Dynapac CA270 Instruction Manual Download Page 8

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2000h-

Maintenance

ICA270-IN2EN1.pdf

2012-11-05

Fuel pre-filter - Replacement..................................................................... 80

Maintenance - 1000h ............................................................................................................. 81

Hydraulic fluid filter - Replacement ........................................................... 81

Hydraulic fluid reservoir - Draining ............................................................ 82

Fuel tank - Drainage.................................................................................. 83

Rear axle differential - Oil change............................................................. 84

Rear axle transmission - Oil change ......................................................... 85

Rear axle's planetary gears - Draining the oil ........................................... 85

Rear axle's planetary gears - Oil change - Oil filling ................................. 86

Maintenance - 2000h ............................................................................................................. 87

Hydraulic reservoir - Changing the fluid .................................................... 87

Drum - Oil change ..................................................................................... 88

Steering hitch - Check............................................................................... 88

Controls - Lubrication ................................................................................ 89

Summary of Contents for CA270

Page 1: ...ratory roller Vibratory roller CA270 CA270 Engine Engine Cummins 4BT 3 9 102C Cummins 4BT 3 9 102C Serial number Serial number 10000153x0E000909 10000153x0E000909 Carraro rear axle Carraro rear axle O...

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: ...ols 23 Locations Control panel and controls 24 Function description 25 Controls in the cab 27 Function description of instruments and controls in the cab 28 Electrical system 29 Main fuses 29 Relays 3...

Page 5: ...n Activation 39 Braking 40 Normal braking 40 Emergency braking 40 Switching off 41 Parking 41 Master switch 41 Chocking the drums 42 Long term parking 43 Engine 43 Battery 43 Air cleaner exhaust pipe...

Page 6: ...ummary 51 Preventive maintenance 53 Acceptance and delivery inspection 53 Warranty 53 Maintenance Lubricants and symbols 55 Maintenance symbols 56 Maintenance Maintenance schedule 57 Service and maint...

Page 7: ...70 Articulation Lubrication 71 Steering joint Lubrication 71 Tires Air pressure Wheel nuts Tightening 72 Maintenance 250h 73 Rear axle differential Check oil level 73 Rear axle transmission box Check...

Page 8: ...oir Draining 82 Fuel tank Drainage 83 Rear axle differential Oil change 84 Rear axle transmission Oil change 85 Rear axle s planetary gears Draining the oil 85 Rear axle s planetary gears Oil change O...

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

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 rang...

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 ICA270 IN2EN1 pdf 2012 11 05 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: ...roller 5550 218 5 H1 Height with Canopy STD D 2977 117 2 H1 Height with Canopy STD D 2977 117 2 H3 Height without Canopy STD D 2190 86 2 H3 Height without Canopy STD D 2190 86 2 D Diameter drum 1523 6...

Page 21: ...5 0 O 2 Overhang right frame side 127 5 0 R 1 Turn radius external 5400 212 6 R 1 Turn radius external 5400 212 6 R 2 Turn radius internal 3100 122 R 2 Turn radius internal 3100 122 W 1 Width tractor...

Page 22: ...Manufacturer Model Cummins 4BT 3 9C Water cooled turbo diesel Manufacturer Model Cummins 4BT 3 9C Water cooled turbo diesel Power SAE J1995 76 kW 103 hp Power SAE J1995 76 kW 103 hp Engine speed 2300...

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: ...platform 1 Machine plate 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 and address the ty...

Page 26: ...amily 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 t...

Page 27: ...ng Rotating 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 1...

Page 28: ...itted 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 ha...

Page 29: ...Machine description ICA270 IN2EN1 pdf 2012 11 05 4700904165 Warning Toxic gas option ACC Read the instruction manual 4700903590 Emergency exit 21...

Page 30: ...t Diesel fuel Lifting point Hoisting plate Handbook compartment Master switch Hoisting plate Handbook compartment Master switch Hydraulic fluid Tire pressure Securing point Hydraulic fluid Tire pressu...

Page 31: ...n Off 15 Driving lights High beam 31 Parking brake On Off 16 Hazard flashers 32 Transport mode Traction control Optionr 16 Hazard flashers 32 Transport mode Traction control Optionr 17 Hazard beacon 1...

Page 32: ...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 Seat...

Page 33: ...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 34: ...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 35: ...wiper 2 Rear wiper Optional 3 Front and rear windshield washers 5 6 7 8 9 Fig Cab rear 9 Switch cab lighting Optional Fig Cab right side Heater Option 5 Control temperature 6 Control cirkulation 7 Con...

Page 36: ...ow 5 Control temperature Optional In the left position the heating is OFF In the right position maximum heating 5 Control temperature Optional In the left position the heating is OFF In the right posi...

Page 37: ...1 is 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 1 Fig Driving compartment 1 Contr...

Page 38: ...2012 11 05 Relays Fig Control column 1 Flasher relay 2 Stop light relay 3 Working lights relay 4 Fuse boxes 1 2 4 3 1 k7 Direction indicators 1 k7 Direction indicators 2 K6 Stop lights 2 K6 Stop light...

Page 39: ...rs 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 lightning 10A 4 Rotating hazard beacon 10A 8 In...

Page 40: ...ver after which the cover 4 can be lifted off the heater box Fuses in heater box Fig Heater box in cab 1 Plug 5 Fuse x1 6 Fuse x1 7 Cover for fuse box 7 6 1 5 To access the fuses x2 in the heater box...

Page 41: ...key 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...

Page 42: ...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 43: ...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 44: ...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 hig...

Page 45: ...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 46: ...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 cha...

Page 47: ...low 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 vi...

Page 48: ...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 49: ...s 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 Befo...

Page 50: ...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 51: ...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 batte...

Page 52: ...e 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...

Page 53: ...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 ma...

Page 54: ...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 a...

Page 55: ...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 56: ...sher 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 blockin...

Page 57: ...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 58: ...rking 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 59: ...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...

Page 60: ...Operating instructions Summary ICA270 IN2EN1 pdf 2012 11 05 52...

Page 61: ...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 62: ...Preventive maintenance ICA270 IN2EN1 pdf 2012 11 05 54...

Page 63: ...0 P N 9106230330 20 liters Air temperature over 40 C 104 F Shell Tellus S2 V100 or equivalent Air temperature over 40 C 104 F Shell Tellus S2 V100 or equivalent BIOLOGICAL HYDRAULIC FLUID When it leav...

Page 64: ...operating in areas with extremely high or extremely low ambient temperatures See the Special instructions chapter or consult Dynapac Other fuel and lubricants are required when operating in areas with...

Page 65: ...eder filter 18 Flywheel casing hydraulic pumps 30 Cooler 6 Bleeder filter 18 Flywheel casing hydraulic pumps 30 Cooler 7 Hydraulic fluid filter x1 19 Wheel nuts 31 Hydraulic fluid cooler 7 Hydraulic f...

Page 66: ...setting 1 Check for free circulation of cooling air 1 Check for free circulation of cooling air 35 Check coolant level Refer to the engine manual 35 Check coolant level Refer to the engine manual 3 C...

Page 67: ...ional 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 22 Check oil level in rear axle...

Page 68: ...ir 8 Drain the condensate from hydraulic reservoir 25 Drain condensate from fuel tank 25 Drain condensate from fuel tank 21 Change oil in rear axle differential 21 Change oil in rear axle differential...

Page 69: ...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 70: ...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 Scrapers Pad drum Fig Scrapers 1 Screws 2 Scr...

Page 71: ...k Fig Cooler grille 1 Filler cap coolant 1 Ensure that the diesel engine has free circulation of cooling air through the vents in the hood Observe extreme caution if the filler cap must be opened when...

Page 72: ...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 73: ...Fuel tank 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 qualit...

Page 74: ...specification Brakes Check Check operation of the brakes as follows Check operation of the brakes as follows Checking the emergency stop Fig Instrument panel 1 Emergency stop 2 Parking brake lamp 1 2...

Page 75: ...Parkering brake lamp 1 2 Drive the roller slowly forward Hold the steering wheel firmly and brace yourself for a sudden stop Push in the parking brake switch 1 The roller should stop immediately with...

Page 76: ...Maintenance 10h ICA270 IN2EN1 pdf 2012 11 05 68...

Page 77: ...de 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 t...

Page 78: ...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 79: ...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 80: ...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 81: ...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 82: ...dge 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 Leve...

Page 83: ...ith oil risk for overheating Do not overfill with oil risk for overheating Radiator Check Cleaning Fig Engine compartment 1 Water cooler 2 Hydraulic fluid cooler 1 2 Check that air can pass unobstruct...

Page 84: ...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 1...

Page 85: ...e drained oil and filter to environmentally correct handling Deliver the drained oil and filter to environmentally correct handling Battery Check electrolyte level Fig Battery shelf 1 Quick screws 2 B...

Page 86: ...well tightened Clean corroded cable shoes and grease them with acid free Vaseline Always disconnect the negative cable first when disconnecting the battery When connecting the battery always connect...

Page 87: ...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 88: ...od ventilation air extraction if the diesel engine is run indoors Risk of carbon monoxide poisoning Loosen the hose clamps 2 and remove the pre filter 1 Fit the new filter taking care to fit in the di...

Page 89: ...ir 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 blocke...

Page 90: ...re 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 91: ...tationary 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 92: ...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 oi...

Page 93: ...h 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 l...

Page 94: ...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 95: ...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 96: ...anner 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 wh...

Page 97: ...pdf 2012 11 05 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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Dynapac CA270, Instruction Manual

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