricants and other recommended oils and fluids Before leaving the factory, the systems and components are filled with the oils and fluids specified in the lubricant specification. These are suitable for ambient temperatures in the range -15°C to +40°C (5°F - 105°F).

  • Page 22: High Pressure Cleaning

    Special instructions High pressure cleaning Do not spray directly onto electrical components. Do not use high pressure cleaning for Do not use high pressure cleaning for dashboard/display. dashboard/display. The Electrical Drive Control and the computer The Electrical Drive Control and the computer box may not be washed with high pressure box may not be washed with high pressure cleaning and not at all with water.

  • Page 23: Jump Starting (24V)

    Special instructions When fitting batteries, always connect the When fitting batteries, always connect the positive cable first. positive cable first. Dispose of old batteries in an environmentally Dispose of old batteries in an environmentally friendly way. Batteries contain toxic lead. friendly way.
  • Page 24 Special instructions 2015-12-20 4812273394.pdf...

  • Page 25: Technical Specifications

    Technical specifications Technical specifications Vibrations - Operator station (ISO 2631) The vibration levels are measured in accordance with the operational cycle described in The vibration levels are measured in accordance with the operational cycle described in EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched on, on soft polymer material and with the operator’s seat in the transport position.

  • Page 26: Dimensions, Side View

    4990 4990 Length with extra water tanks *) Length with extra water tanks *) 5400 5400 Thickness, drum amplitude, Nominal Thickness, drum amplitude, Nominal CC424HF, CC4200 CC424HF, CC4200 0.71 0.71 CC524/624HF, CC5200/6200 CC524/624HF, CC5200/6200 0.79 0.79 *) option, applies to CC524/624HF, CC5200/6200...

  • Page 27: Dimensions, Top View

    Technical specifications Dimensions, top view Dimensions Dimensions Machine width, standard Machine width, standard CC424HF, CC4200 CC424HF, CC4200 1890 1890 74.5 74.5 CC524HF, CC5200 CC524HF, CC5200 2110 2110 83.1 83.1 CC624HF, CC6200 CC624HF, CC6200 2290 2290 90.2 90.2 Machine width, asymmetrical...

  • Page 28: Weights And Volumes

    Technical specifications Weights and volumes Weights Weights Service weight Service weight without ROPS without ROPS ROPS ROPS (EN500) (EN500) CC424HF, CC4200 CC424HF, CC4200 (kg) (kg) 9 900 9 900 10 200 10 200 10 400 10 400 (lbs) (lbs) 21 830...

  • Page 29: General

    (CE-2006) (CE-2006) (CE-2006) (CE-2006) CC424HF, CC4200 CC424HF, CC4200 54 (kN) 54 (kN) 31 950 31 950 22 275 22 275 20 925 20 925 12 150 (lb) 12 150 (lb) CC524HF, CC5200...

  • Page 30: Hydraulic System

    Technical specifications Electrical system Electrical system Battery Battery 24V (2x12V 74Ah) 24V (2x12V 74Ah) Alternator Alternator 24V 45A 24V 45A (IIIA/T3) (IIIA/T3) Fuses Fuses See the Electrical system section - See the Electrical system section - fuses fuses Bulbs (if mounted) Bulbs (if mounted) Watt Watt...

  • Page 31: Tightening Torque

    Technical specifications Tightening torque Tightening torque in Nm for oiled or dry bolts tightened with a torque wrench. Metric coarse screw thread, bright galvanized (fzb): STRENGTH CLASS: 8.8, Oiled 8.8, Oiled 8.8, Dry 8.8, Dry 10.9, Oiled 10.9, Oiled 10.9, Dry 10.9, Dry 12.9, Oiled 12.9, Oiled...
  • Page 32 Technical specifications 2015-12-20 4812273394.pdf...

  • Page 33: Machine Description

    Machine description Machine description Diesel engine The machine is equipped with a completely electronically controlled water-cooled four-cylinder, turbocharged (WGT) diesel engine with direct injection (HPCR) and intercooler. WGT - Waste Gate Turbo HPCR - High Pressure Common Rail fuel injection Electrical system The machine has the following control units (ECU, Electronic Control Unit) and electronic units.

  • Page 34: Vibration System

    Machine description The steering angle is proportional to the amount the steering wheel is turned. In some markets, the machine is also equipped with an emergency steering system, either manually or electro-hydraulically. Vibration system The vibration system is a hydrostatic system in which a hydraulic motor drives the eccentric shaft, which generates the drum's vibrations.

  • Page 35: Identification

    Machine description Identification Product and component plates 1, 2 Product plate - Product Identification Number (PIN), model/type designation Product plate - Product Identification Number (PIN), model/type designation Engine plate - Type description, product and serial numbers Engine plate - Type description, product and serial numbers Cab/ROPS plate - Certification, product and serial numbers Cab/ROPS plate - Certification, product and serial numbers Component plate, drum - Product and serial numbers...

  • Page 36: Machine Plate

    Machine description Machine plate The machine type plate (1) is attached to the front left side of the frame, beside the steering joint. The plate specifies among other things the manufacturers name and address, the type of machine, the PIN, Product Identification Number (serial number), operating weight, engine power and year of manufacture.

  • Page 37: Engine Plates

    Machine description Engine plates The engine type plates (1) are affixed to the top and on the right side of the engine. The plates specify the type of engine, serial number and the engine specification. Please specify the engine serial number when ordering spares.
  • Page 38 Machine description 4700904895 Warning - Brake disengagement Study the towing chapter before disengaging the brakes. Danger of being crushed. 4700903459 Warning - Instruction manual The operator must read the safety, operation and maintenance instructions before operating the machine. 4700904083 Warning - Edge cutter (option) Warning of rotating parts.

  • Page 39: Decals

    Machine description Decals Location - decals Fig. Location, decals and signs Warning, Crush zone Warning, Crush zone 4700903422 4700903422 12. Master switch 12. Master switch 4700904835 4700904835 Warning, Rotating engine Warning, Rotating engine 4700903423 4700903423 13. Coolant 13. Coolant 4700388449 4700388449 components components...

  • Page 40: Info Decals

    Machine description Info decals Manual compartment Manual compartment Battery voltage Battery voltage Master switch Master switch Coolant Coolant Water Water Hydraulic fluid level Hydraulic fluid level Hydraulic fluid Hydraulic fluid Biological hydraulic fluid Biological hydraulic fluid Diesel fuel Diesel fuel Bio hydraulic fluid PANOLIN Bio hydraulic fluid PANOLIN Fixing point...

  • Page 41: Instruments/Controls

    Machine description Instruments/Controls Control panel and controls 28/30 29/31 Fig. Control panel Ignition switch Ignition switch Vibration rear drum Vibration rear drum Parking brake Parking brake Forward & Reverse lever Forward & Reverse lever Work mode (Off-set and Work mode (Off-set and Hazard lights Hazard lights vibration permitted plus soft...

  • Page 42: Function Descriptions

    Machine description Functions Functions Direction indicators Direction indicators Driving lights Driving lights Full/Dipped beam Full/Dipped beam Parking lights Parking lights Horn Horn Figure. Steering column switch (optional) Function descriptions Designation Designation Symbol Symbol Function Function Ignition key Ignition key The electric circuit is broken. The electric circuit is broken.
  • Page 43 Machine description Designation Designation Symbol Symbol Function Function Main beam indicator Main beam indicator Shows main beam activated (Activated via the Shows main beam activated (Activated via the steering column switch). steering column switch). Amplitude selector, high Amplitude selector, high Activation produces high amplitude.
  • Page 44 Machine description Designation Designation Symbol Symbol Function Function Speed limiter Speed limiter Limitation of the machine's max. speed (max.speed is Limitation of the machine's max. speed (max.speed is obtained with full deflection of the F/R lever). Set the obtained with full deflection of the F/R lever). Set the knob to the required position and read the speed on knob to the required position and read the speed on the display (30).

  • Page 45: Display Explanations

    Machine description Designation Designation Symbol Symbol Function Function Position 2: Normal position Position 2: Normal position Position 3: Used for maximum transport speed or for Position 3: Used for maximum transport speed or for high speed during smooth rolling without vibration high speed during smooth rolling without vibration Edge press/cutter, UP/DOWN Edge press/cutter, UP/DOWN...
  • Page 46 Machine description A status screen provides information on the fuel level, water level in the sprinkler tank, machine hours and voltage level. Fuel and water levels are specified in per cent (%). This screen is active until the Diesel engine is started or an active screen choice is made via the function buttons below the display.
  • Page 47 Machine description Scroll/Selection buttons to choose Scroll/Selection buttons to choose between available functions. between available functions. Alarm log button to display engine and Alarm log button to display engine and machine alarms. machine alarms. Settings/Button select menu, which opens Settings/Button select menu, which opens the main menu.
  • Page 48 Machine description When an engine alarm is activated, the alarm is shown on the display. The engine alarm is sent out from the engine ECM, which handles the monitoring of the engine functions. The message, which consists of an SPN and FMI code, can be interpreted via the engine supplier error code list.

  • Page 49: Machine Alarm

    Machine description Machine alarm Symbol Symbol Designation Designation Function Function Warning symbol, hydraulic fluid filter Warning symbol, hydraulic fluid filter If the symbol is shown when the diesel engine is running at If the symbol is shown when the diesel engine is running at full speed, the hydraulic fluid filter must be changed.

  • Page 50: Main Menu

    Machine description Alarms received are saved/logged and can be seen by selecting Display alarms. Selection of Display alarms. "ENGINE ALARM" Saved/Logged engine alarms. "MACHINE ALARM" Saved/Logged machine alarms. These alarms come from the other systems on the machine. "MAIN MENU" In the main menu it is also possible to change some user and machine settings, access the service menu for calibration purposes (special service personnel...

  • Page 51: User Settings

    Machine description "USER SETTINGS" Users can change the light settings, choose between the Metric or Imperial system, and set warning sounds On/Off. Adjustment of the light and contrast settings on the display, including brightness of the panel light. 2015-12-20 4812273394.pdf...

  • Page 52: Machine Settings

    Machine description "MACHINE SETTINGS" The selection "Sprinkler Pump: 1 & 2" is in machine settings. If the machine is fitted with double sprinkler pumps (Option) this is the menu in which the selection is made for which of the sprinkler pumps are to be activated to water the drum(s).
  • Page 53 Machine description "ADJUSTMENTS" "TESTMODES" - Installation personnel only, requires pin code. "CALIBRATION" - service personnel only, requires password. "EDC Calibration" used to calibrate the joystick and speed potentiometer. "TX Program" only used to change software in the display and requires special equipment and know-how. "EDC CALIBRATION"...

  • Page 54: About

    Machine description "ABOUT" It is also possible to see the version of the installed software. Operator help when starting When trying to start the machine without having set one, two or three of the conditions required to start machine, the missing conditions are shown in the display.

  • Page 55: Instruments And Controls, Cab

    Machine description Instruments and controls, cab Radio/CD Fig. Cab roof, front Fig. Right rear cab post 2015-12-20 4812273394.pdf...

  • Page 56: Function Description Of Instruments And Controls In The Cab

    Machine description Function description of instruments and controls in the cab Designation Designation Symbol Symbol Function Function Heater control Heater control Turn to the right to increase heating. Turn to the right to increase heating. Turn to the left to reduce heating. Turn to the left to reduce heating.

  • Page 57: Using The Cab Controls

    Machine description Using the cab controls. Defroster To quickly remove ice or mist, make sure that only the front and rear air nozzles are open. Turn the heater and fan dial (1 and 2) to max. Adjust the nozzle so that it blows on the window to be de-iced, or to remove mist.

  • Page 58: Electrical System

    Machine description Electrical system The machine's main switchbox (1) is located on the rear of the operator platform. There is a plastic cover over the distribution box and fuses. On the plastic cover there is a 24V socket. Fig. Main electrical central 1.

  • Page 59: Power In Engine Compartment/Battery Compartment

    Machine description Power in engine compartment/battery compartment The fuses in the engine compartment are located alongside the master switch. The roller is equipped with 24 V electrical system and an AC alternator. Connect the correct polarities (ground) to the Connect the correct polarities (ground) to the battery.

  • Page 60: Fuses In Cab

    Machine description Fuses in cab The electrical system in the cab has a separate fuse box located on the front right side of the cab roof. The figure shows fuse amperage and function. Fig. Cab roof fuse box (F7) All fuses are flat pin fuses. 1.

  • Page 61: Operation

    Operation Operation Before starting Master switch - Switching on Remember to carry out daily maintenance. Refer to the maintenance instructions. The master switch is located in the engine compartment. Turn the key (1) to the on position. The entire roller is now supplied with power. If the main battery/master switch is covered, the If the main battery/master switch is covered, the engine hood must be unlocked during operation,...

  • Page 62: Operator's Seat - Adjustment

    Operation Operator's seat - Adjustment Adjust the operator’s seat so that the position is comfortable and so that the controls are within easy reach. The seat can be adjusted as follows. - Length adjustment (1) - Weight adjustment (2) Fig. Operator's seat - Back support angle (3) 1.

  • Page 63: Parking Brake

    Operation Parking brake Ensure that the parking brake (1) is definitely Ensure that the parking brake (1) is definitely switched on. switched on. Brake is always activated in Neutral. (automatic 2 sec.) The parking brake must be activated to start the Fig.

  • Page 64: Interlock

    Operation Interlock The roller is equipped with Interlock. The diesel engine with switch off after 7 seconds if the operator gets off the seat when going forwards/backwards. If the control is in neutral when the operator stands up a buzzer will go on until the parking brake is activated. If the parking brake is activated, the diesel engine will not stop if the forward/reverse lever is moved out of neutral.

  • Page 65: Operator Position

    Operation Operator position If a ROPS (Roll Over Protective Structure) or a cab is fitted to the roller, always wear the seat belt (1) provided and wear a protective helmet. Replace the seat belt (1) if it shows signs of Replace the seat belt (1) if it shows signs of wear or has been subjected to high levels of wear or has been subjected to high levels of...

  • Page 66: Starting

    Operation Starting Starting the engine Make sure that the emergency stop is OFF and the parking brake ON. Set the forward/reverse lever (1) in neutral position, and set the speed selector (2) in the idling position (LO). The diesel engine cannot be started in any other position of the controls.

  • Page 67: Display When Activating Choice Via The Button Set

    Operation When starting and driving a machine that is cold, When starting and driving a machine that is cold, remember that the hydraulic fluid is also cold and remember that the hydraulic fluid is also cold and that braking distances can be longer than normal that braking distances can be longer than normal until the machine reaches the working temperature.

  • Page 68: Alarm Descriptions

    Operation Alarm descriptions Symbol Symbol Designation Designation Function Function Warning lamp, hydraulic filter Warning lamp, hydraulic filter If the lamp comes on while the engine is running at full If the lamp comes on while the engine is running at full speed, the hydraulic filter must be changed.

  • Page 69: Driving

    Operation Driving Operating the roller Under no circumstances is the machine to be Under no circumstances is the machine to be operated from the ground. The operator must be operated from the ground. The operator must be seated inside the machine during all operation. seated inside the machine during all operation.
  • Page 70 Operation The machine's gear position is shown in the center of the speedometer; select the gear/speed for the task. The machine does not need to be stopped to change gear position. Fig. The display shows the selection in the middle (position 1, 2 or 3) Max.

  • Page 71: Interlock/Emergency Stop/Parking Brake - Check

    Operation Interlock/Emergency stop/Parking brake - Check The interlock, emergency stop and parking brake must The interlock, emergency stop and parking brake must be checked daily before operating. A function check of be checked daily before operating. A function check of the interlock and emergency stop requires a restart.

  • Page 72: Pivotal Steering (Optional)

    Operation Pivotal steering (Optional) The machine must be in the operating position to activate the pivotal steering. Use the two front buttons (1) on the forward/reverse lever to operate the pivotal steering. To reset the rear drum to neutral, adjust the buttons (1) until the display (2) shows that the machine has aligned the drums.

  • Page 73: Vibration

    Operation The operator can choose between two tools, the edge cutter or edge compactor. The edge cutter (1) in the figure is shown in the operating position. The edge compactor (1) can easily be replaced with the edge cutter by releasing the bolted joint (3). Fig.

  • Page 74: Manual Vibration - Switching On

    Operation Manual vibration - Switching on Never activate vibration when the roller is Never activate vibration when the roller is stationary. This can damage both the surface and stationary. This can damage both the surface and the machine. the machine. Engage and disengage vibration using the switch (1) on the front of the forward/reverse lever.

  • Page 75: Emergency Braking

    Operation If the forward/reverse lever is moved quickly (forwards or backwards) toward/past neutral, the system switches to a rapid braking Mode and the machine stops. Activate normal driving Mode again by moving the forward/reverse lever back to neutral. Emergency braking Braking is normally activated using the forward/reverse lever.

  • Page 76: Parking

    Operation Parking Chocking the drums Never disembark from the machine when the Never disembark from the machine when the diesel engine is running, unless the parking brake diesel engine is running, unless the parking brake is activated. is activated. Make sure that the roller is parked in a safe place Make sure that the roller is parked in a safe place with respect to other road users.

  • Page 77: Long-Term Parking

    Long-term parking Long-term parking The following instructions should be followed The following instructions should be followed when long term parking (more than one month). when long term parking (more than one month). These measures apply when parking for a period of up to 6 months.

  • Page 78: Hoods, Tarpaulin

    Long-term parking Hoods, tarpaulin * Lower the instrument cover over the instrument panel. * Cover the entire roller with a tarpaulin. A gap must be left between the tarpaulin and the ground. * If possible, store the roller indoors and ideally in a building where the temperature is constant.

  • Page 79: Miscellaneous

    Miscellaneous Miscellaneous Lifting Locking the articulation Articulation must be locked to prevent inadvertent Articulation must be locked to prevent inadvertent turning before lifting the roller. turning before lifting the roller. Turn the steering wheel so the roller is straight forward. Activate the parking brake and switch off the machine.

  • Page 80: Lifting The Roller

    Miscellaneous Weight: refer to the hoisting plate on the Lifting the roller roller The machine’s gross weight is specified on the The machine’s gross weight is specified on the hoisting plate (1). Refer also to the Technical hoisting plate (1). Refer also to the Technical specifications.

  • Page 81: Unlocking The Articulation

    Miscellaneous Unlocking the articulation Remember to unlock the articulation before Remember to unlock the articulation before operating. operating. Insecure and remove the locking devices and put them in the storing place. Figure. Articulation in open position 2. Lock Unlocking the articulation Remember to restore the steering joint lock on the Remember to restore the steering joint lock on the steering joint to open before operating.

  • Page 82: Short Distance Towing With The Engine Running

    Miscellaneous Short distance towing with the engine running Activate the parking brake, and temporarily stop Activate the parking brake, and temporarily stop the diesel engine. Chock the drums to prevent the the diesel engine. Chock the drums to prevent the roller from moving roller from moving Open the left door to the engine compartment to...

  • Page 83: Towing The Roller

    Miscellaneous Towing the roller When towing/recovering, the roller must be braked When towing/recovering, the roller must be braked by the towing vehicle. A towing bar must be used by the towing vehicle. A towing bar must be used as the roller has no brakes. as the roller has no brakes.

  • Page 84: Transport

    Miscellaneous Transport Tie-down and secure the machine according to the Cargo Securing Certificate for the specific machine if this is avaliable and applicable. If not, tie down and secure the machine according to the cargo securing rules that are valid for the country where the transport takes place.

  • Page 85: Loading Cc224-624Hf, Cc2200-6200

    Miscellaneous Loading CC224-624HF, CC2200-6200 Securing vibratory roller CC224-624HF, CC2200-6200 from Dynapac for transport. (The instructions also apply to Combi machines) Roller loaded in forward direction Direct of travel The lashings can be moved to a rear point on the roller if there is no edge line on the trailer. The lashings can be moved to a rear point on the roller if there is no edge line on the trailer.
  • Page 86 Operating instructions - Summary Load carrier Load carrier When loaded, the vibratory roller is centered laterally on the platform (± 5 cm). When loaded, the vibratory roller is centered laterally on the platform (± 5 cm). The parking brake is applied and in good working condition, and the articulated joint lock is The parking brake is applied and in good working condition, and the articulated joint lock is closed.

  • Page 87: Operating Instructions - Summary

    Operating instructions - Summary Operating instructions - Summary Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Make sure that all instructions in the MAINTENANCE section are followed. Make sure that all instructions in the MAINTENANCE section are followed. Turn the master switch to the ON position.
  • Page 88 Operating instructions - Summary 21. When recovering - Refer to the relevant section in the Instruction Manual. 21. When recovering - Refer to the relevant section in the Instruction Manual. 2015-12-20 4812273394.pdf...

  • Page 89: Preventive Maintenance

    Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost. The Maintenance section includes the periodic maintenance that must be carried out on the machine. The recommended maintenance intervals assume that the machine is used in a normal environment and working conditions.
  • Page 90 Preventive maintenance 2015-12-20 4812273394.pdf...

  • Page 91: Maintenance - Lubricants And Symbols

    Maintenance - Lubricants and symbols Maintenance - Lubricants and symbols Always use high-quality lubricants and the Always use high-quality lubricants and the amounts recommended. Too much grease or amounts recommended. Too much grease or oil can cause overheating, resulting in rapid oil can cause overheating, resulting in rapid wear.

  • Page 92: Maintenance Symbols

    Maintenance - Lubricants and symbols TRANSMISSION OIL TRANSMISSION OIL Air temperature -15°C (5°F) - Air temperature -15°C (5°F) - AtlasCopco Gear oil AtlasCopco Gear oil P/N 4812160579 (5 liters) P/N 4812160579 (5 liters) above +40°C (104°F) above +40°C (104°F) 1000 1000 COOLANT COOLANT...

  • Page 93: Maintenance - Maintenance Schedule

    Maintenance - Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points 6, 7 Fig. Service and maintenance points Engine oil Engine oil Coolant Coolant 17. Steering joint 17. Steering joint Oil filter Oil filter 10. Air cleaner 10. Air cleaner 18.

  • Page 94: General

    Maintenance - Maintenance schedule General Periodic maintenance should be carried out after the number of hours specified. Use the daily, weekly etc. periods where number of hours cannot be used. Remove all dirt before filling, when checking Remove all dirt before filling, when checking oils and fuel and when lubricating using oil or oils and fuel and when lubricating using oil or grease.

  • Page 95: Every 50 Hours Of Operation (Weekly)

    Maintenance - Maintenance schedule Every 50 hours of operation (Weekly) Refer to the contents to find the page number of the sections referred to ! Pos. Pos. Action Action Comment Comment in fig in fig Check the oil level in the drum gears Check the oil level in the drum gears Draining the fuel prefilter Draining the fuel prefilter...

  • Page 96: Every 500/1500 Hours Of Operation

    Maintenance - Maintenance schedule Every 500/1500 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. Pos. Action Action Comment Comment in fig in fig Clean the hydraulic fluid cooler/water cooler Clean the hydraulic fluid cooler/water cooler Or when necessary Or when necessary...

  • Page 97: Every 1000 Hours Of Operation

    Maintenance - Maintenance schedule Every 1000 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. Pos. Action Action Comment Comment Replacethe filter element in the air cleaner Replacethe filter element in the air cleaner Check the condition of the batteries Check the condition of the batteries 1,2 Change the diesel engine oil and oil filter *...

  • Page 98: Every 2000 Hours Of Operation

    Maintenance - Maintenance schedule Every 2000 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. Pos. Action Action Comment Comment in fig in fig Check the filter element in the air cleaner Check the filter element in the air cleaner Replace when necessary Replace when necessary...

  • Page 99: Maintenance, 10H

    Maintenance, 10h Maintenance, 10h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 100: Coolant Level - Check

    Maintenance, 10h Coolant level - Check Check that the coolant level is between the max. and min. marks (2). Observe great caution if the cap has to be opened Observe great caution if the cap has to be opened while the engine is hot. Wear protective gloves and while the engine is hot.

  • Page 101: Hydraulic Reservoir - Check Fluid Level

    Maintenance, 10h Hydraulic reservoir - Check fluid level Place the roller on a level surface and check that the oil level in the sight glass (1) is between the max and min markings. Top up with the type of hydraulic fluid specified in the lubricant specification, if the level is too low.

  • Page 102: Sprinkler System/Drum Check

    Maintenance, 10h Sprinkler system/Drum Check Start the sprinkler system and make sure that none of the nozzles (1) are clogged. If necessary, clean blocked nozzles and the coarse filter placed by the water pump (2). See next section. Figure. Front drum 1.

  • Page 103: Sprinkler System/Drum Cleaning Of Sprinkler Nozzle

    Maintenance, 10h Sprinkler system/Drum Cleaning of sprinkler nozzle Dismantle the blocked nozzle by hand. Blow the nozzle and fine filter (1) clean using compressed air. Alternatively, fit replacement parts and clean the blocked parts later on. Nozzle Nozzle Colour Colour Ø...

  • Page 104: Scrapers, Spring-Action Check

    Maintenance, 10h Scrapers, spring-action Check Make sure that the scrapers are undamaged. Release with the arm (1). Loosen the screws (3) to adjust the scraper blade up or down. Figure. Outer scrapers 1. Release arm 2. Scraper blade 3. Adjusting screw Asphalt remnants can accumulate on the scraper and affect the contact force.
  • Page 105 Maintenance, 10h The adjusting screw (2) is adjusted until the scraper blade has a gap of approx. 1 mm (0.04 in) to the roller, or lies loosely on the roller, along its entire length. Tighten the lock nut (3). Figure. Scraper setting 1.
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  • Page 107: Maintenance - 50H

    Maintenance - 50h Maintenance - 50h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 108: Fuel Filter - Draining

    Maintenance - 50h Fuel filter - Draining Unscrew the drain plug (1) at the bottom of the fuel filter. With the aid of the secondary hand-operated pump, make certain that all sediment comes out. See Cummins service manual. Tighten the drain plug as soon as uncontaminated fuel runs out.

  • Page 109: Maintenance - 250 / 750 / 1250 / 1750H

    Maintenance - 250 / 750 / 1250 / 1750h Maintenance - 250 / 750 / 1250 / 1750h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or...

  • Page 110: Battery - Check Condition

    Maintenance - 250 / 750 / 1250 / 1750h Battery - Check condition The batteries are sealed and maintenance-free. Make sure there is no open flame in the vicinity Make sure there is no open flame in the vicinity when checking the electrolyte level. Explosive gas when checking the electrolyte level.

  • Page 111: Air Conditioning (Optional) Drying Filter - Inspection

    Maintenance - 250 / 750 / 1250 / 1750h Air conditioning (Optional) Drying filter - Inspection With the unit in operation, check using the sight glass (1) that bubbles are not visible on the drying filter. Park the roller on a level surface, chock the wheels Park the roller on a level surface, chock the wheels and activate the parking brake.
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  • Page 113: Maintenance - 500 / 1500H

    Maintenance - 500 / 1500h Maintenance - 500 / 1500h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 114: Backup Filter - Change

    Maintenance - 500 / 1500h Release the clips (1), pull off the cover (2), and pull out the main filter (3). Do not remove the backup filter (4). Clean the air cleaner if necessary, see section Air cleaner - Cleaning. When replacing the main filter (3), insert a new filter and refit the air cleaner in the reverse order.

  • Page 115: Air Cleaner - Cleaning

    Maintenance - 500 / 1500h Air cleaner - Cleaning Wipe clean on both sides of the outlet Wipe clean the inside of the cover (2) and the filter pipe. housing (5). See the previous illustration. Wipe also both surfaces for the outlet pipe; see adjacent figure.

  • Page 116: Engine

    Maintenance - 500 / 1500h Fill with fresh engine oil, see Lubricant specification or the engine manual for the correct grade of oil. Fill with the requisite volume of engine oil. See technical specifications before starting the machine. Allow the engine to idle for a few minutes, and then switch off the engine.

  • Page 117: The Engine Fuel Filter - Replacement/Cleaning

    Maintenance - 500 / 1500h The engine fuel filter - replacement/cleaning The fuel filter is placed on the left side of the engine compartment. Unscrew the bottom and drain off any water, and then replace the filter unit. Figure. Engine compartment, left side 1.

  • Page 118: Rubber Elements And Attachment Screws Check

    Maintenance - 500 / 1500h Rubber elements and attachment screws Check Check all rubber elements (1). Replace all elements if 25% or more than 25% of the number on one side of the drum have cracks deeper than 10-15 mm (0.4-0.6 in).

  • Page 119: Pivot Bearing (Optional) - Lubrication

    Maintenance - 500 / 1500h Pivot bearing (Optional) - Lubrication Grease each nipple (1) with five strokes of a hand-operated grease gun. Use grease as specified in the lubricant specification. Fig. Rear drum 1. Grease nipples x 4 Edge cutter (Optional) - Lubrication Refer to the operation section for information on Refer to the operation section for information on...
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  • Page 121: Maintenance - 1000H

    Maintenance - 1000h Maintenance - 1000h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 122: Backup Filter - Change

    Maintenance - 1000h Backup filter - Change Change the backup filter with a new filter after every second replacement of the main filter. To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.

  • Page 123: Diesel Engine Oil Change

    Maintenance - 1000h Diesel engine Oil change The engine's oil drain plug is located under the rear frame on the machine on the right side.The drain plug is accessed by first removing the rubber plug on the underside of the frame. Drain the oil when the engine is warm.

  • Page 124: The Engine Fuel Filter - Replacement/Cleaning

    Maintenance - 1000h The engine fuel filter - replacement/cleaning The fuel filter is placed on the left side of the engine compartment. Unscrew the bottom and drain off any water, and then replace the filter unit. Figure. Engine compartment, left side 1.

  • Page 125: Drum - Oil Change

    Maintenance - 1000h Drum - Oil change Take great care when draining the fluid. Wear Take great care when draining the fluid. Wear protective gloves and goggles. protective gloves and goggles. Set the roller so that the drain plug (1), the large plug, is at the lowest position in its rotation.

  • Page 126: Drum Gear - Checking The Oil Level

    Maintenance - 1000h Drum gear - Checking the oil level Move the machine until the inspection/filling holes are in position for filling. Fig. Drum gear Fill with the requisite volume of new oil. See technical specifications. Use transmission oil, see lubricant specifications.

  • Page 127: Hydraulic Reservoir Cap - Check

    Maintenance - 1000h Check the hydraulic fluid level in the sight glass (3) and top off as required. See under the heading 'Every 10 hours of operation' for more information. Start the engine and check that the filter does not leak. Figure.

  • Page 128: Rubber Elements And Attachment Screws Check

    Maintenance - 1000h Rubber elements and attachment screws Check Check all rubber elements (1). Replace all elements if 25% or more than 25% of the number on one side of the drum have cracks deeper than 10-15 mm (0.4-0.6 in). Check using a knife blade or pointed object.

  • Page 129: Steering Axle - Lubrication

    Maintenance - 1000h Steering axle - Lubrication Loosen and remove the protection plates (4) of the driver seat sliding on the platform to access the lubrication point (1). Lubricate the spline joint point between the steering axle (2) and the steering valve (3) with three to five strokes of a hand-operated grease gun.

  • Page 130: Cab

    Maintenance - 1000h Fresh air filter - Replacing There is one fresh air filter (1), placed on the front of the cab. Remove the protective cover. Undo the screws (2) and remove the complete holder. Remove the filter insert and replace with a new filter. The filter may need to be changed more often if the machine is operated in a dusty environment.

  • Page 131: Air Conditioning (Optional) Drying Filter - Inspection

    Maintenance - 1000h Air conditioning (Optional) Drying filter - Inspection With the unit in operation, check using the sight glass (1) that bubbles are not visible on the drying filter. Park the roller on a level surface, chock the wheels Park the roller on a level surface, chock the wheels and activate the parking brake.

  • Page 132: Steering Hitch - Tightening

    Maintenance - 1000h Steering hitch - Tightening Nobody must be allowed near the steering joint Nobody must be allowed near the steering joint when the engine is running. Risk of being when the engine is running. Risk of being crushed when the steering is operated. Switch crushed when the steering is operated.

  • Page 133: Maintenance - 2000H

    Maintenance - 2000h Maintenance - 2000h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.

  • Page 134: Backup Filter - Change

    Maintenance - 2000h Backup filter - Change Change the backup filter with a new filter after every second replacement of the main filter. To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.

  • Page 135: Diesel Engine Oil Change

    Maintenance - 2000h Diesel engine Oil change The engine's oil drain plug is located under the rear frame on the machine on the right side.The drain plug is accessed by first removing the rubber plug on the underside of the frame. Drain the oil when the engine is warm.

  • Page 136: The Engine Fuel Filter - Replacement/Cleaning

    Maintenance - 2000h The engine fuel filter - replacement/cleaning The fuel filter is placed on the left side of the engine compartment. Unscrew the bottom and drain off any water, and then replace the filter unit. Figure. Engine compartment, left side 1.

  • Page 137: Drum - Oil Change

    Maintenance - 2000h Drum - Oil change Take great care when draining the fluid. Wear Take great care when draining the fluid. Wear protective gloves and goggles. protective gloves and goggles. Set the roller so that the drain plug (1), the large plug, is at the lowest position in its rotation.

  • Page 138: Drum Gear - Checking The Oil Level

    Maintenance - 2000h Drum gear - Checking the oil level Move the machine until the inspection/filling holes are in position for filling. Fig. Drum gear Fill with the requisite volume of new oil. See technical specifications. Use transmission oil, see lubricant specifications.

  • Page 139: Hydraulic Reservoir Cap - Check

    Maintenance - 2000h Check the hydraulic fluid level in the sight glass (3) and top off as required. See under the heading 'Every 10 hours of operation' for more information. Start the engine and check that the filter does not leak. Figure.

  • Page 140: Hydraulic Reservoir Fluid Change

    Maintenance - 2000h Hydraulic reservoir Fluid change Take care when draining the hydraulic fluid. Wear Take care when draining the hydraulic fluid. Wear protective gloves and goggles. protective gloves and goggles. Open left engine compartment. The drain plug/valve is in the area under the hydraulic tank. Place a receptacle that holds at least 50 liters (13.2 gal) under the engine compartment.

  • Page 141: Seat Bearing - Lubrication

    Maintenance - 2000h Seat bearing - Lubrication Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism. Remove the cover (5) to access the lubrication nipple (1).

  • Page 142: Watering System - Draining

    Maintenance - 2000h Watering system - Draining Remember that there is a risk of freezing during Remember that there is a risk of freezing during the winter. Empty the tank, pump, filter and lines, the winter. Empty the tank, pump, filter and lines, or mix antifreeze in the water.

  • Page 143: Steering Joint - Check

    Maintenance - 2000h Steering joint - Check Inspect the steering joint to detect any damage or cracks. Check and tighten any loose bolts. Check also for any stiffness or play in the steering joint. Fig. Steering joint Steering hitch - Tightening Nobody must be allowed near the steering joint Nobody must be allowed near the steering joint when the engine is running.

  • Page 144: Cab

    Maintenance - 2000h Fresh air filter - Replacing There is one fresh air filter (1), placed on the front of the cab. Remove the protective cover. Undo the screws (2) and remove the complete holder. Remove the filter insert and replace with a new filter. The filter may need to be changed more often if the machine is operated in a dusty environment.

  • Page 145: Air Conditioning (Optional) Drying Filter - Inspection

    Maintenance - 2000h Air conditioning (Optional) Drying filter - Inspection With the unit in operation, check using the sight glass (1) that bubbles are not visible on the drying filter. Park the roller on a level surface, chock the wheels Park the roller on a level surface, chock the wheels and activate the parking brake.

  • Page 146: Disposal

    Disposal Disposal Correctly sorted disposal must be carried out after replacing wear and spare parts and after the mach- ine has been withdraw from service (scrapped). The materials must be sorted correctly according to metal, plastic, electronic scrap, various operating substances etc.
  • Page 147 Dynapac (China) Compaction & Paving Equipment Co., Ltd. Atlas Copco Construction Technique Product Company China No. 38, QuanWang Road, WuQing High Tech Industrial Park, 301700, Tianjin, China www.atlascopco.com...

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