Atlas Copco CC234HF User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812159801_A.pdf4812159801_A.pdf
Vibratory rollerVibratory roller
CC234HF/334HFCC234HF/334HF
CC2300/3300CC2300/3300
EngineEngine
Cummins QSB 3.3 (IIIA/T3)Cummins QSB 3.3 (IIIA/T3)
Deutz TCD 3.6 L04 (IIIB/T4i)Deutz TCD 3.6 L04 (IIIB/T4i)
Serial numberSerial number
10000313x0A009396 -10000313x0A009396 -
10000317x0A009737 -10000317x0A009737 -
10000338x0A011354 -10000338x0A011354 -
10000342x0A011649 -10000342x0A011649 -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in SwedenPrinted in Sweden

2000h-Maintenance
4812159801_A.pdf2014-03-31
Table of Contents
Introduction .............................................................................................................................. 1
Warning symbols......................................................................................... 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
CE marking and Declaration of conformity.................................................. 3
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Slopes ......................................................................................................... 7
Driving near edges ...................................................................................... 8
Safety (Optional) ...................................................................................................................... 9
Air conditioning............................................................................................ 9
Edge cutter/compactor ................................................................................ 9
Working lights - Xenon .............................................................................. 10
Special instructions ................................................................................................................ 11
Standard lubricants and other recommended oils and fluids .................... 11
Higher ambient temperatures, above +40°C (104°F)................................ 11
Lower ambient temperature - Freeze risk ................................................. 11
Temperatures............................................................................................ 11
High pressure cleaning ............................................................................. 12
Fire fighting ............................................................................................... 12
Roll Over Protective Structure (ROPS), ROPS approved cab .................. 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

2000h-Maintenance
4812159801_A.pdf 2014-03-31
Dimensions, top view ................................................................................ 17
Weights and volumes................................................................................ 18
Working capacity....................................................................................... 18
General ..................................................................................................... 19
Hydraulic system....................................................................................... 20
Automatic Climate Control (ACC) (Optional)............................................. 20
Tightening torque ...................................................................................... 21
Machine description ............................................................................................................... 23
Diesel engine ............................................................................................ 23
Electrical system ....................................................................................... 23
Propulsion system..................................................................................... 23
Brake system ............................................................................................ 24
Steering system ........................................................................................ 24
Vibration system........................................................................................ 24
Cab............................................................................................................ 24
ROPS ........................................................................................................ 24
Identification ............................................................................................................ 25
Product and component plates ................................................................. 25
Product identification number on the frame .............................................. 26
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
Display explanations ................................................................................. 36

2000h-Maintenance
4812159801_A.pdf2014-03-31
Machine alarm........................................................................................... 40
"MAIN MENU" ........................................................................................... 41
"USER SETTINGS" .................................................................... 42
"MACHINE SETTINGS".............................................................. 43
"SERVICE MENU"...................................................................... 43
"ABOUT"..................................................................................... 45
Operator help when starting...................................................................... 45
Operator help Workmode.......................................................................... 45
Instruments and controls, cab ................................................................... 46
Function description of instruments and controls in the cab ..................... 47
Using the cab controls............................................................................... 48
Defroster ..................................................................................... 48
Heat ............................................................................................ 48
AC/ACC ...................................................................................... 48
Electrical system (version 1).................................................................................... 49
Fuse boxes in main switchbox .................................................................. 49
Electrical system (version 2).................................................................................... 50
Fuse card in main switchbox..................................................................... 50
Power in engine compartment/battery compartment ................................ 51
Main fuse panel (Cummins) ...................................................................... 51
Fuse box at master switch (Deutz)............................................................ 52
Fuses in cab.............................................................................................. 53
Operation ............................................................................................................................... 55
Before starting ......................................................................................................... 55
Master switch - Switching on..................................................................... 55
Control panel, adjustments ....................................................................... 55
Operator's seat - Adjustment..................................................................... 56
Operator's seat, comfort - Adjustments..................................................... 56
Parking brake ............................................................................................ 57
Display - Control........................................................................................ 57

2000h-Maintenance
4812159801_A.pdf 2014-03-31
Interlock..................................................................................................... 58
Operator position....................................................................................... 59
View .......................................................................................................... 59
Starting .................................................................................................................... 60
Starting the engine .................................................................................... 60
Display when activating choice via the button set..................................... 61
Alarm descriptions..................................................................................... 62
Driving ..................................................................................................................... 63
Operating the roller ................................................................................... 63
Machine with gear change in separate spring-return switch
(gear position switch).................................................................. 63
Interlock/Emergency stop/Parking brake - Check ..................................... 65
Pivotal steering (Optional)......................................................................... 66
Edge cutting (Optional) ............................................................................. 66
Vibration .................................................................................................................. 67
Manual/Automatic vibration....................................................................... 67
Manual vibration - Switching on ................................................................ 68
Amplitude/frequency - Changeover........................................................... 68
Braking .................................................................................................................... 68
Normal braking.......................................................................................... 68
Emergency braking ................................................................................... 69
Switching off.............................................................................................. 69
Parking .................................................................................................................... 70
Chocking the drums .................................................................................. 70
Master switch ............................................................................................ 70
Long-term parking.................................................................................................................. 71
Engine ....................................................................................................... 71
Battery....................................................................................................... 71
Air cleaner, exhaust pipe........................................................................... 71
Watering system ....................................................................................... 71

2000h-Maintenance
4812159801_A.pdf2014-03-31
Fuel tank ................................................................................................... 71
Hydraulic reservoir .................................................................................... 71
Hoods, tarpaulin ........................................................................................ 72
Steering cylinder, hinges, etc. ................................................................... 72
Miscellaneous ........................................................................................................................ 73
Lifting ....................................................................................................................... 73
Locking the articulation ............................................................................. 73
Lifting the roller.......................................................................................... 74
Lifting the roller with jack:.......................................................................... 74
Unlocking the articulation .......................................................................... 75
Towing/Recovering.................................................................................................. 75
Short distance towing with the engine running.......................................... 76
Short distance towing when the engine is inoperative. ............................. 76
Towing the roller........................................................................................ 77
Trailer eye ................................................................................................. 77
Transport ................................................................................................................. 78
Loading CC224-624HF, CC2200-6200..................................................... 79
Operating instructions - Summary ......................................................................................... 81
Preventive maintenance ........................................................................................................ 83
Acceptance and delivery inspection.......................................................... 83
Warranty.................................................................................................... 83
Maintenance - Lubricants and symbols ................................................................................. 85
Maintenance symbols ............................................................................... 86
Maintenance - Maintenance schedule ................................................................................... 87
Service and maintenance points ............................................................... 87
General ..................................................................................................... 87
Every 10 hours of operation (Daily)........................................................... 88
After the FIRST 50 hours of operation ...................................................... 88
Every 50 hours of operation (Weekly)....................................................... 89
Every 250 hours of operation (Monthly) .................................................... 89

2000h-Maintenance
4812159801_A.pdf 2014-03-31
Every 500/1500 hours of operation ........................................................... 90
Every 1000 hours of operation .................................................................. 91
Every 2000 hours of operation .................................................................. 92
Maintenance, 10h .................................................................................................................. 93
Diesel engine - Check oil level .................................................................. 93
Coolant level - Check ................................................................................ 94
Fuel tank - Refueling ................................................................................. 94
Water tank, Std - Filling............................................................................. 95
Hydraulic reservoir - Check fluid level....................................................... 95
Sprinkler system/Drum
Check ........................................................................................................ 96
Cleaning the coarse filter .......................................................................... 96
Sprinkler system/Drum
Cleaning of sprinkler nozzle ...................................................................... 97
Emergency watering (Accessory) - Extra pump in pump system.............. 97
Scrapers, spring-action
Check ........................................................................................................ 98
Scrapers
Setting - Adjustment.................................................................................. 98
Maintenance - 50h ............................................................................................................... 101
Fuel filter - Draining................................................................................. 101
Drum gearbox - Checking the oil level .................................................... 102
Maintenance - 250 / 750 / 1250 / 1750h .............................................................................. 103
Diesel engine
Oil change ............................................................................................... 103
Engine
Replacing oil filter.................................................................................... 104
Hydraulic fluid cooler
Checking - Cleaning................................................................................ 104
Battery
- Check condition .................................................................................... 105
Air conditioning (Optional)
- Inspection.............................................................................................. 105

2000h-Maintenance
4812159801_A.pdf2014-03-31
Air conditioning (Optional)
Drying filter - Inspection .......................................................................... 106
Edge cutter (Optional)
- Lubrication ............................................................................................ 106
Maintenance - 500 / 1500h .................................................................................................. 107
Diesel engine
Oil change ............................................................................................... 107
Engine
Replacing oil filter.................................................................................... 108
The engine fuel filter - replacement/cleaning .......................................... 108
Hydraulic fluid cooler
Checking - Cleaning................................................................................ 109
Battery
- Check condition .................................................................................... 109
Air cleaner
Checking - Change the main air filter...................................................... 110
Backup filter - Change............................................................................. 110
Air cleaner
- Cleaning................................................................................................ 111
Drum - oil level
Inspection - filling .................................................................................... 112
Hydraulic reservoir cap - Check .............................................................. 112
Rubber elements and attachment screws
Check ...................................................................................................... 113
Seat bearing - Lubrication ....................................................................... 113
Pivot bearing (Optional) - Lubrication...................................................... 114
Air conditioning (Optional)
- Inspection.............................................................................................. 114
Air conditioning (Optional)
Drying filter - Inspection .......................................................................... 115
Edge cutter (Optional)
- Lubrication ............................................................................................ 115
Maintenance - 1000h ........................................................................................................... 117
Diesel engine
Oil change ............................................................................................... 117

2000h-Maintenance
4812159801_A.pdf 2014-03-31
Engine
Replacing oil filter.................................................................................... 118
The engine fuel filter - replacement/cleaning .......................................... 118
Hydraulic fluid cooler
Checking - Cleaning................................................................................ 119
Air cleaner
Checking - Change the main air filter...................................................... 119
Backup filter - Change............................................................................. 120
Air cleaner
- Cleaning................................................................................................ 120
Battery
- Check condition .................................................................................... 121
Hydraulic filter
Change.................................................................................................... 121
Hydraulic reservoir cap - Check .............................................................. 122
Drum - Changing the oil .......................................................................... 123
Drum gearbox - Oil change ..................................................................... 123
Rubber elements and attachment screws
Check ...................................................................................................... 124
Seat bearing - Lubrication ....................................................................... 124
Pivot bearing (Optional) - Lubrication...................................................... 125
Cab
Fresh air filter - Replacing ....................................................................... 125
Air conditioning (Optional)
- Overhaul ............................................................................................... 126
Air conditioning (Optional)
Drying filter - Inspection .......................................................................... 126
Edge cutter (Optional)
- Lubrication ............................................................................................ 127
Steering hitch - Tightening ...................................................................... 127
Maintenance - 2000h ........................................................................................................... 129
Diesel engine
Oil change ............................................................................................... 129
Engine
Replacing oil filter.................................................................................... 130

2000h-Maintenance
4812159801_A.pdf2014-03-31
The engine fuel filter - replacement/cleaning .......................................... 130
Hydraulic fluid cooler
Checking - Cleaning................................................................................ 131
Air cleaner
Checking - Change the main air filter...................................................... 131
Backup filter - Change............................................................................. 132
Air cleaner
- Cleaning................................................................................................ 132
Battery
- Check condition .................................................................................... 133
Hydraulic filter
Change.................................................................................................... 133
Drum - Changing the oil .......................................................................... 134
Drum gearbox - Oil change ..................................................................... 135
Rubber elements and attachment screws
Check ...................................................................................................... 135
Seat bearing - Lubrication ....................................................................... 136
Hydraulic reservoir cap - Check .............................................................. 136
Hydraulic reservoir
Fluid change............................................................................................ 137
Fuel tank
- Cleaning............................................................................................... 137
Watering system
- Draining................................................................................................ 138
Water tank - Cleaning ............................................................................. 138
Steering joint - Check.............................................................................. 139
Pivot bearing (Optional) - Lubrication...................................................... 139
Cab
Fresh air filter - Replacing ....................................................................... 139
Air conditioning (Optional)
- Overhaul ............................................................................................... 140
Air conditioning (Optional)
Drying filter - Inspection .......................................................................... 140
Edge cutter (Optional)
- Lubrication ............................................................................................ 141

2000h-Maintenance
4812159801_A.pdf 2014-03-31
Steering hitch - Tightening ...................................................................... 141

Introduction
4812159801_A.pdf2014-03-31
Introduction
Warning symbols
The machine
Dynapac CC234HF/334HF, CC2300/3300 is a
self-propelled vibratory tandem roller in 8/9 metric
tonnes class featuring 1500/1730 mm (59/68 in) wide
split drums. The machine is equipped with drive,
brakes, vibration and timer for water sprinkler on both
drums. Propulsion and braking are applied to all drum
halves.
CC234HF/334HF, CC2300/3300 is also available as
Combi with four rubber wheels at rear replacing the
split steel drum.
A variety of different engine power settings, operator
platforms, control possibilities and options makes the
machine available in a lot of different configurations.
Intended use
The machines is mainly designed to be used for thin
and thick asphalt layers with regards to dual vibration
amplitudes that are optimized for this purpose. It is
also possible to compact granular soil material, such
as sand and gravel.
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.
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.
1

Introduction
4812159801_A.pdf 2014-03-31
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.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
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.
2

Introduction
4812159801_A.pdf2014-03-31
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.
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.
3

Introduction
4812159801_A.pdf 2014-03-31
4

Safety - General instructions
4812159801_A.pdf2014-03-31
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
5

Safety - General instructions
4812159801_A.pdf 2014-03-31
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
6

Safety - when operating
4812159801_A.pdf2014-03-31
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.
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 right
opening side-windows.
To exit the cab in an emergency, release the
hammer on the rear right post and break the right
opening side-windows.
It is recommended that ROPS (Roll Over Protective
Structure) or a ROPS approved cab, is always
used when driving on slopes or unsafe ground.
It is recommended that ROPS (Roll Over Protective
Structure) or a ROPS approved cab, is always
used when driving on slopes or unsafe ground.
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.
7

Safety - when operating
4812159801_A.pdf 2014-03-31
Driving near edges
Fig. Position of drums when driving
near an edge
1. Pivotal steering
1≥ 2/3
When driving near an edge, minimum 2/3 of the drum
width must be on solid ground.
When using pivotal steering, only one drum
should be allowed to move into the position
shown in the picture. The other drum must be in
contact with the ground across its full width.
When using pivotal steering, only one drum
should be allowed to move into the position
shown in the picture. The other drum must be in
contact with the ground across its full width.
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.
8