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Maintenance - Maintenance schedule

ICA362-4EN3.pdf

2012-06-12

Every 2000 hours of operation (Yearly)

Refer to the contents to find the page number of the
sections referred to !

Pos. in fig

Action

Comment

Pos. in fig

Action

Comment

Change the hydraulic fluid

Change the oil in the drum cartridge

Change the oil in the drum gearbox

Lubricate the Forward/Reverse lever

Checking the steering hitch

Overhaul air conditioning

Optional

Overhaul air conditioning

Optional

Summary of Contents for ICA362

Page 1: ...roller Vibratory roller CA362 CA362 Engine Engine Cummins QSB 6 7C Cummins QSB 6 7C Serial number Serial number 72X21159 72X21159 10000117x0A000001 10000117x0A000001 Translation of original instructio...

Page 2: ......

Page 3: ...rike 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...

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

Page 5: ...tion 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...

Page 6: ...covering 58 Towing 58 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...

Page 7: ...5 Maintenance 10h 77 Scrapers 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 reservoi...

Page 8: ...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 Fi...

Page 9: ...rvoir Oil change 105 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...

Page 10: ...e ICA362 4EN3 pdf 2012 06 12...

Page 11: ...in life threatening or serious injury if the warning is ignored CAUTION Marks a danger or hazardous procedure that can result in damage to the machine or property if the warning is ignored CAUTION Ma...

Page 12: ...cancer birth defects and other reproductive harm General This manual contains instructions for machine operation and maintenance The machine must be correctly maintained for maximal performance The m...

Page 13: ...marketed in EU EEC This machine is CE marked This shows that on delivery it complies with the basic health and safety directives applicable for the machine in accordance with machinery directive 2006...

Page 14: ...Introduction ICA362 4EN3 pdf 2012 06 12 4...

Page 15: ...s 8 Avoid driving across slopes Drive straight up or straight down the slope 8 Avoid driving across slopes Drive straight up or straight down the slope 9 When driving close to edges ditches or holes m...

Page 16: ...ns to the roller that could affect safety Changes are only to be made after written approval has been given by Dynapac 18 Avoid using the roller before the hydraulic fluid has reached its normal worki...

Page 17: ...full Always take into consideration that loose ground steering the machine vibration on machine speed across the ground and raising the center of gravity can all cause the machine to topple at smaller...

Page 18: ...Safety when operating ICA362 4EN3 pdf 2012 06 12 8...

Page 19: ...ured 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 secure...

Page 20: ...frigerants 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...

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 ICA362 4EN3 pdf 2012 06 12 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: ...2996 117 9 H2 Height without ROPS D 2190 86 H2 Height without ROPS D 2190 86 H2 Height without ROPS PD 2212 87 08 H2 Height without ROPS PD 2212 87 08 D Diameter drum D 1543 60 75 D Diameter drum D 1...

Page 27: ...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...

Page 28: ...ear 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 St...

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...

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 40 0 Vibration system 40 0 Control systems 1...

Page 32: ...Technical specifications ICA362 4EN3 pdf 2012 06 12 22...

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

Page 34: ...del C Check letter D No coding E Production unit F Serial number Engine plates The engine type plates 1 are affixed to the top and on the right side of the engine The plates specify the type of engine...

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 ICA362 4EN3 pdf 2012 06 12 4700908229 Warning Risk of crushing The articulation must be locked when lifting Read the instruction manual 4700904165 Warning Toxic gas option ACC Read the instruct...

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

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 ICA362 4EN3 pdf 2012 06 12 Controls in the cab First aid kit optional 1 2 34 5 6 Fig Cab roof front Fig Cab right side Fig Cab right side AC optional 9 7 7 11 8 10 8 Fig Cab rear 12 Fig Cab roo...

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

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

Page 47: ...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: ...ptional 1 Fig Strike off blade 1 Cotter pin Always ensure that the strike off blade is secured by the locking pin 1 when driving with the blade in its raised position Always lower the blade to the gro...

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

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

Page 58: ...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: ...ull 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 uppe...

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 a...

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...

Page 62: ...ntil 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 un...

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 als...

Page 64: ...Operation ICA362 4EN3 pdf 2012 06 12 54...

Page 65: ...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 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...

Page 67: ...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 68: ...00 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 kno...

Page 69: ...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 70: ...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 71: ...00 kN 44961 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 72: ...Operating instructions Summary ICA362 4EN3 pdf 2012 06 12 62...

Page 73: ...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 74: ...Operating instructions Summary ICA362 4EN3 pdf 2012 06 12 64...

Page 75: ...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 76: ...Preventive maintenance ICA362 4EN3 pdf 2012 06 12 66...

Page 77: ...in hydraulic system 23 liters 6 gal Oil in hydraulic system 23 liters 6 gal Lubrication oil diesel engine 14 liter 14 8 qts Lubrication oil diesel engine 14 liter 14 8 qts Coolant diesel engine 29 li...

Page 78: ...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 79: ...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 80: ...Maintenance Lubricants and symbols ICA362 4EN3 pdf 2012 06 12 70...

Page 81: ...eel 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 fil...

Page 82: ...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 83: ...e 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 Chec...

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 hydrauli...

Page 85: ...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 86: ...Maintenance Maintenance schedule ICA362 4EN3 pdf 2012 06 12 76...

Page 87: ...t 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 import...

Page 88: ...n 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...

Page 89: ...ition 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 ca...

Page 90: ...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 manua...

Page 91: ...s 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...

Page 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...nal 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 th...

Page 98: ...Maintenance 50h ICA362 4EN3 pdf 2012 06 12 88...

Page 99: ...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 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...

Page 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...e 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 pl...

Page 112: ...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 113: ...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 114: ...Maintenance 1000h ICA362 4EN3 pdf 2012 06 12 104...

Page 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 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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