Dynapac CA250 i Instruction Manual Download Page 1

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Instructions manual

Operating & Maintenance

ICA250i-IN2EN1.pdf

Vibratory roller

CA250 i

Engine

KOEL 4R1040TA

Serial number

10000154x0E000866 -

Original instruction

Reservation for changes

Reservation for changes
Printed in India

Printed in India

Summary of Contents for CA250 i

Page 1: ...f ICA250i IN2EN1 pdf Vibratory roller Vibratory roller CA250 i CA250 i Engine Engine KOEL 4R1040TA KOEL 4R1040TA Serial number Serial number 10000154x0E000866 10000154x0E000866 Original instruction Or...

Page 2: ......

Page 3: ...ts and other recommended oils and fluids 7 Higher ambient temperatures above 40 C 104 F 7 Temperatures 7 High pressure cleaning 7 Fire fighting 7 Roll Over Protective Structure ROPS ROPS approved cab...

Page 4: ...decals 21 Instruments controls 22 Locations Instruments and controls 22 Locations Control panel and controls 23 Function description 24 Electrical system 26 Main fuses 26 Relays 26 Fuses 27 Operation...

Page 5: ...m parking 39 Engine 39 Battery 39 Air cleaner exhaust pipe 39 Fuel tank 39 Hydraulic reservoir 39 Steering cylinder hinges etc 40 Hoods tarpaulin 40 Tires All weather 40 Miscellaneous 41 Lifting 41 Lo...

Page 6: ...ce schedule 53 Service and maintenance points 53 General 53 Every 10 hours of operation Daily 54 After the FIRST 50 hours of operation 54 Every 50 hours of operation Weekly 55 Every 250 hours of opera...

Page 7: ...level 68 Rear axle planetary gears Check oil level 68 Drum Checking the oil level 69 Radiator Check Cleaning 69 Bolted joints Checking tightening torque 70 Rubber elements and fastening screws Check...

Page 8: ...i IN2EN1 pdf 2012 12 19 Rear axle s planetary gears Oil change Oil filling 80 Maintenance 2000h 81 Hydraulic reservoir Changing the fluid 81 Drum Oil change 82 Steering hitch Check 82 Controls Lubrica...

Page 9: ...o the machine or property if the warning is ignored Safety information It is recommended to at least train operators in handling and daily maintenance of the machine in accordance with the instruction...

Page 10: ...ions 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...

Page 11: ...ds 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...

Page 12: ...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 work...

Page 13: ...with the machine stationary The steering angle was zero the vibration was switched OFF and all tanks were full Always take into consideration that loose ground steering the machine vibration on machin...

Page 14: ...3 of the drum width must be on solid ground Keep in mind that the machine s center of gravity moves outwards when steering For example the center of gravity moves to the right when you steer to the l...

Page 15: ...The temperature limits apply to standard versions of rollers Rollers equipped with additional equipment such as noise suppression may need to be more carefully monitored in the higher temperature ran...

Page 16: ...attempt to repair a damaged ROPS structure or cab These must be replaced with new ROPS structure or cabs Battery handling When removing batteries always disconnect the negative cable first When remov...

Page 17: ...tery 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 equipment off Switch off the engine on t...

Page 18: ...Special instructions ICA250i IN2EN1 pdf 2012 12 19 10...

Page 19: ...e 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...

Page 20: ...ped roller 5550 218 5 H1 Height with ROPS STD D 2905 114 4 H1 Height with ROPS STD D 2905 114 4 H3 Height without ROPS cab STD D 2266 89 2 H3 Height without ROPS cab STD D 2266 89 2 D Diameter drum 15...

Page 21: ...internal 3100 122 R2 Turn radius internal 3100 122 W1 Width tractor section 2130 83 9 W1 Width tractor section 2130 83 9 W2 Width drum 2130 83 9 W2 Width drum 2130 83 9 Weights and volumes Weights We...

Page 22: ...ude STD D 100 kN 22 500 lb General Engine Engine Manufacturer Model KOEL 4R1040TA Water cooled turbo diesel Manufacturer Model KOEL 4R1040TA Water cooled turbo diesel Power SAE J1995 78 kW 105 hp Powe...

Page 23: ...tion system 42 5 Control systems 17 5 Control systems 17 5 Brake release 1 4 Brake release 1 4 ROPS bolts Bolt dimensions M24 PN 4700904562 Bolt dimensions M24 PN 4700904562 Strength class 10 9 Streng...

Page 24: ...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 2...

Page 25: ...t 1 Fig Operator platform 1 Machine plate 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 manufacturers name...

Page 26: ...Family Model C Check letter D No coding E Production unit F Serial number Engine plates 1 Fig Engine 1 Type plate The engine plate 1 is affixed to the right side of the engine The plate specifies the...

Page 27: ...g engine components 8 Diesel fuel 14 Tire pressure 3 Warning Hot surfaces 9 Hydraulic fluid Biohydraulic fluid 15 Hoisting plate 3 Warning Hot surfaces 9 Hydraulic fluid Biohydraulic fluid 15 Hoisting...

Page 28: ...ted 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 hand...

Page 29: ...Diesel fuel Lifting point Coolant Diesel fuel Lifting point Hoisting plate Handbook compartment Master switch Hoisting plate Handbook compartment Master switch Hydraulic fluid Tire pressure Securing p...

Page 30: ...n Off 15 Driving lights High beam 31 Parking brake On Off 16 Hazard flashers 32 Transport mode Traction control Optional 16 Hazard flashers 32 Transport mode Traction control Optional 17 Hazard beacon...

Page 31: ...l level 5 Handbook compartment 26 Fuel level 6 Forward Back control 27 Water temperature diesel engine 6 Forward Back control 27 Water temperature diesel engine 7 Seat switch 28 Battery charging 7 Sea...

Page 32: ...es forward etc The roller s speed is proportional to the distance the lever is from the neutral position The further the lever is from the neutral position the higher the speed 7 Seat switch Remain se...

Page 33: ...Stop the engine immediately and locate the fault 24 Warning lamp oil pressure This lamp lights if the lubricating pressure in the engine is too low Stop the engine immediately and locate the fault 25...

Page 34: ...placed by the battery disconnector 4 The fuse is of the flat pin type The fuel solenoid relay 2 and the starter relay 3 are also fitted here Main fuse 40A Orange Relays Fig Control column 1 Flasher re...

Page 35: ...Horn buzzer control panel 10A 6 Windshield wipers cabin 10A 3 Reserve 7 Compaction meter 10A 3 Reserve 7 Compaction meter 10A 4 Rotating hazard beacon 10A 8 Indicators warning indicators cab interior...

Page 36: ...Machine description ICA250i IN2EN1 pdf 2012 12 19 28...

Page 37: ...y 1 to the ON position The entire roller is now supplied with power The engine hood must be unlocked when operating so that the battery can be quickly disconnected if necessary The engine hood must be...

Page 38: ...e seat is secure before beginning operation Do not forget to use the seat belt 4 Do not forget to use the seat belt 4 Instruments and lamps Checking 2 22 1 Fig Instrument panel 1 Starter switch 2 Emer...

Page 39: ...latform are intact Worn elements will impair comfort Check that rubber elements 3 on the platform are intact Worn elements will impair comfort Ensure that the anti slip 4 on the platform is in good co...

Page 40: ...e switch 31 is activated Set the forward reverse lever 6 in neutral The engine can only be started when the lever is in neutral Turn the vibration switch 20 to the Off position position O At normal hi...

Page 41: ...mal 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 norm...

Page 42: ...which direction of travel is required The speed increases as the lever is moved away from the neutral position The speed should always be controlled by using the forward reverse lever and never by ch...

Page 43: ...elow Vibration Activation 4 Fig Forward Reverse lever 4 Switch vibration On Off Never activate vibration when the roller is stationary This can damage both the surface and the machine Never activate v...

Page 44: ...riving 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 Emergency braking 3...

Page 45: ...ns Turn the starter switch 1 to the left to switched off position 1 At the end of the shift lower the instrument cover 22 and lock it Parking Master switch 1 Fig Engine compartment 1 Master switch Bef...

Page 46: ...rums 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 ground Keep in mi...

Page 47: ...and 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 batt...

Page 48: ...ne 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 instrumen...

Page 49: ...and locking lug 4 and secure the stud in position with the locking pin 2 1 Weight refer to the hoisting plate on the roller 1 Fig Roller prepared for lifting 1 Hoisting plate Lifting the roller The m...

Page 50: ...ing 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...

Page 51: ...ock the drums to prevent the roller from moving when the brakes are mechanically disengaged Rear axle brake Fig Rear axle 1 Lock screw 2 Loch nut 3 Brake release screw On both sides remove the lock sc...

Page 52: ...asher Tighten to the bottom of the threading into the piston without blocking the screw 2 Use a screw fitted with a nut and washer Tighten to the bottom of the threading into the piston without blocki...

Page 53: ...2 mph and only towed short distances max 300 m 330 yards The roller must be towed slowly max 3 km h 2 mph and only towed short distances max 300 m 330 yards Fig Towing When towing retrieving a machine...

Page 54: ...arking brakes should now be re activated and the wheels are locked Clear the area of any personnel and that the parking brakes work properly before removing the stop blocks from drum and wheels Remove...

Page 55: ...e 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 distanc...

Page 56: ...Operating instructions Summary ICA250i IN2EN1 pdf 2012 12 19 48...

Page 57: ...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...

Page 58: ...Preventive maintenance ICA250i IN2EN1 pdf 2012 12 19 50...

Page 59: ...temperature 15 C 50 C 5 F 122 F Shell Tellus S2 V68 or equivalent AtlasCopco Hydraulic 300 P N D971800001 20 liters HYDRAULIC FLUID Air temperature 15 C 50 C 5 F 122 F Shell Tellus S2 V68 or equivale...

Page 60: ...emely low ambient temperatures See the Special instructions chapter or consult Dynapac Maintenance symbols Engine oil level Tyre pressure Engine oil level Tyre pressure Engine oil filter Air filter En...

Page 61: ...g hydraulic pumps 29 Cooler 6 Bleeder filter 18 Flywheel casing hydraulic pumps 29 Cooler 7 Hydraulic fluid filter x1 19 Wheel nuts 30 Hydraulic fluid cooler 7 Hydraulic fluid filter x1 19 Wheel nuts...

Page 62: ...tting 1 Check for free circulation of cooling air 1 Check for free circulation of cooling air 34 Check coolant level Refer to the engine manual 34 Check coolant level Refer to the engine manual 3 Chec...

Page 63: ...in fig Action Comment Pos in fig Action Comment 22 Check oil level in rear axle planetary gearing 22 Check oil level in rear axle planetary gearing 14 Check oil level in the drum 14 Check oil level in...

Page 64: ...ear axle differential 22 Change oil in the rear axle planetary gearing 22 Change oil in the rear axle planetary gearing Check engine valve clearances Refer to the engine manual Check engine valve clea...

Page 65: ...g Ensue that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Scrapers Check adjustment It is important to consider movement of the drum when the...

Page 66: ...llows Undo the screws 2 on the scraper attachment Then adjust the scraper blade 1 to 20 mm from the drum Tighten the screws 2 Repeat the procedure for the other scraper blades x4 Soften scrapers Optio...

Page 67: ...ween the max min markings 1 Make sure that cooling air flows freely through the protective grille to the engine The coolant is hot and under pressure at working temperature and the escaping steam can...

Page 68: ...Filling Fig Filling with fuel 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 diese...

Page 69: ...lower marks For further details refer to the engine s instruction manual Brakes Check Check operation of the brakes as follows Check operation of the brakes as follows Checking the emergency stop Fig...

Page 70: ...immediately with the engine running After testing the brakes set the forward reverse lever in neutral Reset the parkering brake switch 1 The roller is now ready for operation Refer also to the section...

Page 71: ...ide poisoning Air cleaner Checking Change the main air filter Change the air cleaner main filter when the warning lamp on the control panel comes on when the engine is running at maximum speed Change...

Page 72: ...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 W...

Page 73: ...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 Steer...

Page 74: ...ve the same rolling radius This is necessary to ensure proper functioning of the anti slip in the rear axle When changing the tires it is important that both of them have the same rolling radius This...

Page 75: ...indoors Risk of carbon monoxide poisoning Ensue that there is good ventilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Rear axle differential Check oil level Fig...

Page 76: ...edge of the plug hole Top up with oil to the right level if the level is low Use transmission oil see lubricant specification Clean and refit the plug Rear axle planetary gears Check oil level Fig Lev...

Page 77: ...sk for overheating Do not overfill with oil risk for overheating Radiator Check Cleaning Fig Engine compartment 1 Water cooler 2 Hydraulic fluid cooler 3 Charge air cooler 1 3 2 Check that air can pas...

Page 78: ...m and lightly oiled Wheel nuts 4 Check that all nuts are tightened 630 Nm oiled The above applies to new or replaced components only Rubber elements and fastening screws Check Fig Drum vibration side...

Page 79: ...Top off with distilled water to the right level if the level is low If the ambient temperature is below freezing run the engine for a while before topping off with distilled water Otherwise the electr...

Page 80: ...Maintenance 250h ICA250i IN2EN1 pdf 2012 12 19 72...

Page 81: ...ilation air extraction if the engine is run indoors Risk of carbon monoxide poisoning Bleeder filter Inspection Cleaning Fig Hydraulic reservoir 2 Filler cap Air filter 3 Sight glass 3 2 If passage in...

Page 82: ...e gloves and goggles The oil drain plug 1 is most easily accessible from the bottom of the engine and is located attached to a hose on the rear axle Drain the oil when the engine is warm Place a recep...

Page 83: ...oir so that over pressure inside the reservoir can be eliminated Check that the bleeder filter 2 is not clogged air must flow through the cap in both directions If passage in either direction is block...

Page 84: ...ere is no leakage of hydraulic fluid from the filter Check level of fluid in the sight glass 3 and top up as required Hydraulic fluid reservoir Draining Fig Hydraulic reservoir bottom 1 Drainage tap 2...

Page 85: ...stationary for an extended period e g after being stationary overnight The fuel level should be as low as possible The roller should preferably have been standing with this side slightly lower so that...

Page 86: ...s 1 and the drain plug 2 and drain the oil into a suitable receptacle The volume is approximately 15 liters 16 qts Save the oil and hand in to an environment friendly waste disposal station Save the o...

Page 87: ...sh oil in the level filler hole until the oil level reaches the lower edge of the plug hole Use transmission oil see lubricant specification Use transmission oil see lubricant specification Refit the...

Page 88: ...Level Filler plug Set the roller so that the plug 4 in the planetary gear is at 3 o clock Wipe clean and remove the plug 4 Fill with oil to the lower edge of the level hole Use transmission oil See lu...

Page 89: ...ervoir Changing the fluid Fig Hydraulic reservoir bottom 1 Stop cock 3 4 2 Plug 1 2 Observe care when draining the hydraulic fluid Wear protective gloves and goggles Observe care when draining the hyd...

Page 90: ...manner Save the oil and dispose 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 w...

Page 91: ...pdf 2012 12 19 Controls Lubrication Fig F B control 2 Screws 2 Grease Forward Back throttle mechanical mechanism Take away the outer hatch down below the seat by loosening the screws 2 Grease the work...

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