Atlas Copco CA3500DCO User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812160101_A.pdf4812160101_A.pdf
Vibratory rollerVibratory roller
CA3500DCOCA3500DCO
CA3600DCOCA3600DCO
CA5000DCOCA5000DCO
CA6000DCOCA6000DCO
EngineEngine
Cummins QSB 4.5 (IIIA/T3) / (IIIB/T4i)Cummins QSB 4.5 (IIIA/T3) / (IIIB/T4i)
Deutz TCD 2012 L6 (IIIA/T3) / TCD 6.1 L6 (IIIB/T4i) Deutz TCD 2012 L6 (IIIA/T3) / TCD 6.1 L6 (IIIB/T4i)
Serial numberSerial number
10000145x0A010028 -10000145x0A010028 -
10000146x0A00xxxx -10000146x0A00xxxx -
10000147x0A00xxxx -10000147x0A00xxxx -
10000148x0A00xxxx -10000148x0A00xxxx -
10000133x0A00xxxx -10000133x0A00xxxx -
10000129x0A008983 -10000129x0A008983 -
10000135x0A00xxxx -10000135x0A00xxxx -
10000131x0A00xxxx -10000131x0A00xxxx -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in SwedenPrinted in Sweden

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Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Warning symbols......................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
CE marking and Declaration of conformity.................................................. 3
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Driving near edges ...................................................................................... 7
Slopes ......................................................................................................... 8
Safety (Optional) ...................................................................................................................... 9
Air conditioning............................................................................................ 9
Special instructions ................................................................................................................ 11
Standard lubricants and other recommended oils and fluids .................... 11
Higher ambient temperatures, above +40°C (104°F)................................ 11
Temperatures............................................................................................ 11
High pressure cleaning ............................................................................. 11
Fire fighting ............................................................................................... 12
Roll Over Protective Structure (ROPS), ROPS approved cab .................. 12
Welding ..................................................................................................... 12
Battery handling ........................................................................................ 12
Jump starting (24V)................................................................................... 13
Technical specifications ......................................................................................................... 15
Vibrations - Operator station ..................................................................... 15
Noise level................................................................................................. 15
Electrical system ....................................................................................... 15
Dimensions, side view............................................................................... 16
Dimensions, top view ................................................................................ 17
Weights and volumes................................................................................ 18

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Working capacity....................................................................................... 18
General ..................................................................................................... 20
Liquid-filled tyres (Ballasted tyres).............................................. 21
Hydraulic system....................................................................................... 21
Automatic Climate Control (ACC) (Optional)............................................. 21
Tightening torque ...................................................................................... 22
Machine description ............................................................................................................... 23
Diesel engine, Cummins ........................................................................... 23
Diesel engine, Deutz ................................................................................. 23
Electrical system ....................................................................................... 23
Propulsion system/Transmission .............................................................. 23
Brake system ............................................................................................ 24
Steering system ........................................................................................ 24
Vibration system........................................................................................ 24
Cab............................................................................................................ 24
FOPS and ROPS ...................................................................................... 24
Identification ............................................................................................................ 25
Product and component plates ................................................................. 25
Product identification number on the frame .............................................. 25
Machine plate............................................................................................ 26
Explanation of 17PIN serial number.......................................................... 26
Engine plates ............................................................................................ 27
Decals...................................................................................................................... 28
Location - decals ....................................................................................... 28
Safety decals............................................................................................. 29
Info decals................................................................................................. 31
Instruments/Controls ............................................................................................... 32
Control panel and controls ........................................................................ 32
Function descriptions ................................................................................ 33
Warning indication - membrane panel (Keypad)....................................... 35

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Display explanations ................................................................................. 36
Machine alarm........................................................................................... 39
Dynapac Sub System (DSS)..................................................................... 40
"MAIN MENU" ........................................................................................... 41
"USER SETTINGS" .................................................................... 41
"SERVICE MENU"...................................................................... 42
"ABOUT"..................................................................................... 43
"MACHINE SETTINGS".............................................................. 43
Operator help when starting...................................................................... 44
Operator help Workmode.......................................................................... 44
Display when activating choice via the button set..................................... 45
DCO view and status .................................................................. 45
Error messages (DCO) ............................................................... 46
Instruments and controls, cab ................................................................... 47
Function description of instruments and controls in the cab ..................... 48
Using the cab controls............................................................................... 49
Defroster ..................................................................................... 49
Heat ............................................................................................ 49
AC/ACC ...................................................................................... 49
ACC - Control panel .................................................................................. 50
Main display screen .................................................................................. 50
ACC - Operation menus............................................................................ 50
Electrical system...................................................................................................... 52
Fuses in the main switchbox (Cummins) .................................................. 53
Fuses at master switch (Cummins)........................................................... 53
Fuse box at master switch (Cummins)...................................................... 54
Fuses in the main switchbox (Deutz) ........................................................ 54
Fuses at master switch (Deutz)................................................................. 55
Fuse box at master switch (Deutz)............................................................ 56
Operation ............................................................................................................................... 57

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Before starting ......................................................................................................... 57
Master switch - Switching on..................................................................... 57
Operator's seat - Adjustment..................................................................... 57
Operator's seat, comfort - Adjustments..................................................... 58
Control panel, adjustments ....................................................................... 58
Parking brake ............................................................................................ 59
Display - Control........................................................................................ 59
Interlock..................................................................................................... 60
Operator position....................................................................................... 60
View .......................................................................................................... 61
Starting .................................................................................................................... 62
Starting the engine .................................................................................... 62
Driving ..................................................................................................................... 63
Operating the roller ................................................................................... 63
Machine with TC (Anti-Spin) ....................................................... 63
Slopes (TC (Anti-Spin))............................................................... 64
Interlock/Emergency stop/Parking brake - Check ..................................... 65
Dynapac Compaction Meter (DCM) including Active Bouncing Control
(ABC) - Optional........................................................................................ 65
Setting limit................................................................................................ 66
Operation CMV ......................................................................................... 67
Vibration .................................................................................................................. 67
Different operating modes......................................................................... 68
Advice when using DCO ........................................................................... 70
Braking .................................................................................................................... 71
Normal braking.......................................................................................... 71
Emergency braking ................................................................................... 71
Switching off.............................................................................................. 72
Parking .................................................................................................................... 72
Chocking the drums .................................................................................. 72

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Master switch ............................................................................................ 73
Long-term parking.................................................................................................................. 75
Engine ....................................................................................................... 75
Battery....................................................................................................... 75
Air cleaner, exhaust pipe........................................................................... 75
Fuel tank ................................................................................................... 75
Hydraulic reservoir .................................................................................... 75
Tires (All-weather)..................................................................................... 75
Hoods, tarpaulin ........................................................................................ 76
Miscellaneous ........................................................................................................................ 77
Lifting ....................................................................................................................... 77
Locking the articulation ............................................................................. 77
Lifting the roller.......................................................................................... 78
Lifting the roller with jack:.......................................................................... 78
Unlocking the articulation .......................................................................... 79
Towing/Recovering.................................................................................................. 79
Short distance towing with the engine running.......................................... 80
Short distance towing when the engine is inoperative. ............................. 81
Towing the roller........................................................................................ 82
Transport ................................................................................................................. 82
Securing CA1500-CA4600 for loading ...................................................... 83
Securing CA5000 for loading .................................................................... 85
Securing CA5500/6000/6500 for loading .................................................. 87
Operating instructions - Summary ......................................................................................... 89
Preventive maintenance ........................................................................................................ 91
Acceptance and delivery inspection.......................................................... 91
Warranty.................................................................................................... 91
Maintenance - Lubricants and symbols ................................................................................. 93
Maintenance symbols ............................................................................... 94
Maintenance - Maintenance schedule ................................................................................... 95

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Service and maintenance points ............................................................... 95
General ..................................................................................................... 95
Periodic service (service message) - Optional.......................................... 96
Every 10 hours of operation (Daily)........................................................... 97
After the FIRST 50 hours of operation ...................................................... 97
Every 50 hours of operation (Weekly)....................................................... 97
Every 250 / 750 / 1250 / 1750 hours of operation ..................................... 98
Every 500 / 1500 hours of operation ......................................................... 98
Every 1000 hours of operation .................................................................. 99
Every 2000 hours of operation ................................................................ 100
Every other year...................................................................................... 101
Maintenance, 10h ................................................................................................................ 103
Scrapers - Check, adjustment................................................................. 103
Air circulation - Check ............................................................................. 104
Coolant level - Check .............................................................................. 104
Diesel engine Check oil level ................................................................. 105
Fuel tank - Filling..................................................................................... 105
Hydraulic reservoir - Check fluid level..................................................... 106
Maintenance - 50h ............................................................................................................... 107
Hydraulic filter - Replacement ................................................................. 107
Tires - Air pressure - Wheel nuts - Tightening ........................................ 109
Drum gearbox - Oil change ..................................................................... 109
Steering hitch - Tightening ...................................................................... 110
Air cleaner
- Check hoses and connections .............................................................. 111
Drum - Oil change ................................................................................... 111
Gearbox - Oil change .............................................................................. 113
Maintenance - 250 / 750 / 1250 / 1750h .............................................................................. 115
Rear axle differential - Check oil level..................................................... 115
Rear axle planetary gears - Check oil level............................................. 116

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Drum - Checking the oil level .................................................................. 116
Gearbox - Checking the oil level ............................................................. 117
Drum gearbox - Checking the oil level .................................................... 118
Radiator - Check/Cleaning ...................................................................... 118
Rubber elements and fastening screws - Check..................................... 119
Battery
- Check condition .................................................................................... 119
Air conditioning (Optional)
- Inspection.............................................................................................. 120
Automatic Climate Control (Optional) - Inspection .................................. 120
Maintenance - 500 / 1500h .................................................................................................. 121
Air cleaner
Checking - Change the main air filter...................................................... 121
Backup filter - Change............................................................................. 122
Air cleaner
- Cleaning................................................................................................ 122
Rear axle differential - Check oil level..................................................... 123
Rear axle planetary gears - Check oil level............................................. 123
Drum - Checking the oil level .................................................................. 124
Gearbox - Oil change .............................................................................. 125
Drum gearbox - Checking the oil level .................................................... 125
Radiator - Check/Cleaning ...................................................................... 126
Fuel pre-filter - Replacement................................................................... 126
Replacing the fuel filter............................................................................ 127
Diesel engine - Oil and Filter change ...................................................... 128
Controls and moving joints - Lubrication ................................................. 128
Seat bearing - Lubrication ....................................................................... 129
Maintenance - 1000h ........................................................................................................... 131
Hydraulic filter - Replacement ................................................................. 131
Air cleaner
Checking - Change the main air filter...................................................... 132
Backup filter - Change............................................................................. 133

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Air cleaner
- Cleaning................................................................................................ 134
Rear axle differential - Oil change........................................................... 135
Rear axle planetary gear - Oil change .................................................... 135
Drum - Checking the oil level .................................................................. 136
Gearbox - Oil change .............................................................................. 137
Drum gearbox - Oil change ..................................................................... 137
Radiator - Check/Cleaning ...................................................................... 138
Fuel pre-filter - Replacement................................................................... 138
Replacing the fuel filter............................................................................ 139
Diesel engine - Oil and Filter change ...................................................... 140
Seat bearing - Lubrication ....................................................................... 141
Hydraulic reservoir - Draining.................................................................. 141
Fuel tank - Draining (Optional) ................................................................ 142
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 142
Steering hitch - Tightening ...................................................................... 143
Maintenance - 2000h ........................................................................................................... 145
Hydraulic reservoir - Oil change.............................................................. 145
Hydraulic filter - Replacement ................................................................. 146
Drum gearbox - Oil change ..................................................................... 147
Air cleaner
Checking - Change the main air filter...................................................... 147
Backup filter - Change............................................................................. 148
Air cleaner
- Cleaning................................................................................................ 148
Rear axle planetary gear - Oil change .................................................... 149
Rear axle differential - Oil change........................................................... 150
Drum - Oil change ................................................................................... 150
Gearbox - Oil change .............................................................................. 152
Radiator - Check/Cleaning ...................................................................... 152

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Fuel pre-filter - Replacement................................................................... 153
Replacing the fuel filter............................................................................ 153
Diesel engine - Oil and Filter change ...................................................... 154
Seat bearing - Lubrication ....................................................................... 155
Hydraulic reservoir - Draining.................................................................. 155
Fuel tank - Draining (Optional) ................................................................ 156
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 156
Automatic Climate Control (Optional)
- Overhaul ............................................................................................... 157
Drying filter - Check................................................................................. 157
Steering hitch - Tightening ...................................................................... 158

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Introduction
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Introduction
The machine
CA3500/3600DCO are models of Dynapac's
medium-heavy earth compaction rollers. The machine
is a D (smooth drum) variant with optimized
compaction system "Compaction Optimizer" (CO).
CA5000/6000DCO are models of Dynapac's heavy
earth compaction rollers. The machine is a D (smooth
drum) variant with optimized compaction system
"Compaction Optimizer" (CO).
Intended use
All types of base courses and subbase courses can be
compacted.
Dynapac Compaction Optimizer (DCO) optimizes the
compaction work by continuously adjusting the
compaction effect to the composition of the surface. It
can be used together with another roller accessory,
the Dynapac Compaction Analyzer (DCA), which
enables the compaction results to be documented and
stored.
The cab and safety-related accessories are described
in this manual. Other accessories, such as tachograph
"and "Analyzer" (DCA) 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
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
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Introduction
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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.
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.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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.
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Introduction
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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.
If the roller is equipped with a Step IIIB/4i diesel
engine and a particle filter (DPF-filter), the engine
will automatically burn out soot. See more under
the sections "Machine description" and
"Operation".
If the roller is equipped with a Step IIIB/4i diesel
engine and a particle filter (DPF-filter), the engine
will automatically burn out soot. See more under
the sections "Machine description" and
"Operation".
CE marking and Declaration of conformity
(Applies to machines marketed in EU/EEC)
This machine is CE marked. This shows that on
delivery it complies with the basic health and safety
directives applicable for the machine in accordance
with machinery directive 2006/42/EC and that it also
complies with other directives applicable for this
machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable directives and
supplements, as well as the harmonized standards
and other regulations that are applied.
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Introduction
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Safety - General instructions
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Safety - General instructions
(Also read the safety manual)
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
2. Ensure that all instructions in the MAINTENANCE section are followed.2. Ensure that all instructions in the MAINTENANCE section are followed.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
4. Never use the roller if it is in need of adjustment or repair.4. Never use the roller if it is in need of adjustment or repair.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
7. Drive slowly in sharp bends.7. Drive slowly in sharp bends.
8. Avoid driving across slopes. Drive straight up or straight down the slope.8. Avoid driving across slopes. Drive straight up or straight down the slope.
9. When driving close to edges, ditches or holes, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
9. When driving close to edges, ditches or holes, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
11. Drive particularly carefully on uneven ground.11. Drive particularly carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
14. Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
14. Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
15. Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
15. Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
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Safety - General instructions
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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
surface the machine is being used on.
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
surface the machine is being used on.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. See instructions in the STOP section.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. See instructions in the STOP section.
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
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Safety - when operating
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Safety - when operating
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
Driving near edges
Fig. Position of drum when driving near
an edge
Minimum
2/3
When driving near an edge, minimum 2/3 of the drum
width must be on solid ground.
Keep in mind that the machine's center of gravity
moves outwards when steering. For example, the
center of gravity moves to the right when you
steer to the left.
Keep in mind that the machine's center of gravity
moves outwards when steering. For example, the
center of gravity moves to the right when you
steer to the left.
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Safety - when operating
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Slopes
Fig. Operating on slopes
Max 20° or 36%
This angle has been measured on a hard, flat surface
with the machine stationary.
The steering angle was zero, the vibration was
switched OFF and all tanks were full.
Always take into consideration that loose ground,
steering the machine, vibration on, machine speed
across the ground and raising the center of gravity can
all cause the machine to topple at smaller slope
angles than those specified here.
To exit the cab in an emergency, release the
hammer on the rear right post and break the rear
window.
To exit the cab in an emergency, release the
hammer on the rear right post and break the rear
window.
It is recommended that ROPS (Roll Over Protective
Structure) or a ROPS-approved cab is always used
when driving on slopes or unsafe ground. Always
wear a seat belt.
It is recommended that ROPS (Roll Over Protective
Structure) or a ROPS-approved cab is always used
when driving on slopes or unsafe ground. Always
wear a seat belt.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
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