Atlas Copco CA300 User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
ICA300-IN2EN1.pdfICA300-IN2EN1.pdf
Vibratory rollerVibratory roller
CA300CA300
EngineEngine
Cummins 4BT 3.9 102CCummins 4BT 3.9 102C
Serial numberSerial number
10000115x0E001462 -10000115x0E001462 -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in IndiaPrinted in India

2000h-Maintenance
ICA300-IN2EN1.pdf2013-12-16
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
Driving near edges ...................................................................................... 5
Slopes ......................................................................................................... 5
Air conditioning............................................................................................ 6
Special instructions .................................................................................................................. 7
Standard lubricants and other recommended oils and fluids ...................... 7
Higher ambient temperatures, above +40°C (104°F).................................. 7
Temperatures.............................................................................................. 7
High pressure cleaning ............................................................................... 7
Fire fighting ................................................................................................. 7
Roll Over Protective Structure (ROPS), ROPS approved cab .................... 8
Battery handling .......................................................................................... 8
Jump starting............................................................................................... 9
Technical specifications ......................................................................................................... 11
Vibrations - Operator station ..................................................................... 11
Noise level................................................................................................. 11
Electrical system ....................................................................................... 11
Dimensions, side view............................................................................... 12
Dimensions, top view ................................................................................ 13
Weights and volumes................................................................................ 13
Working capacity....................................................................................... 14
General ..................................................................................................... 14
Hydraulic system....................................................................................... 15

2000h-Maintenance
ICA300-IN2EN1.pdf 2013-12-16
ROPS - bolts ............................................................................................. 15
Tightening torque ...................................................................................... 16
Machine description ............................................................................................................... 17
Identification ............................................................................................................ 17
Product identification number on the frame .............................................. 17
Machine plate............................................................................................ 17
Explanation of 17PIN serial number.......................................................... 18
Engine plates ............................................................................................ 18
Decals...................................................................................................................... 19
Location - decals ....................................................................................... 19
Safety decals............................................................................................. 20
Info decals................................................................................................. 22
Instrument/Controls ................................................................................................. 23
Locations - Instruments and controls ........................................................ 23
Locations - Control panel and controls...................................................... 24
Function description .................................................................................. 25
Controls in the cab .................................................................................... 27
Function description of instruments and controls in the cab ..................... 28
Electrical system...................................................................................................... 29
Main fuses................................................................................................. 29
Relays ....................................................................................................... 29
Fuses ........................................................................................................ 30
Fuses and relay in cab heater box (Optional) ........................................... 30
Fuses in heater box................................................................................... 31
Relay in heater box ................................................................................... 31
Fuses, battery disconnector/fuse box (Cab) ............................................. 32
Operation ............................................................................................................................... 33
Before starting ......................................................................................................... 33
Master switch - Switching on.................................................................... 33
Driver seat (Std.) - Adjustment.................................................................. 33

2000h-Maintenance
ICA300-IN2EN1.pdf2013-12-16
Driver seat (Option)- Adjustment............................................................... 34
Instruments and lamps - Checking............................................................ 34
Operator position....................................................................................... 35
View .......................................................................................................... 35
Interlock..................................................................................................... 36
Starting .................................................................................................................... 36
Start of diesel motor .................................................................................. 36
Operation................................................................................................................. 38
Operating the roller ................................................................................... 38
Vibration .................................................................................................................. 39
Vibration On/Off ........................................................................................ 39
Vibration - Activation ................................................................................. 39
Braking .................................................................................................................... 40
Normal braking.......................................................................................... 40
Emergency braking ................................................................................... 40
Switching off.............................................................................................. 41
Parking .................................................................................................................... 41
Master switch ............................................................................................ 41
Chocking the drums .................................................................................. 42
Long-term parking.................................................................................................................. 43
Engine ....................................................................................................... 43
Battery....................................................................................................... 43
Air cleaner, exhaust pipe........................................................................... 43
Fuel tank ................................................................................................... 43
Hydraulic reservoir .................................................................................... 43
Steering cylinder, hinges, etc. ................................................................... 44
Hoods, tarpaulin ........................................................................................ 44
Tires (All-weather)..................................................................................... 44
Miscellaneous ........................................................................................................................ 45
Lifting ....................................................................................................................... 45

2000h-Maintenance
ICA300-IN2EN1.pdf 2013-12-16
Locking the articulation ............................................................................. 45
Lifting the roller.......................................................................................... 45
Unlocking the articulation .......................................................................... 46
Towing/Recovering.................................................................................................. 46
Alternative 1 .............................................................................................. 46
Short distance towing with the engine running.......................................... 46
Alternative 2 .............................................................................................. 47
Towing short distances where the engine is inoperative........................... 47
Rear axle brake......................................................................................... 47
Drum gearbox brake ................................................................................. 47
Towing the roller........................................................................................ 48
Roller prepared for transport ..................................................................... 48
Operating instructions - Summary ......................................................................................... 49
Preventive maintenance ........................................................................................................ 51
Acceptance and delivery inspection.......................................................... 51
Warranty.................................................................................................... 51
Maintenance - Lubricants and symbols ................................................................................. 53
Maintenance symbols ............................................................................... 54
Maintenance - Maintenance schedule ................................................................................... 55
Service and maintenance points ............................................................... 55
General ..................................................................................................... 55
Every 10 hours of operation (Daily)........................................................... 56
After the FIRST 50 hours of operation ...................................................... 56
Every 50 hours of operation (Weekly)....................................................... 57
Every 250 hours of operation (Monthly) .................................................... 57
Every 500 hours of operation (Every three months) ................................. 58
Every 1000 hours of operation (Every six months) ................................... 58
Every 2000 hours of operation (Yearly) .................................................... 58
Maintenance, 10h .................................................................................................................. 59
Scrapers - Check, adjustment................................................................... 59

2000h-Maintenance
ICA300-IN2EN1.pdf2013-12-16
Steel scrapers (Optional) .......................................................................... 60
Scrapers, Pad-drum .................................................................................. 60
Soften scrapers (Optional) ........................................................................ 61
Air circulation - Check ............................................................................... 61
Coolant level - Check ................................................................................ 62
Diesel engine Check oil level ................................................................... 63
Fuel tank - Filling....................................................................................... 63
Hydraulic reservoir - Check fluid level....................................................... 64
Brakes - Check.......................................................................................... 64
Maintenance - 50h ................................................................................................................. 67
Air cleaner
Checking - Change the main air filter........................................................ 67
Backup filter - Change............................................................................... 68
Air cleaner
- Cleaning.................................................................................................. 68
Articulation - Lubrication............................................................................ 69
Steering joint - Lubrication ........................................................................ 69
Tires - Air pressure - Wheel nuts - Tightening .......................................... 70
Automatic Climate Control (Optional) - Inspection .................................... 70
Maintenance - 250h ............................................................................................................... 73
Rear axle differential - Check oil level....................................................... 73
Rear axle planetary gears - Check oil level............................................... 74
Drum gearbox - Checking the oil level ...................................................... 74
Drum cartridge - Checking the oil level ..................................................... 75
Drum cartridge - Cleaning the ventilation screw ....................................... 76
Radiator - Check/Cleaning ........................................................................ 76
Bolted joints - Checking tightening torque................................................. 76
Rubber elements and fastening screws - Check....................................... 77
Diesel engine - Oil and Filter change ........................................................ 77
Battery - Check electrolyte level................................................................ 78

2000h-Maintenance
ICA300-IN2EN1.pdf 2013-12-16
Battery cell ................................................................................................ 78
Air conditioning (Optional)
- Inspection................................................................................................ 79
Maintenance - 500h ............................................................................................................... 81
Replacing the fuel filter.............................................................................. 81
Fuel pre-filter - Cleaning............................................................................ 82
Bleeder filter - Inspection/Cleaning ........................................................... 82
Maintenance - 1000h ............................................................................................................. 83
Air filter - Change ...................................................................................... 83
Backup filter - Change............................................................................... 83
Hydraulic fluid filter - Replacement ........................................................... 84
Hydraulic fluid reservoir - Draining ............................................................ 85
Fuel tank - Drainage.................................................................................. 86
Air conditioning (Optional)
Fresh air filter - Change ............................................................................ 86
Rear axle differential - Oil change............................................................. 87
Rear axle's planetary gears - Draining the oil ........................................... 88
Rear axle's planetary gears - Oil change - Oil filling ................................. 89
Maintenance - 2000h ............................................................................................................. 91
Hydraulic reservoir - Changing the fluid .................................................... 91
Drum cartridge - Oil change ...................................................................... 92
Drum gearbox - Oil change ....................................................................... 93
Steering hitch - Check............................................................................... 93
Controls - Lubrication ................................................................................ 94
Automatic Climate Control (Optional)
- Overhaul ................................................................................................. 94
Drying filter - Check................................................................................... 95
Compressor - Check (Optional) ................................................................ 96

Introduction
ICA300-IN2EN1.pdf2013-12-16
Introduction
The machine
CA300 is one of Dynapac's medium-heavy soil
compaction rollers. It is available in STD and D
versions.
Intended use
All types of base courses and subbase courses can be
compacted deeper and the interchangeable drums, D
to PD, and vice versa, facilitate even greater variety in
the range of application.
The cab and safety-related accessories are described
in this manual. Other accessories, such as compaction
meter, tachograph and field computer, are described
in separate instructions.
Warning symbols
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
Safety information
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
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Introduction
ICA300-IN2EN1.pdf 2013-12-16
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
General
This manual contains instructions for machine
operation and maintenance.
The machine must be correctly maintained for
maximal performance.
The machine should be kept clean so that any
leakages, loose bolts and loose connections are
discovered at as early a point in time as possible.
Inspect the machine every day, before starting.
Inspect the entire machine so that any leakages or
other faults are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
This manual contains instructions for periodic
maintenance normally carried out by the operator.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
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