Dynapac CA282D Instruction Manual Download Page 9

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2000h-

Maintenance

ICA282-1EN3.pdf

2012-06-18

Steering hitch - Check............................................................................. 106

Automatic Climate Control (Optional)
- Overhaul ............................................................................................... 106

Compressor - Check (Optional) .............................................................. 107

Drying filter - Check................................................................................. 107

Summary of Contents for CA282D

Page 1: ...roller Vibratory roller CA282D CA282D Engine Engine Cummins QSB 4 5 Cummins QSB 4 5 Serial number Serial number 66811364 66811364 10000126x0A000001 10000126x0A000001 Translation of original instructio...

Page 2: ......

Page 3: ...r conditioning 9 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 fig...

Page 4: ...al 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...

Page 5: ...tion 44 View 45 Starting 46 Starting the engine 46 Operating 47 Operating the roller 47 Operating on difficult surfaces Optional 49 Drive drum wheels 49 Vibration 50 Amplitude frequency Changeover 50...

Page 6: ...rnative 2 57 Towing short distances where the engine is inoperative 57 Rear axle brake 57 Drum gearbox brake 57 Drum gearbox brake Option 58 Towing the roller 59 Roller prepared for transport 59 Opera...

Page 7: ...Air circulation Check 77 Coolant level Check 78 Diesel engine Check oil level 78 Hydraulic reservoir Check fluid level 79 Fuel tank Filling 79 Brakes Check 80 Maintenance 50h 81 Air cleaner Checking...

Page 8: ...ication 94 Fuel pre filter Cleaning 94 Diesel engine Oil and Filter change 95 Steering chain and seat bearing Lubrication 95 Seat bearing Lubrication 96 Maintenance 1000h 97 Hydraulic filter Replaceme...

Page 9: ...e ICA282 1EN3 pdf 2012 06 18 Steering hitch Check 106 Automatic Climate Control Optional Overhaul 106 Compressor Check Optional 107 Drying filter Check 107...

Page 10: ...e ICA282 1EN3 pdf 2012 06 18...

Page 11: ...y 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 recommended to at least train operators in...

Page 12: ...d loose connections are discovered at as early a point in time as possible Inspect the machine every day before starting Inspect the entire machine so that any leakages or other faults are detected Ch...

Page 13: ...th 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 Dec...

Page 14: ...Introduction ICA282 1EN3 pdf 2012 06 18 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 ICA282 1EN3 pdf 2012 06 18 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: ...Safety Optional ICA282 1EN3 pdf 2012 06 18 10...

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 ICA282 1EN3 pdf 2012 06 18 14...

Page 25: ...tion 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...

Page 26: ...D 2972 117 H1 Height with ROPS STD D 2972 117 H1 Height with cab STD D 2972 117 H1 Height with cab STD D 2972 117 H2 Height without ROPS STD D 2190 86 H2 Height without ROPS STD D 2190 86 D Diameter...

Page 27: ...left frame side 107 4 21 O1 Overhang left frame side 107 4 21 O2 Overhang right frame side 107 4 21 O2 Overhang right frame side 107 4 21 R1 Turn radius external 5400 212 6 R1 Turn radius external 54...

Page 28: ...0 066 in Amplitude low 0 8 mm 0 031 in Amplitude low 0 8 mm 0 031 in Vibration frequency high amplitude 33 Hz 1980 vpm Vibration frequency high amplitude 33 Hz 1980 vpm Vibration frequency low amplit...

Page 29: ...re 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 16 psi Tractor t...

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: ...treated 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 1...

Page 32: ...Technical specifications ICA282 1EN3 pdf 2012 06 18 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: ...er 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 num...

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 ICA282 1EN3 pdf 2012 06 18 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: ...l fuel Lifting point Hoisting plate Handbook compartment Master switch Hoisting plate Handbook compartment Master switch Hydraulic fluid Biological hydraulic fluid Securing point Hydraulic fluid Biolo...

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: ...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...

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: ...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 r...

Page 44: ...iption ICA282 1EN3 pdf 2012 06 18 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: ...tion 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 Hazar...

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: ...ICA282 1EN3 pdf 2012 06 18 View Fig view Before starting make sure that the view forwards and backwards is unobstructed All cab windows should be clean and the rear view mirrors should be correctly ad...

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: ...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 b...

Page 59: ...full speed the main filter must be cleaned or replaced See the Maintenance Manual If the warning lamp for the air filter 30 comes on during operation when the diesel engine is running at full speed th...

Page 60: ...itude 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 42 Fig Control panel 3...

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: ...s 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 i...

Page 64: ...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...

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: ...de 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 ad...

Page 68: ...n 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 b...

Page 69: ...60 kN 37094 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...

Page 70: ...Operating instructions Summary ICA282 1EN3 pdf 2012 06 18 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 ICA282 1EN3 pdf 2012 06 18 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 ICA282 1EN3 pdf 2012 06 18 64...

Page 75: ...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 li...

Page 76: ...logically 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 l...

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 ICA282 1EN3 pdf 2012 06 18 68...

Page 79: ...heel 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 fi...

Page 80: ...culation 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 Ref...

Page 81: ...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 Che...

Page 82: ...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 hydrauli...

Page 83: ...raulic 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 cartrid...

Page 84: ...Maintenance Maintenance schedule ICA282 1EN3 pdf 2012 06 18 74...

Page 85: ...Scrapers Check adjustment 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 th...

Page 86: ...raper tooth and drum Center each scraper tooth 2 between the pads Tighten the screws 1 Steel scrapers Optional Fig Scrapers 1 Scraper blades x4 2 Screws 1 2 If necessary adjust distance to the drum as...

Page 87: ...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...

Page 88: ...ual Flush the system every other year and change the coolant Make sure also that the air flow through the cooler is unobstructed Flush the system every other year and change the coolant Make sure also...

Page 89: ...to the lower edge of the filler pipe 1 Follow the engine manufacturer s specification with regard to the quality of diesel fuel Stop the engine Short circuit press the filler gun against a non insulat...

Page 90: ...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 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: ...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 Steeri...

Page 94: ...itted 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 Clima...

Page 95: ...Cab 1 Condensor element 1 Where cooling capacity is markedly reduced clean the condensor element 1 located on the rear edge of the cab Also clean the cooling unit in the cab See under the heading 200...

Page 96: ...Maintenance 50h ICA282 1EN3 pdf 2012 06 18 86...

Page 97: ...plied 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 leve...

Page 98: ...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...

Page 99: ...idge 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 f...

Page 100: ...ng 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 Wea...

Page 101: ...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 102: ...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 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: ...he 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 indoor...

Page 105: ...ter 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...

Page 106: ...ation 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...

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: ...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 p...

Page 110: ...l 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...

Page 111: ...ean 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...

Page 112: ...Maintenance 1000h ICA282 1EN3 pdf 2012 06 18 102...

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: ...neath 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 fille...

Page 115: ...eptacle 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 speci...

Page 116: ...low 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 com...

Page 117: ...ble 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...

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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