Dynapac CA 152 Instruction Manual Download Page 1

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Instructions manual

ICA152-4EN3.pdf

Driving & Maintenance

Vibratory roller

CA152

Engine

Cummins QSB 3.3

Serial number

*64X22468* -

10000105x0A000001 -

Translation of original instruction

Reservation for changes

Reservation for changes
Printed in Sweden

Printed in Sweden

Summary of Contents for CA 152

Page 1: ...roller Vibratory roller CA152 CA152 Engine Engine Cummins QSB 3 3 Cummins QSB 3 3 Serial number Serial number 64X22468 64X22468 10000105x0A000001 10000105x0A000001 Translation of original instruction...

Page 2: ......

Page 3: ...r conditioning 9 Strike off blade 10 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...

Page 4: ...ation of 17PIN serial number 24 Engine plates 24 Decals 25 Location decals 25 Safety decals 26 Info decals 28 Instruments Controls 29 Locations Instruments and controls 29 Locations Control panel and...

Page 5: ...perator position 44 View 45 Strike off blade Optional 45 Starting 46 Starting the engine 46 Operating 47 Operating the roller 47 Operating the strike off blade Optional 49 Vibration 50 Amplitude frequ...

Page 6: ...th the engine running 56 Alternativ 2 57 Towing short distances where the engine is inoperative 57 Rear axle brake 57 Releasing the drum brake 58 Drum motor brake 58 Towing the roller 59 Roller prepar...

Page 7: ...76 Air circulation Check 76 Coolant level Check 77 Hydraulic reservoir Check fluid level 77 Diesel engine Check oil level 78 Fuel tank Filling 78 Brakes Check 79 Maintenance 50h 81 Air cleaner Checki...

Page 8: ...tion 94 Steering chain and seat bearing Lubrication 94 Pre filter Cleaning 95 Seat bearing Lubrication 95 Maintenance 1000h 97 Hydraulic filter Replacement 97 Hydraulic reservoir Draining 98 Fuel tank...

Page 9: ...e ICA152 4EN3 pdf 2012 06 12 Steering joint Check 107...

Page 10: ...e ICA152 4EN3 pdf 2012 06 12...

Page 11: ...tening 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 o...

Page 12: ...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 m...

Page 13: ...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...

Page 14: ...Introduction ICA152 4EN3 pdf 2012 06 12 4...

Page 15: ...s 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 m...

Page 16: ...ns 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 worki...

Page 17: ...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...

Page 18: ...Safety when operating ICA152 4EN3 pdf 2012 06 12 8...

Page 19: ...elease refrigerants into the atmosphere The cooling system is pressurized Incorrect handling can result in serious personal injury Do not disconnect or undo the hose couplings The cooling system is pr...

Page 20: ...he locking pin 1 when driving with the blade in its raised position Always lower the blade to the ground before leaving or parking the roller Ensure always that the strike off blade is secured by the...

Page 21: ...s above 40 C 104 F For operation of the machine at higher ambient temperatures however maximum 50 C 122 F the following recommendations apply The diesel engine can be run at this temperature using nor...

Page 22: ...high pressure water entering the vent hole in the filler cap This could cause malfunctions such as the blocking of filters Never aim the water jet directly at the fuel tank cap This is particularly im...

Page 23: ...tery Do not connect the negative cable to the negative terminal on the dead battery A spark can ignite the oxy hydrogen gas formed around the battery Check that the battery used for jump starting has...

Page 24: ...Special instructions ICA152 4EN3 pdf 2012 06 12 14...

Page 25: ...on level of 2 5 m s specified in the same directive Limit is 5 m s Measured hand arm vibrations also were below the action level of 2 5 m s specified in the same directive Limit is 5 m s Noise level T...

Page 26: ...H1 Height with cab STD D 2815 111 H1 Height with cab P PD 2857 112 H1 Height with cab P PD 2857 112 H2 Height without ROPS STD D 2051 81 H2 Height without ROPS STD D 2051 81 H2 Height without ROPS P...

Page 27: ...1 Thickness left frame side 88 3 5 O1 Thickness left frame side 88 3 5 O2 Thickness right frame side 88 3 5 O2 Thickness right frame side 88 3 5 R1 Turn radius external 4530 178 R1 Turn radius externa...

Page 28: ...ab P 7750 kg 17 086 lbs Service weight with cab PD 7900 kg 17 417 lbs Service weight with cab PD 7900 kg 17 417 lbs Fluid volumes Fluid volumes Fuel tank 225 liters 59 4 gal Fuel tank 225 liters 59 4...

Page 29: ...rt 2 200 rpm Electrical system Electrical system Battery 12V 170Ah Battery 12V 170Ah Alternator 12V 60A Alternator 12V 60A Fuses See the Electrical system section fuses Fuses See the Electrical system...

Page 30: ...370 470 520 560 620 M22 446 497 626 699 752 839 M22 446 497 626 699 752 839 M24 570 640 800 900 960 1080 M24 570 640 800 900 960 1080 M30 1130 1260 1580 1770 1900 2100 M30 1130 1260 1580 1770 1900 21...

Page 31: ...reated Hydraulic system Opening pressure MPa Opening pressure MPa Drive system 38 0 Drive system 38 0 Supply system 2 0 Supply system 2 0 Vibration system 33 0 Vibration system 33 0 Control systems 18...

Page 32: ...Technical specifications ICA152 4EN3 pdf 2012 06 12 22...

Page 33: ...ig Operator platform 1 Machine plate The machine type plate 1 is attached to the front left side of the frame beside the steering joint The plate specifies the manufacturer s name and address the type...

Page 34: ...mily Model C Check letter D No coding E Production unit F Serial number Engine plates The engine type plate 1 is attached on the right side of the engine The plate specifies the type of engine its ser...

Page 35: ...ic fluid 4700272372 4700904601 3 Warning Hot surfaces 4700903424 9 Hoisting plate 4700904870 15 Tie down point 3 Warning Hot surfaces 4700903424 9 Hoisting plate 4700904870 15 Tie down point 4 Warning...

Page 36: ...crush zone Two crush zones on machines fitted with pivotal steering 4700903423 Warning Rotating engine components Keep your hands at a safe distance from the danger zone 4700903424 Warning Hot surfac...

Page 37: ...iption ICA152 4EN3 pdf 2012 06 12 4700908229 Warning Risk of crushing The articulation must be locked when lifting Read the instruction manual 4700904165 Warning Toxic gas option ACC Read the instruct...

Page 38: ...point Noise power level Diesel fuel Lifting point Hoisting plate Handbook compartment Master switch Hoisting plate Handbook compartment Master switch Hydraulic fluid Biological hydraulic fluid Securin...

Page 39: ...ne temperature 12 Engine temperature 13 Engine revs Vibration frequency 13 Engine revs Vibration frequency 14 Compaction meter Speedometer see pos 21 14 Compaction meter Speedometer see pos 21 15 Fuel...

Page 40: ...ning lamp hydraulic fluid filter 37 Emergency stopp 29 Warning lamp hydraulic fluid filter 37 Emergency stopp 30 Warning lamp air filter 38 Vibration ON OFF 30 Warning lamp air filter 38 Vibration ON...

Page 41: ...witch lights and the main beam is on In the left position the dipped beam is on 8 Driving lighting switch Optional Lights off 8 Driving lighting switch Optional Lights off Parking lights on Parking li...

Page 42: ...es high amplitude 25 CMV selector Optional Mode 150 gives reading on outer scale Mode 50 gives reading on inner scale 25 CMV selector Optional Mode 150 gives reading on outer scale Mode 50 gives readi...

Page 43: ...ess once and release to switch the vibration on press again to switch the vibration off The above only applies when the amplitude selector 17 is in the High or Low position 39 Forward Reverse lever Th...

Page 44: ...iption ICA152 4EN3 pdf 2012 06 12 Controls in the cab First aid kit optional 1 2 34 5 6 Fig Cab roof front Fig Cab right side Fig Cab right side AC optional 9 7 7 11 8 10 8 Fig Cab rear 12 Fig Cab roo...

Page 45: ...m See the Electrical system section in the operation manual for functional descriptions of the fuses 7 Heater control Right mode maximum heating In the left position the heating is off 7 Heater contro...

Page 46: ...ontrol system is protected against overload by 27 fuses and 12 relays The quantity depends on how much extra equipment the machine has The four fuse boxes 1 and relays 3 are located behind the lower i...

Page 47: ...umination 7 5A 5 Low High speed Strike off blade 7 5A 5 Flow divider 7 5A 5 Low High speed Strike off blade 7 5A 5 Flow divider 7 5A 6 Reverse warning 3A 6 Reserve 6 Reverse warning 3A 6 Reserve 7 Ins...

Page 48: ...ted on the front right side of the cab roof The figure shows fuse amperage and function All fuses are flat pin fuses Main fuses Fig Engine compartment 1 Starter relay 2 Main fuses 3 Preheating relays...

Page 49: ...ompartment QSB engine ignition 5A QSB engine ignition 5A Diagnostics lamps engine 5A Diagnostics lamps engine 5A ECM electronics 30A ECM electronics 30A Power socket 12V 10A Power socket 12V 10A Relay...

Page 50: ...ab Fig Cab roof front 1 Instrument plate 2 K30 Relay for air conditioning fan 3 K31 Relay for air con fans radio 4 Fuse box 1 2 3 4 To replace the relays for the air conditioning fan the condensor fan...

Page 51: ...ngine hood must be unlocked when operating so that the battery can be quickly disconnected if necessary Operator s seat Adjusting 3 1 2 Fig Operator s seat 1 Locking lever Length adjustment 2 Lever We...

Page 52: ...on Always make sure that the seat is secure before beginning operation Operator s seat in cab Adjusting 6 4 2 1 3 5 Fig Operator s seat 1 Lever length adjustment 2 Wheel height adjustment 3 Wheel seat...

Page 53: ...hat the fuel gauge 15 shows a reading Check that the warning lamps for charging 31 oil pressure 28 and the parking brake 27 come on The hourmeter 26 registers and shows the number of hours the diesel...

Page 54: ...ar a protective helmet Replace the seat belt 1 if it shows signs of wear or has been subjected to high levels of force Replace the seat belt 1 if it shows signs of wear or has been subjected to high l...

Page 55: ...ptional 1 Fig Strike off blade 1 Cotter pin Always ensure that the strike off blade is secured by the locking pin 1 when driving with the blade in its raised position Always lower the blade to the gro...

Page 56: ...a minute or so before trying again Fig Instrument panel 1 Starter switch 10 Voltmeter Optional 16 Preheating lamp 23 Engine speed control 24 Amplitude selector 27 Brake lampa 28 Oil pressure lamp 31 C...

Page 57: ...nces is the machine to be operated from the ground The operator must be seated inside the machine during all operation Turn the engine speed control 23 to the position for 2 200 rpm Deactivate the par...

Page 58: ...fluid is also cold and that braking distances can be longer than normal until the machine reaches the working temperature When starting and driving a machine that is cold remember that the hydraulic...

Page 59: ...ll speed the main filter must be cleaned or replaced See the Maintenance Manual Operating the strike off blade Optional 1 Fig Controls 1 Lever Before driving make certain that the blade is in its uppe...

Page 60: ...Setting the amplitude may not be performed when vibration is in operation Switch the vibration off first and wait until vibration stops before setting amplitude Manual vibration Switching on 38 Fig C...

Page 61: ...d pull up the emergency stop 37 The roller is fitted with an Interlock and therefore the operator must sit in the seat to start the engine Normal braking 38 39 42 Fig Control panel 38 Vibration On Off...

Page 62: ...users Chock the drums if the roller is parked on sloping ground Make sure that the roller is parked in a safe place with respect to other road users Chock the drums if the roller is parked on sloping...

Page 63: ...nd apply grease to unpainted surfaces Engine Refer to the manufacturer s instructions in the engine manual that is supplied with the roller Battery Remove the battery from the machine Clean the batter...

Page 64: ...ine compartment and the cab Grease both ends of the forward reverse control bright parts see under the heading Every 500 hours of operation Hoods tarpaulin Lower the instrument cover over the instrume...

Page 65: ...nd locking lug 4 and secure the stud in position with the locking pin 2 Weight refer to the hoisting plate on the roller 1 1 Fig Roller prepared for lifting 1 Hoisting plate Lifting the roller The mac...

Page 66: ...eters 1 000 ft using the instructions below 2 2 1 1 Fig Propulsion pump 1 Towing valve 2 Locknut Alternative 1 Short distance towing with the engine running Depress the emergency parking brake knob an...

Page 67: ...xle brake Undo the locknut 3 and adjust the adjustment screws 4 by hand until full resistance is felt and then one additional turn The adjustment screws are located on the rear axle two screws on each...

Page 68: ...es Screw in the nut 4 so that it is flush with the washer and then an additional 1 1 2 varv while holding the screw 3 The brake is now disengaged and the machine can be towed After towing remember to...

Page 69: ...N 31500 lbf Restore the items for towing according to alternative 1 or 2 on the preceding pages Restore the items for towing according to alternative 1 or 2 on the preceding pages Roller prepared for...

Page 70: ...Operating instructions Summary ICA152 4EN3 pdf 2012 06 12 60...

Page 71: ...the forward reverse lever with care 10 Drive the roller Operate the forward reverse lever with care 11 Test the brakes Remember that the braking distance will be longer if the roller is cold 11 Test...

Page 72: ...Operating instructions Summary ICA152 4EN3 pdf 2012 06 12 62...

Page 73: ...rrival before delivery to the customer delivery inspection must be conducted as per the check list in the warranty document Any transport damage must be immediately reported to the transport company W...

Page 74: ...Preventive maintenance ICA152 4EN3 pdf 2012 06 12 64...

Page 75: ...ts Lubrication oil diesel engine 7 2 liters 7 4 qts Coolant diesel engine 17 5 liters 4 5 gal Coolant diesel engine 17 5 liters 4 5 gal Always use high quality lubricants and the amounts recommended T...

Page 76: ...L Air temp 15 C 40 C 5 F 104 F Shell Spirax S3 AX 80W 90 API GL 5 or equivalent Dynapac Gear Oil 300 P N 4812030756 5 litres P N 4812030117 20 litres DRUM OIL Air temp 15 C 40 C 5 F 104 F Shell Spirax...

Page 77: ...l filter Air filter Engine oil filter Air filter Hydraulic reservoir level Battery Hydraulic reservoir level Battery Hydraulic fluid filter Recycling Hydraulic fluid filter Recycling Transmission oil...

Page 78: ...Maintenance Lubricants and symbols ICA152 4EN3 pdf 2012 06 12 68...

Page 79: ...Flywheel casing hydraulic pumps 32 Hydraulic fluid cooler 7 Bleeding filter 20 Wheel nuts 33 Drive belts cooling alternator 7 Bleeding filter 20 Wheel nuts 33 Drive belts cooling alternator 8 Hydrauli...

Page 80: ...ng 1 Check for free circulation of cooling air 1 Check for free circulation of cooling air 31 Check coolant level Refer to the engine manual 31 Check coolant level Refer to the engine manual 2 Check t...

Page 81: ...nal Every 250 hours of operation Monthly Refer to the contents to find the page number of the sections referred to Pos in fig Action Comment Pos in fig Action Comment 23 Check oil level in rear axle p...

Page 82: ...Pos in fig Action Comment Pos in fig Action Comment 7 Check bleeder filter on hydraulic reservoir 7 Check bleeder filter on hydraulic reservoir 8 Change the hydraulic fluid filter 8 Change the hydrau...

Page 83: ...ydraulic fluid 9 Change the hydraulic fluid 10 Change the hydraulic fluid 10 Change the hydraulic fluid 12 Change the oil in the drum 12 Change the oil in the drum 15 Change the oil in the drum 15 Cha...

Page 84: ...Maintenance Maintenance schedule ICA152 4EN3 pdf 2012 06 12 74...

Page 85: ...off and the emergency parking brake should be applied if not otherwise specified Scrapers Check adjustment Fig Scrapers 1 Scraper beam 2 Screws 1 2 If necessary adjust distance to the drum as follows...

Page 86: ...engine has free circulation of cooling air through the protective grille in the hood To open the engine hood turn the locking arm 1 upward Raise the hood to its fully open position checking that the r...

Page 87: ...eze See the lubrication specifications in these instructions and in the engine manual Flush the system every other year and change the coolant Make sure also that the air flow through the cooler is un...

Page 88: ...nk Filling Fig Fuel tank 1 Filler pipe 1 Refuel daily with diesel fuel up to the lower edge of the filler pipe 1 Follow the engine manufacturer s specification with regard to the quality of diesel fue...

Page 89: ...er checking the emergency stop set the forward reverse lever 2 in neutral Pull up the emergency stop 1 Start the engine The roller is now ready for operation Checking the parking brake Fig Control pan...

Page 90: ...Maintenance 10h ICA152 4EN3 pdf 2012 06 12 80...

Page 91: ...p on the control panel comes on when the engine is running at maximum speed Change the air cleaner main filter when the warning lamp on the control panel comes on when the engine is running at maximum...

Page 92: ...Cleaning Wipe clean the inside of the cover 2 and the filter housing 5 See the previous illustration Wipe clean on both sides of the outlet pipe Outer edge of outlet pipe Inner edge of outlet pipe Wi...

Page 93: ...cy parking brake knob before lubricating Turn the steering wheel fully to the right so that all the nipples 4 on the left side of the steering system are accessible Use grease as per the lubricant spe...

Page 94: ...parking brake control With the unit in operation open the engine hood and check using the sight glass 1 that bubbles are not visible on the drying filter The filter is located on the left side of the...

Page 95: ...ear axle Check the tightening torque of the wheel nuts 2 at 630 Nm 465 lbf ft Check both wheels and all nuts This only applies to a new machine or newly fitted wheels Check the safety manual that acco...

Page 96: ...Maintenance 50h ICA152 4EN3 pdf 2012 06 12 86...

Page 97: ...under the roller when the engine is running Park on a level surface Block the wheels securely Wipe clean and remove the level plug 1 and check that the oil level reaches the lower edge of the plug hol...

Page 98: ...for overheating Do not overfill with oil risk for overheating Radiator Check Cleaning Fig Engine compartment 1 Water cooler 2 Charge air cooler 3 Hydraulic fluid cooler 1 2 3 Check that air can pass u...

Page 99: ...ter change Observe care when draining hot engine oil Wear protective gloves and goggles Observe care when draining hot engine oil Wear protective gloves and goggles Fig Left side of engine 1 Drain plu...

Page 100: ...rews 2 Battery cover 3 Battery 1 1 2 3 Never use a naked flame when checking the battery as the electrolyte emits explosive gas while the alternator is charging Never use a naked flame when checking t...

Page 101: ...first when disconnecting the battery When connecting the battery always connect the positive cable first Always disconnect the negative cable first when disconnecting the battery When connecting the...

Page 102: ...Maintenance 250h ICA152 4EN3 pdf 2012 06 12 92...

Page 103: ...noxide poisoning Ensue that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Replacing the fuel filter Fig Engine compartment 1 Fuel filter 1 Pla...

Page 104: ...ce 3 Adjusting nut 4 Nuts 5 Control valve mount 1 2 3 4 5 a Optional on rollers without cab Keep in mind that the chain is a vital part of the steering mechanism Keep in mind that the chain is a vital...

Page 105: ...out cab Keep in mind that the chain is a vital part of the steering mechanism Keep in mind that the chain is a vital part of the steering mechanism Remove the cover 5 to access the lubrication nipple...

Page 106: ...Maintenance 500h ICA152 4EN3 pdf 2012 06 12 96...

Page 107: ...hat there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Hydraulic filter Replacement Fig Hydraulic reservoir 2 Filler cap Bleeding filter 3 Sight gl...

Page 108: ...n an additional half revolution Do not tighten the filter too hard as this could damage the gasket First tighten the filter until its seal is in contact with the filter attachment Then turn an additio...

Page 109: ...1 Remove the plug and drain the water and sediment until only pure fuel runs from the plug Refit the plug Rear axle differential Oil change Fig Rear axle 1 Level Filler plug 2 Drain plugs 1 2 Never w...

Page 110: ...e is approx 0 8 liters 0 85 qts Save the oil and dispose of it in an approved manner Save the oil and dispose of it in an approved manner Fig Planetary gear filling position 1 Plug 1 Position the roll...

Page 111: ...ilter can also be accessed via the right cab window Use a step ladder to reach the filter 1 The filter can also be accessed via the right cab window Loosen the two screws 2 on the cab s right side Tak...

Page 112: ...Maintenance 1000h ICA152 4EN3 pdf 2012 06 12 102...

Page 113: ...ervoir 1 Drainage tap 2 Plug 1 2 Obtain a container for collecting the used fluid The container should be able to hold at least 60 liters 16 gal Observe care when draining hot hydraulic fluid Wear pro...

Page 114: ...pose of it in an approved manner Clean and remove the drain plug 1 Allow all of the oil to drain off Fill with oil according to Drum Checking the oil level Take great care when draining warm fluids an...

Page 115: ...rful The air jet can damage the element flanges if it is too powerful Wear protective goggles when working with compressed air Wear protective goggles when working with compressed air Inspect the cond...

Page 116: ...in serious personal injury The cooling system is pressurized Incorrect handling can result in serious personal injury The system contains pressurized refrigerant It is forbidden to release refrigerant...

Page 117: ...ce 2000h ICA152 4EN3 pdf 2012 06 12 Steering joint Check Fig Steering joint Inspect the steering joint to detect any damage or cracks Check and tighten any loose bolts Check also for any stiffness and...

Page 118: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden...

Page 119: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden...

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