Atlas Copco CP275 Tier II User manual

Instructions ManualInstructions
Operating & Maintenance
Rubber wheel roller
CP275 Tier II
Diesel ngine
Cummins 4BTAA3.9
Serial number
10000508x0C002027-
Translation of original instruction
4812268997.pdf
Reservation for changes
Printed in China

Contents
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Table of contents
Instruction ......................................................................................................................................... 1
The machine..................................................................................................................................... 1
Intended use .................................................................................................................................... 1
Warning symbols ............................................................................................................................. 1
Safety information............................................................................................................................ 2
General ............................................................................................................................................ 3
Safety – General instructions........................................................................................................... 5
Safety – when operating................................................................................................................... 7
Slopes.............................................................................................................................................. 7
Driving near edges ........................................................................................................................... 8
Safety (Optional) ............................................................................................................................... 9
Air conditioning (Optional)................................................................................................................ 9
Special instructions.........................................................................................................................11
Special instructions.........................................................................................................................11
Standard lubricants and other recommended oil and fluids...........................................................11
High 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
Jumping starting (24V).................................................................................................................14
Technical specifications......................................................................................................................15
Technical specifications ..................................................................................................................15
Noise level ......................................................................................................................................15
Technical specifications - Dimensions .............................................................................................16
Weights and volumes ......................................................................................................................17
Working capacity.............................................................................................................................18

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General ...........................................................................................................................................18
Tightening torques..........................................................................................................................19
Machine description............................................................................................................................21
Identification ...................................................................................................................................21
Product identification number on the frame .....................................................................................21
Machine plate..................................................................................................................................21
Explanation of 17PIN serial number .................................................................................................22
Engine plate....................................................................................................................................22
Safety decals...................................................................................................................................24
Locations – Control panel and controls............................................................................................27
Locations & control, cab..................................................................................................................28
Function description of instruments and controls in the cab ............................................................29
Using the cab controls.....................................................................................................................30
Defroster......................................................................................................................................30
Heat.............................................................................................................................................30
AC ...............................................................................................................................................30
Electrical system.............................................................................................................................31
Fuse ............................................................................................................................................32
Cab, fuse.....................................................................................................................................32
Operation ...........................................................................................................................................33
Before starting ................................................................................................................................33
Master switch – Switching on .......................................................................................................33
Before starting ................................................................................................................................34
1
.
Control panel and lights - Check ...............................................................................................34
2
.
Forward and backward lever - Check.........................................................................................34
3
.
Parking brake - Check...............................................................................................................35
View................................................................................................................................................35
Operator position ............................................................................................................................36
Interlock..........................................................................................................................................36
Operating the roller .........................................................................................................................37

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Speed selecting...............................................................................................................................37
Operating on a slope .......................................................................................................................38
Checking the treads on the tires ......................................................................................................39
Variable tire pressure (air-on-the-run) (Option).................................................................................39
Ballast box......................................................................................................................................40
Driving (Ground Pressure)...............................................................................................................41
Ground pressure..........................................................................................................................41
Low tire pressure – 380kPa (55 psi) ..............................................................................................42
Normal tire pressure – 510kPa (70 psi)..........................................................................................43
High tire pressure – 780kPa (110 psi)............................................................................................43
Interlock/Emergency stop/Parking brake - Check .............................................................................44
Normal braking................................................................................................................................44
Emergency braking .........................................................................................................................45
Switching off...................................................................................................................................45
Chocking the wheels .......................................................................................................................45
Master switch..................................................................................................................................46
Long-term parking ..............................................................................................................................47
Miscellaneous.....................................................................................................................................49
Lifting .............................................................................................................................................49
Lifting the roller ...........................................................................................................................49
Lifting the roller with jack.............................................................................................................49
Roller prepare for transport .............................................................................................................50
Towing the roller .............................................................................................................................52
Operating instructions - Summary.......................................................................................................53
Preventive maintenance......................................................................................................................55
Maintenance – Lubricants and symbols...............................................................................................57
Maintenance – Maintenance schedules................................................................................................59
Service and maintenance points......................................................................................................59
General ...........................................................................................................................................60
Every 10 hours of operation (Daily)..................................................................................................60

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After the FIRST 50 hours of operation ..............................................................................................61
Every 50 hours of operation (Weekly)...............................................................................................61
Every 250 hours of operation (Monthly)............................................................................................62
Every 500 hours of operation (Every three months)..........................................................................62
Every 1000 hours of operation (Every six months)............................................................................63
Every 2000 hours of operation (Yearly).............................................................................................64
Maintenance – 10h ..............................................................................................................................65
Diesel engine – Check oil level.........................................................................................................65
Hydraulic reservoir – Check fluid level .............................................................................................66
Coolant level – Check......................................................................................................................66
Fuel tank – Refueling.......................................................................................................................67
Wheel scrapers – Control ................................................................................................................68
Removing the scrapers....................................................................................................................68
Water tank, std – Filling ...................................................................................................................69
Brake fluid level – Check .................................................................................................................69
Sprinkler system .............................................................................................................................70
Cleaning of sprinkler nozzle .........................................................................................................70
Sprinkler system - Check..............................................................................................................70
Sprinkler system – Freeze risk......................................................................................................71
Freeze protection .........................................................................................................................71
Check the emergency stop system pressure.................................................................................71
Tires - Tire pressure ........................................................................................................................72
Maintenance – 50h ..............................................................................................................................73
Air cleaner – Checking – Change the main air filter...........................................................................73
Air cleaner – Cleaning .....................................................................................................................74
Backup filter – Change ....................................................................................................................74
Tires – Tire pressure........................................................................................................................75
Fuel filter – Draining ........................................................................................................................76
Air conditioning (Optional) – Inspection...........................................................................................77
Air conditioning (Optional) – Cleaning .............................................................................................77

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Air conditioner compressor belt – Check .........................................................................................78
Upper/Lower Pivot bearing - Lubrication..........................................................................................79
Maintenance – 250h ............................................................................................................................81
Fuel filter – Replacing......................................................................................................................81
Diesel engine – Oil change...............................................................................................................82
The engine fuel filter – Changing .....................................................................................................83
Diesel engine – Replacing oil filter ...................................................................................................83
Hydraulic oil cooler – Checking – Cleaning ......................................................................................84
Air conditioning (Optional) – Inspection...........................................................................................84
Battery – Check condition................................................................................................................85
Driven chain maintenance ...............................................................................................................86
Driving gear – Check oil level...........................................................................................................87
Maintenance – 500h ............................................................................................................................89
Hydraulic reservoir – Check.............................................................................................................89
Maintenance – 1000h...........................................................................................................................91
Air cleaner – Changing ....................................................................................................................91
Fuel tank - Cleaning.........................................................................................................................92
Watering system – Draining.............................................................................................................92
Backup filter – Change....................................................................................................................92
Hydraulic filter – Change .................................................................................................................93
Cab – Fresh air filter - Replacing......................................................................................................94
Wheel gear – Oil change..................................................................................................................94
Drive gear – Replenishing the oil .....................................................................................................95
Propulsion pump filter – Replace.....................................................................................................95
Emergency stop – Adjustment.........................................................................................................96
Maintenance – 2000h...........................................................................................................................97
Hydraulic reservoir – Fluid change...................................................................................................97
Fuel tank – Cleaning........................................................................................................................98
Water system – Draining..................................................................................................................98
Water tank – Cleaning......................................................................................................................99

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Air conditioning (Optional) – Overhaul .............................................................................................99
Air conditioning (Optional) – Drying filter – Inspection ...................................................................100
Engine – Replacing the coolant......................................................................................................101
Gear oil – Replacement..................................................................................................................102
Hydraulic oil change (2000 hours or 1 year)....................................................................................102
Drive chain – Adjustment...............................................................................................................103
Additional instruction .......................................................................................................................105
Oil spray system (Optional) ...........................................................................................................105
Spray volume – Adjustment...........................................................................................................106
Maintenance – Oil spray system (Optional) ....................................................................................106
Temporary cleaning.......................................................................................................................106
Air on the run (Optional)................................................................................................................107
Air charge and discharge...............................................................................................................108
Maintenance – Air on the run (Optional).........................................................................................108
Disposal..........................................................................................................................................111

Introduction
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Introduction
The machine
Dynapac CP275 is a heavy rubber wheel roller in the 27
tones class, with a working width of 2370 mm.
It has five guide wheels at the front, and four drive
wheels at the back. The hydrostatic drives, flexible
ballast solution, and a wide range of optional equipment
mean that the machine is available in many different
configurations.
Intended use
CP275 is mainly used together with other asphalt
rollers for surface sealing. Thanks to its weight, it is also
suitable for soil compaction.
The attachment or installation of additional devices,
which are used to intervene in the function of the
machine or with which its function are supplement, is
only permitted with the written approval of the
manufacturer.
If necessary, approval should be sought from local
authorities.
Consent from the authorities is however no substitute
for approval from the manufacturer.
Warning symbols
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.

Introduction
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Safety information
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.
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.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Replace immediately the instruction
m
anuals if lost, damaged or unreadable.
Ensure good ventilation (extraction of air
by fan) where the engine is run indoors.
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.

Introduction
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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 ENVIROMENT! 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 manufacture’s engine manual.

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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.
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.
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.
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.
8.
Avoid driving across slopes. Drive straight up or straight down the slope.
9.
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.
Drive particularly carefully on uneven ground.
11.
Use the safety equipment provided. The seat belt must
be worn on
machines fitted with ROPS.
12.
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.
Safety measures before refueling:
-
Shut off the engine
-
Do not smoke
-
No naked flame in the vicinity of the machine
-
Ground the filling device nozzle to the tank to avoid sparks
14.
Before repairs or service:
-
Chock the wheels.
-
Lock the hitch system when necessary.
15.
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.

Safety – General instructions
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16. 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.
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. Refer to the operating instruction in the STOP section.
18.
For your own protection always wear:
-
Helmet
-
working boots with steel toecaps
-
ear protectors
-
reflecting clothing/high visibility jacket
-
working gloves

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.
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
This angle has been measured on a hard, flat surface
with the machine stationary.
The steering angle is zero, the tires have normal air
pressure and all the tanks are full.
Always take into consideration that loose ground, the
steering of the machine, different tire pressures, the
operating speed and that an increase in the center of
gravity can all cause the machine to topple even on
slopes with lesser gradients 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.
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 use the lowest gear when operating
on slopes.
Where possible, avoid driving across
slopes. Drive instead straight up and down sloping
ground.
Fig. Operating on slopes
Max. 15
°
or 27%

Safety – When operating
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Driving near edges
When driving close to edges or holes, make sure that at
least 1/4 of the outer tires are on the previously
compacted material.
Fig.
Position of wheels when
driving near an edge
At least 1/4

Safety (Optional)
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Safet
y (Optional)
Air conditioning (Optional)
The system contains pressurized
refrigerant. It is forbidden to release refrigerants
into the atmosphere.
Work on the refrigerant
circuit is only to be
carried out by authorized companies.
The cooling system is pressurized.
Incorrect handling can result in serious personal
injury. Do not disconnect or undo the hose
couplings.
The system must be re-
filled with an
approved refrigerant by authorized personnel when
necessary. See decal on or in the vicinity of the
installation.
Fig. Operating on slopes

Safety (Optional)
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Special instructions
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Special instructions
Standard lubricants and other recommended oils
and fluids
Before leaving the factory, the systems and
components are filled with the oils and fluids specified
in the lubricant specification. These are suitable for
ambient temperatures in the range
-
15°C to +40°C
-
105°F).
Higher ambient temperatures, above +40°C (104°F)
For operation of the machine at higher ambient
temperatures, however maximum +50°C (12
2°F), the
following recommendations apply:
The diesel engine can be run at this temperature using
normal oil. However, the following fluids must be used
for other components:
Hydraulic system
-
mineral oil Shell Tellus T100 or
similar.
Lower ambient
temperature - Freeze risk
Make sure that the watering system is empty/drained
of water (sprinkler, hoses, tank/s) or that anti
-freeze
has been added, to prevent the system freezing.
Temperatures
The temperature limits apply
to standard versions of
rollers.
Roll
ers equipped with additional equipment, such as
noise suppression, may need to be more carefully
monitored in the higher temperature ranges.

Special instructions
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High pressure cleaning
Do not spray water directly onto electrical components
or the instrument panels.
Place a plastic bag over the fuel filler cap and secure
with a rubber band. This is to avoid high pressure water
entering the vent hole in the filler cap. This could cause
malfunctions, such as the bloc
king of filters.
Fire fighting
If the machine catches fire, use an ABC
-class powder
fire extinguisher.
A BE
-class carbon dioxide fire extinguisher can also
be used.
Roll Over Protective Structure (ROPS), ROPS
approved cab
If the machine is fitted with a Roll Over
Protective Structure (ROPS, or ROPS approved
cab) never carry out any welding or drilling in the
structure or cab.
Never attempt to repair a damaged ROPS
structure or cab. These must be replaced with new
ROPS str
ucture or cabs.
Battery handling
When removing
batteries, always
disconnect
the negative cable first.