Dynapac CA 302 Instruction Manual Download Page 8

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2000h-

Maintenance

ICA302-4EN4.pdf

2012-04-12

Rear axle differential - Check oil level....................................................... 89

Rear axle planetary gears - Check oil level............................................... 90

Drum gearbox - Checking the oil level ...................................................... 90

Drum cartridge - Checking the oil level ..................................................... 91

Drum cartridge - Cleaning the ventilation screw ....................................... 92

Radiator - Check/Cleaning ........................................................................ 92

Bolted joints - Checking tightening torque................................................. 92

Rubber elements and fastening screws - Check....................................... 93

Battery - Check electrolyte level................................................................ 93

Battery cell ................................................................................................ 94

Air conditioning (Optional)
- Inspection................................................................................................ 94

Maintenance - 500h ............................................................................................................... 95

Replacing the fuel filter.............................................................................. 95

Controls and moving joints - Lubrication ................................................... 96

Fuel pre-filter - Cleaning............................................................................ 96

Diesel engine - Oil and Filter change ........................................................ 97

Steering chain and seat bearing - Lubrication........................................... 97

Seat bearing - Lubrication ......................................................................... 98

Maintenance - 1000h ............................................................................................................. 99

Hydraulic filter - Replacement ................................................................... 99

Hydraulic reservoir - Draining.................................................................. 100

Fuel tank - Drainage................................................................................ 101

Rear axle differential - Oil change........................................................... 101

Rear axle's planetary gears - Draining the oil ......................................... 102

Rear axle's planetary gears - Oil change - Oil filling ............................... 103

Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 103

Maintenance - 2000h ........................................................................................................... 105

Hydraulic reservoir - Oil change.............................................................. 105

Summary of Contents for CA 302

Page 1: ...y roller Vibratory roller CA302 CA302 Engine Engine Cummins QSB 4 5 Cummins QSB 4 5 Serial number Serial number 68X11612 68X11612 10000116x0A000001 10000116x0A000001 Translation of original instruction Translation of original instruction Reservation for changes Reservation for changes Printed in Sweden Printed in Sweden ...

Page 2: ......

Page 3: ...trike off blade 9 Air conditioning 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 cleaning 11 Fire fighting 12 Roll Over Protective Structure ROPS ROPS approved cab 12 Battery handling 12 Jump starting 13 Technical specifications 15 Vibrations Operator station 15 Noise level 15 El...

Page 4: ...anation of 17PIN serial number 24 Engine plate 24 Decals 25 Location decals 25 Safety decals 26 Info decals 28 Instruments Controls 29 Locations Instruments and controls 29 Locations Control panel and controls 30 Function descriptions 31 Controls in the cab 34 Function description of instruments and controls in the cab 35 Electrical system 36 Fuses 36 Fuses in cab 38 Main fuses 38 Fuses at battery...

Page 5: ...ition 44 View 45 Strike off blade Optional 45 Starting 46 Starting the engine 46 Operating 47 Operating the roller 47 Operation of strike off blade Optional 49 Operating on difficult surfaces Optional 50 Drive drum wheels 50 Vibration 50 Amplitude frequency Changeover 50 Manual vibration Switching on 51 Braking 51 Emergency braking 51 Normal braking 52 Switching off 52 Parking 53 Chocking the drum...

Page 6: ... Alternative 1 58 Short distance towing with the engine running 58 Alternative 2 59 Towing short distances where the engine is inoperative 59 Rear axle brake 59 Drum gearbox brake 59 Drum gearbox brake Option 60 Towing the roller 61 Roller prepared for transport 61 Operating instructions Summary 63 Preventive maintenance 65 Acceptance and delivery inspection 65 Warranty 65 Maintenance Lubricants a...

Page 7: ...ers Check adjustment 77 Scrapers Pad drum 78 Flexible scrapers Optional 78 Air circulation Check 79 Coolant level Check 79 Diesel engine Check oil level 80 Hydraulic reservoir Check fluid level 80 Fuel tank Filling 81 Brakes Check 82 Maintenance 50h 83 Air cleaner Checking Change the main air filter 83 Backup filter Change 84 Air cleaner Cleaning 84 Articulation Lubrication 85 Steering joint Lubri...

Page 8: ...tioning Optional Inspection 94 Maintenance 500h 95 Replacing the fuel filter 95 Controls and moving joints Lubrication 96 Fuel pre filter Cleaning 96 Diesel engine Oil and Filter change 97 Steering chain and seat bearing Lubrication 97 Seat bearing Lubrication 98 Maintenance 1000h 99 Hydraulic filter Replacement 99 Hydraulic reservoir Draining 100 Fuel tank Drainage 101 Rear axle differential Oil ...

Page 9: ...4 12 Drum cartridge Oil change 106 Drum gearbox Oil change 107 Forward Reverse lever Lubrication 107 Steering hitch Check 108 Automatic Climate Control Optional Overhaul 108 Compressor Check Optional 109 Drying filter Check 109 ...

Page 10: ... e ICA302 4EN4 pdf 2012 04 12 ...

Page 11: ...rious 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 machi...

Page 12: ...e 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 ent...

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 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 a...

Page 14: ...Introduction ICA302 4EN4 pdf 2012 04 12 4 ...

Page 15: ...ly 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 wi...

Page 16: ...ons 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 work...

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 slope angles than those specified here To exit the cab in an emergency release the hammer on the rear right post and break the rear window To exit the cab in an emergency release the hammer on the r...

Page 18: ...Safety when operating ICA302 4EN4 pdf 2012 04 12 8 ...

Page 19: ...cured by the 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 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 The strike off blade must be retracted to the trans...

Page 20: ...efrigerants 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 pressurized Incorrect handling can result in serious personal injury Do not disconnect or undo the hose couplings The system must be refilled with an approved refrigerant by authorized personnel when necessary ...

Page 21: ...es 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 normal oil However the following fluids must be used for other components Hydraulic system mineral oil Shell Tellus T100 or similar Other components that use transmission oil Shell Spirax AX 85W 140 or ...

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 important when using a high pressure cleaner Never aim the water jet directly at the fuel tank cap This is particularly important when using a high pressure cleaner Fire fighting If the machine catches...

Page 23: ...ttery 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 the same voltage as the dead battery Check that the battery used for jump starting has the same voltage as the dead battery Fig Jump starting 1 2 3 4 Turn the ignition and all power consuming equipme...

Page 24: ...Special instructions ICA302 4EN4 pdf 2012 04 12 14 ...

Page 25: ...ction 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 The noise level is measured in accordance with the operational cycle described in EU directive 2000 14 EC on machines equipped for the EU market on soft polymer material with vibration switched on a...

Page 26: ...985 117 5 H2 Height without ROPS D 2190 86 H2 Height without ROPS D 2190 86 H2 Height without ROPS PD 2210 87 H2 Height without ROPS PD 2210 87 D Diameter drum D 1543 60 75 D Diameter drum D 1543 60 75 D Diameter drum PD 1523 59 96 D Diameter drum PD 1523 59 96 S Thickness drum sweep nominal D 35 1 378 S Thickness drum sweep nominal D 35 1 378 S Thickness drum sweep nominal PD 25 0 984 S Thickness...

Page 27: ...1 Overhang left frame side 127 5 O1 Overhang left frame side 127 5 O2 Overhang right frame side 127 5 O2 Overhang right frame side 127 5 R1 Turn radius external 5400 212 6 R1 Turn radius external 5400 212 6 R2 Turn radius internal 3100 122 R2 Turn radius internal 3100 122 W1 Width tractor section 2130 83 86 W1 Width tractor section 2130 83 86 W2 Width drum 2130 83 86 W2 Width drum 2130 83 86 17 ...

Page 28: ...ar load PD Static linear load PD Static linear load with ROPS D 37 9 kg cm 212 pli Static linear load with ROPS D 37 9 kg cm 212 pli Static linear load with ROPS PD Static linear load with ROPS PD Static linear load with cab D 38 3 kg cm 214 pli Static linear load with cab D 38 3 kg cm 214 pli Static linear load with cab PD Static linear load with cab PD Amplitude high D 1 7 mm 0 066 in Amplitude ...

Page 29: ...system Battery 12V 170Ah Battery 12V 170Ah Alternator 12V 95A Alternator 12V 95A Fuses See the Electrical system section fuses Fuses See the Electrical system section fuses Tire Tire dimensions Tire pressure Tire Tire dimensions Tire pressure Std type 23 1 x 26 0 12 ply 110 kPa 1 1 kp cm 16 psi Std type 23 1 x 26 0 12 ply 110 kPa 1 1 kp cm 16 psi Tractor type 23 1 x 26 0 12 ply 110 kPa 1 1 kp cm 1...

Page 30: ...0 370 470 520 560 620 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 2100 STRENGTH CLASS Metric coarse screw thread bright galvanized fzb Metric coarse thread zinc treated Dacromet GEOMET STRENGTH CLASS M thread 10 9 Oiled 10 9 Dry 12 9 Oiled 12 9 Dry M thread 10 9 Oile...

Page 31: ...ated 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 46 0 Vibration system 46 0 Control systems 18 0 Control systems 18 0 Brake release 1 4 Brake release 1 4 Automatic Climate Control ACC Optional The system described in this manual is type ACC Automatic Climate Control i e a system which maintains ...

Page 32: ...Technical specifications ICA302 4EN4 pdf 2012 04 12 22 ...

Page 33: ...Fig 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 of machine the PIN product identification number serial number service weight engine power and year of manufacture If the machine is delivered outside the EU there are no CE markings and on some mac...

Page 34: ...rer B Family Model C Check letter D No coding E Production unit F Serial number Engine plate The engine type plate 1 are affixed to the top of the engine The plate specify the type of engine serial number and the engine specification 1 Fig Engine 1 Type plate EPA plate Please specify the engine serial number when ordering spares Refer also to the engine manual 24 ...

Page 35: ...lic 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 Ballasted tire 4700903985 10 Tire pressure 4700991990 16 Handbook compartment 4700903425 4 Warning Ballasted tire 4700903985 10 Tire pressure 4700991990 16 Handbook compartment 4700903425 5 Emergenc...

Page 36: ...e 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 surfaces in the engine compartment Keep your hands at a safe distance from the danger zone 4700903985 Warning Ballasted tire Read the instruction manual 4700903590 Emergency exit 4700903459 Warning Instruc...

Page 37: ...ription ICA302 4EN4 pdf 2012 04 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 instruction manual 27 ...

Page 38: ...el fuel Lifting point Hoisting plate Handbook compartment Master switch Hoisting plate Handbook compartment Master switch Hydraulic fluid Biological hydraulic fluid Securing point Hydraulic fluid Biological hydraulic fluid Securing point Sound power level LN version Tire pressure Sound power level LN version Tire pressure 28 ...

Page 39: ...ine 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 gauge 15 Fuel gauge 16 Preheating lamp 16 Preheating lamp 17 Reserve 17 Reserve 18 Fault indicating lamp 18 Fault indicating lamp 19 Diagnostics ON 19 Diagnostics ON 20 Browse in error codes 20 Brow...

Page 40: ...g lamp hydraulic fluid filter 37 Emergency stop 29 Warning lamp hydraulic fluid filter 37 Emergency stop 30 Warning lamp air filter 38 Vibration ON OFF 30 Warning lamp air filter 38 Vibration ON OFF 31 Warning lamp charging 39 Forward Reverse lever 31 Warning lamp charging 39 Forward Reverse lever 32 Warning lamp hydraulic fluid temperature 40 Horn 32 Warning lamp hydraulic fluid temperature 40 Ho...

Page 41: ...switch 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 lights on Front working lights on Front working lights on 9 Warning lamp malfunctioning anti spin function Optional The hydraulic propulsion system is not working satisfactorily if the lamp flashes Loc...

Page 42: ...ves 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 reading on inner scale 26 Hourmeter Engine running time is shown in hours 26 Hourmeter Engine running time is shown in hours 27 Brake warning lamp The lamp come on when the parking or emergency brake knob...

Page 43: ... above only applies when the amplitude selector 17 is in the High or Low position 39 Forward Reverse lever The lever must be in neutral to start the engine The engine cannot be started if the forward reverse lever is in any other position The forward reverse lever controls both the roller s driving direction and speed When the lever is moved forward the roller moves forward The roller s speed is p...

Page 44: ...ription ICA302 4EN4 pdf 2012 04 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 roof rear 13 34 ...

Page 45: ...em 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 control Right mode maximum heating In the left position the heating is off 8 Ventilation fan switch In the left position the fan is OFF To the right the fan has three levels 8 Ventilation fan switch In the...

Page 46: ...control 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 instrument plate which is opened by turning the four quick fit screws 2 a 1 4 turn counter clockwise The machine is equipped with a 12V electrical system and an AC alternator 36 ...

Page 47: ...ation 7 5A 5 Low High speed Strike off blade 7 5A 5 Reserve 5 Low High speed Strike off blade 7 5A 5 Reserve 6 Reverse warning 3A 6 Reserve 6 Reverse warning 3A 6 Reserve 7 Instrumentation 7 5A 7 Hazard beacon 10A 7 Instrumentation 7 5A 7 Hazard beacon 10A 8 Compaction meter 3A 8 Direction indicators main fuse 10A 8 Compaction meter 3A 8 Direction indicators main fuse 10A 9 Hazard beacon 7 5A 9 Po...

Page 48: ...ated 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 3 1 2 There are four main fuses 2 They are located behind the battery master disconnect switch The three screws need to be unscrewed to remove the plastic cover The fuses are of flat pin type The sta...

Page 49: ...compartment 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 Relays Fig Instrument panel K2 VBS relay K2 VBS relay K3 Main relay K3 Main relay K4 Horn relay K4 Horn relay K6 Fuel gauge relay K6 Fuel gauge relay K7 Reversing alarm relay K7 Reversing alarm relay K8 L...

Page 50: ...cab 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 on the cab roof and the radio remove instrumentpanel 1 40 ...

Page 51: ...engine 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 Weight adjustment 3 Locking lever Steering column angle Adjust the operator s seat so that the position is comfortable and so that the controls are within easy reach The seat can be adjusted as follows...

Page 52: ...ion 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 cushion inclination 4 Wheel backrest inclination 5 Wheel armrest inclination 6 Wheel lumbar support adjustment The control unit has three adjustment options transverse travel rotation and steering c...

Page 53: ...that 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 engine has been running The preheating lamp 16 must go on Parking brake Check 42 Fig Control panel 42 Parking brake knob Make sure that the parking brake knob 42 is in activated position The roller c...

Page 54: ...ear 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 levels of force Check that rubber elements 3 on the platform are intact Worn elements will impair comfort Check that rubber elements 3 on the platform are intact Worn elements will impair comfort Ensu...

Page 55: ...Optional 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 ground before leaving parking the roller 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 ground b...

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 Charging lamp 24 27 28 31 1 16 23 10 Let the engine idle for a few minutes to warm longer if the ambient temperature is below 10 C 50 F While the engine is warming up check that the warning lamps for ...

Page 57: ...ances 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 parking brake and check that the steering is working correctly by turning the steering wheel once to the right and once to the left while the roller is stationary Make sure that the area in front of and...

Page 58: ... drum Low rear axle 6 5 km h High drum Low rear axle 6 5 km h High drum High rear axle 16 0 km h High drum High rear axle 16 0 km h Only with accessory Only with accessory The High High mode may only be used for transport runs on an even surface The High High mode may only be used for transport runs on an even surface Carefully move the forward reverse lever 39 forwards or backwards depending on w...

Page 59: ...full speed the main filter must be cleaned or replaced See the Maintenance Manual Operation of strike off blade Optional 1 Fig Controls 1 Lever Before driving make certain that the blade is in its uppermost position raised Inspect the condition of the ground before using the blade Before driving make certain that the blade is in its uppermost position raised Inspect the condition of the ground bef...

Page 60: ... set the knobs in their original positions Vibration Amplitude frequency Changeover 24 Fig Instrument panel 24 Amplitude selector Low 0 High There are two drum vibration settings Use the switch 24 to adjust Turn the knob to the left for low amplitude high frequency and to the right for high amplitude low frequency Setting the amplitude may not be performed when vibration is in operation Switch the...

Page 61: ... Reverse lever Braking is normally activated using the forward reverse lever The hydrostatic transmission retards and slows the roller when the lever is moved towards the neutral position A disc brake in the drum motor and rear axle acts as an emergency brake when in motion and as a parking brake when stationary For emergency braking press the emergency stop 37 hold the steering wheel firmly and b...

Page 62: ...until the machine reaches the working temperature When starting and driving a machine that is cold remember that the hydraulic fluid is also cold and that braking distances can be longer than normal until the machine reaches the working temperature Activate the parking brake knob 42 even for short stops on sloping ground Activate the parking brake knob 42 even for short stops on sloping ground Swi...

Page 63: ... if the roller is parked on sloping ground Remember the risk of freezing during the winter Fill the engine cooling system and the screenwash bottle in the cab with suitable anti freeze mixtures See also the maintenance instructions Remember the risk of freezing during the winter Fill the engine cooling system and the screenwash bottle in the cab with suitable anti freeze mixtures See also the main...

Page 64: ...Operation ICA302 4EN4 pdf 2012 04 12 54 ...

Page 65: ...es 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 battery check that the electrolyte level is correct see under the heading Every 50 hours of operation and trickle charge the battery once a month Air cleaner exhaust pipe Cover the air cleaner see under the heading Every 50 hours of operatio...

Page 66: ... the hinges on the doors to the engine 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 instrument panel Cover the entire roller with a tarpaulin A gap must be left between the tarpaulin and the ground If possible store the roller indoors and ideally in a build...

Page 67: ...and 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 machine s gross weight is specified on the hoisting plate 1 Refer also to the Technical specifications The machine s gross weight is specified on the hoisting plate 1 Refer also to the Technical specifi...

Page 68: ...meters 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 and temporarily shut off the engine Chock the drums to prevent the roller from moving Depress the emergency parking brake knob and temporarily shut off the engine Chock the drums to prevent the roller ...

Page 69: ...ide of the differential housing 5 5 Fig Drum brake 5 Screw Drum gearbox brake The drum brake is disengaged by screwing out the 4 hexagonal socket screws 5 approx 5 mm and then pulling out the engine adapter towards the screw heads The brakes are now disengaged and the roller can be towed After towing remember to reset the towing valves 1 Unscrew the adjusting screw 4 to its original position 34 mm...

Page 70: ...an be towed After towing don t forget to reset the towing valves 1 Screw out the adjustment screw 4 to its original position 34 mm from the stop surface and tighten the locking nuts 3 Loosen the drum brake screws 5 See the section Short distance towing options 1 and 2 After towing don t forget to reset the towing valves 1 Screw out the adjustment screw 4 to its original position 34 mm from the sto...

Page 71: ...223 kN 50132 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 transport Fig Transport 1 Chock 2 Block up 3 Lashing wire 2 1 3 3 Lock the articulation before lifting and transporting Follow the instructions under the relevant heading Lock the articulation be...

Page 72: ...Operating instructions Summary ICA302 4EN4 pdf 2012 04 12 62 ...

Page 73: ...e 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 the brakes Remember that the braking distance will be longer if the roller is cold 12 Use vibration only when the roller is in motion 12 Use vibration only when the roller is in motion 13 IN AN EMERG...

Page 74: ...Operating instructions Summary ICA302 4EN4 pdf 2012 04 12 64 ...

Page 75: ...arrival 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 Warranty The warranty is only valid if the stiplulated delivery inspection and the separate service inspection have been completed as per the warranty document and when the machine has been registered...

Page 76: ...Preventive maintenance ICA302 4EN4 pdf 2012 04 12 66 ...

Page 77: ...l in hydraulic system 23 liters 6 gal Oil in hydraulic system 23 liters 6 gal Lubrication oil diesel engine 11 liter 11 7 qts Lubrication oil diesel engine 11 liter 11 7 qts Coolant diesel engine 24 liter 6 4 gal Coolant diesel engine 24 liter 6 4 gal Always use high quality lubricants and the amounts recommended Too much grease or oil can cause overheating resulting in rapid wear Always use high ...

Page 78: ...ologically degradable fluid The same type of fluid must be used when changing or topping up BP Biohyd SE S46 DRUM OIL Air temp 15 C 40 C 5 F 104 F Mobil SHC 629 Dynapac Drum Oil 1000 P N 4812156456 5 litres DRUM OIL Air temp 15 C 40 C 5 F 104 F Mobil SHC 629 Dynapac Drum Oil 1000 P N 4812156456 5 litres GREASE SKF LGHB2 NLGI Klass 2 or equivalent for the articulated joint Dynapac Roller Grease 0 4...

Page 79: ...il 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 level Fuel filter Transmission oil level Fuel filter Drum oil level Coolant level Drum oil level Coolant level Oil for lubrication Oil for lubrication 69 ...

Page 80: ...Maintenance Lubricants and symbols ICA302 4EN4 pdf 2012 04 12 70 ...

Page 81: ...wheel 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 Hydraulic filter 2 pcs 21 Tires pressure 34 Steering chain 8 Hydraulic filter 2 pcs 21 Tires pressure 34 Steering chain 9 Drainage hydraulic fluid reservoir 22 Rear axle differential 35 Seat bearing 9 Drainage h...

Page 82: ...rculation 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 the engine oil level Refer to the engine manual 2 Check the engine oil level Refer to the engine manual 29 Refuel 29 Refuel 6 Check fluid level in hydraulic reservoir 6 Check fluid level in hydraulic reservoir Test the brak...

Page 83: ...ke off blade bearings Optional 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 planetary gearing 23 Check oil level in rear axle planetary gearing 13 Check oil level in drum gearbox 13 Check oil level in drum gearbox 15 Check oil level in the drum cartr...

Page 84: ... to the contents to find the page number of the sections referred to 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 hydraulic fluid filter 9 Drain the condensate from hydraulic reservoir 9 Drain the condensate from hydraulic reservoir 26 Drain condensate...

Page 85: ...draulic fluid 10 Change the hydraulic fluid 12 Change the oil in the drum cartridge 12 Change the oil in the drum cartridge 15 Change the oil in the drum cartridge 15 Change the oil in the drum cartridge 13 Change the oil in the drum gearbox 13 Change the oil in the drum gearbox 37 Lubricate the Forward Reverse lever 37 Lubricate the Forward Reverse lever 17 Checking the steering hitch 17 Checking...

Page 86: ...Maintenance Maintenance schedule ICA302 4EN4 pdf 2012 04 12 76 ...

Page 87: ...It is important to consider movement of the drum when the machine turns i e the scrapers can be damaged or wear of the drum may increase if adjustment is made closer than the values stated It is important to consider movement of the drum when the machine turns i e the scrapers can be damaged or wear of the drum may increase if adjustment is made closer than the values stated Fig Scrapers 1 Scraper...

Page 88: ...en adjust each scraper tooth 2 to 25 mm 1 0 in between scraper tooth and drum Center each scraper tooth 2 between the pads Tighten the screws 1 Flexible scrapers Optional Fig Scrapers 1 Scraper blade 2 Screws 1 1 2 2 Loosen the screws 2 Then adjust the scraper blade 1 so that it lightly touches the drum Tighten the screws 2 78 ...

Page 89: ...sition block the hood so that it cannot fall Coolant level Check Fig Water tank 1 Max level 2 Min level 3 Filler cap 1 2 3 Check that level of the coolant is between the max and min marks Take great caution if the radiator cap must be opened while the engine is hot Wear protective gloves and goggles Take great caution if the radiator cap must be opened while the engine is hot Wear protective glove...

Page 90: ...s The dipstick is located on the engine s right side Pull up the dipstick 1 and check that the oil level is between the upper and lower marks For further details refer to the engine s instruction manual Hydraulic reservoir Check fluid level Fig Hydraulic reservoir 1 Sight glass 2 Filler pipe 1 2 Place the roller on a level surface and check that the oil level in the sight glass 1 is between the ma...

Page 91: ...ess the filler gun against a non insulated part of the roller before refuelling and against the filler pipe 1 while refuelling Stop the engine Short circuit press the filler gun against a non insulated part of the roller before refuelling and against the filler pipe 1 while refuelling Never refuel while the engine is running Do not smoke and avoid spilling fuel Never refuel while the engine is run...

Page 92: ...ter 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 panel 1 Parking brake knob 2 Forward Reverse lever 1 2 Operate the roller slowly forwards Hold the steering wheel firmly and brace yourself for a sudden stop Activate the parking brake knob 1 The roller...

Page 93: ...mp 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 speed 3 6 4 5 2 Fig Air cleaner 1 Clips 2 Cover 3 Main filter 4 Backup filter 5 Filter housing 6 Dust valve 1 Release the clips 1 pull off the cover 2 and pull out the main filter 3 Do not remove th...

Page 94: ...r 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 Wipe also both surfaces for the outlet pipe see adjacent figure Check that the hose clamps between the filter housing and the suction hose are tight and that the hoses are intact Inspect the entire hos...

Page 95: ...o gain access to all the steering system s lubricating nipples 4 on the right hand side of the machine Use grease as per the lubricant specification Use grease as per the lubricant specification Steering joint Lubrication Fig Articulation right side 1 Lubricating nipples articulation 4 pcs 1 1 Wipe off any dirt and grease from the nipples Grease each nipple 1 with five strokes of a hand operated g...

Page 96: ...fitted wheels Check the safety manual that accompanies the roller before filling the tires with air Check the safety manual that accompanies the roller before filling the tires with air Automatic Climate Control Optional Inspection Fig Drying filter 1 Sight glass 1 The system described in this manual is type ACC Automatic Climate Control Never work under the roller when the engine is running Park ...

Page 97: ...onal Lubrication Fig Strike off blade 1 Lubrication nipples 1 Always lower the blade to the ground before leaving or parking the roller Always lower the blade to the ground before leaving or parking the roller Make sure that nobody is in the way when operating the blade Make sure that nobody is in the way when operating the blade Wipe the nipples clean from grease and dirt three on each side of th...

Page 98: ...Maintenance 50h ICA302 4EN4 pdf 2012 04 12 88 ...

Page 99: ...pplied if not otherwise specified Rear axle differential Check oil level Fig Level check differential housing 1 Level Filler plug 1 Never work under the roller when the engine is running Park on a level surface Block the wheels securely Never work 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 ...

Page 100: ... if the level is low Use transmission oil See lubrication specification Clean and refit the plug Check the fluid level in the same way on the rear axle s other planetary gear Drum gearbox Checking the oil level Fig Oil level check drum gearbox 1 Level plug 2 Filler plug 3 Drain plug 1 2 3 Position the drum so that the filler plug 2 is straight up Wipe clean the area around the level plug 1 and the...

Page 101: ...ridge 2 Drain plug 3 Level plug 2 3 Then loosen the level plug 3 on the underside of the cartridge and unscrew it until the hole in the middle of the plug becomes visible Top off with oil through the filler plug 1 until oil begins to run out from the level plug s 3 hole The level is correct when it stops running Ensure that only MOBIL SHC 629 is used in the cartridges Ensure that only MOBIL SHC 62...

Page 102: ...ing air Be careful when using a high pressure washer do not place the nozzle too close to the radiator Be careful when using a high pressure washer do not place the nozzle too close to the radiator Wear protective goggles when working with compressed air or high pressure water jets Wear protective goggles when working with compressed air or high pressure water jets Bolted joints Checking tightenin...

Page 103: ...crews 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 the battery as the electrolyte emits explosive gas while the alternator is charging Lift up the engine compartment cover and undo the quick release screws 1 Raise the battery cover 2 Wipe the top of t...

Page 104: ...e 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 battery always connect the positive cable first Discard used batteries wisely Batteries contain lead which is harmful to the environment Discard used batteries wisely Batteries contain lead which is ...

Page 105: ...onoxide 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 Place a container underneath to collect fuel that runs out when the filter is released Place a container underneath to collect fuel that runs out when the filter is released Screw off the fuel filter 1 ...

Page 106: ...the cab hinges with grease See the lubrication specification Fuel pre filter Cleaning Fig Engine compartment 1 Fuel prefilter 1 Ensure good ventilation air extraction if the diesel engine is run indoors Risk of carbon monoxide poisoning Ensure good ventilation air extraction if the diesel engine is run indoors Risk of carbon monoxide poisoning See instruction manual for the engine when cleaning th...

Page 107: ...lter to environmentally correct handling Deliver the drained oil and filter to environmentally correct handling Steering chain and seat bearing Lubrication Fig Underneath operator s position 1 Steering chain 2 Chain tightening device 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...

Page 108: ...cation nipple 1 Lubricate the operator seat slew bearing with three strokes of a hand operated grease gun Lubricate the seat locking latch 7 accessible from below Also grease the seat slide rails 6 If the seat starts to be stiff when adjusting it should be lubricated more often than specified here If the seat starts to be stiff when adjusting it should be lubricated more often than specified here ...

Page 109: ...that 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 glass 2 3 Undo the filler cap bleeder filter 2 on top of the reservoir so that over pressure inside the reservoir can be eliminated Make sure that the bleeding filter 2 is not clogged air must have uno...

Page 110: ...rn 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 additional half revolution Do not tighten the filter too hard as this could damage the gasket Start the engine and ensure that there is no leakage of hydraulic fluid from the filters Check level of fluid in...

Page 111: ...ce a container under the plug 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 work under the roller when the engine is running Park on a level surface Block the wheels securely Never work under the roller when the engine is running Park on a level su...

Page 112: ...il planetary gear optional 1 Level Filler plug 1 1 Position the roller with the plug 1 at its lowest position Wipe clean and remove the plug 1 and drain the oil into a receptacle The volume is approx 2 liters 2 1 qts Save the oil and hand in to an environment friendly waste disposal station Save the oil and hand in to an environment friendly waste disposal station 102 ...

Page 113: ...lean and refit the plug 1 Fill with oil in the same way as for the rear axle s second planetary gear Air conditioning Optional Fresh air filter Change Fig Cab 1 Fresh air filter 2 Screw x2 1 2 2 Use a step ladder to reach the filter 1 The filter 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 ...

Page 114: ...Maintenance 1000h ICA302 4EN4 pdf 2012 04 12 104 ...

Page 115: ...servoir 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 protective gloves and goggles Observe care when draining hot hydraulic fluid Wear protective gloves and goggles A suitable container may be an empty oil drum or similar item which is placed beside the r...

Page 116: ...rneath the drain plug 2 Save the oil and hand in to an environment friendly waste disposal station Save the oil and hand in to an environment friendly waste disposal station Clean and unscrew the filler plug 1 and the drain plug 2 Allow all the oil to run out Fit the drain plug and fill with new synthetic oil in accordance with the instructions under Drum cartridge checking the oil level Repeat th...

Page 117: ...ceptacle capacity about 3 5 liters 1 gal Refit the plug 1 and fill with oil up to the level plug 3 according to Drum gearbox Checking the oil level Use transmission oil according to the lubricant specification Clean and refit the level plug 3 and filler plug 2 Forward Reverse lever Lubrication Fig Forward Reverse lever 1 Screw 2 Plate 3 Cam disc 3 2 1 Remove the screws 1 and take off the plate 2 G...

Page 118: ...Blow from above downwards The air jet can damage the element flanges if it is too powerful 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 condenser element attachment Fig Automatic climate control 1 Cooling element 2 Drain valve x2 1 2 Clean all dust from ...

Page 119: ...ible through the sight glass it is a sign that the refrigerant level is too low If so stop the unit The unit may be damaged if it is run with insufficient refrigerant Check the moisture indicator 2 It should be blue If it is beige the dryer cartridge should be changed by an authorized service company The compressor will be damaged if the unit is run with too little refrigerant The compressor will ...

Page 120: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden ...

Page 121: ...Dynapac Compaction Equipment AB Box 504 SE 371 23 Karlskrona Sweden ...

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Dynapac CA 302, Instruction Manual

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