Atlas Copco Dynapac CA250 i User manual

Instructions manualInstructions manual
Operating & MaintenanceOperating & Maintenance
ICA250i-IN3EN1.pdfICA250i-IN3EN1.pdf
Vibratory rollerVibratory roller
CA250 iCA250 i
EngineEngine
KOEL 4R1040TAKOEL 4R1040TA
Serial numberSerial number
10000154x0E001169 -10000154x0E001169 -
Original instructionOriginal instruction
Reservation for changesReservation for changes
Printed in IndiaPrinted in India

2000h-Maintenance
ICA250i-IN3EN1.pdf2013-06-24
Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Warning symbols......................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
Safety - General instructions.................................................................................................... 3
Safety - when operating ........................................................................................................... 5
Slopes ......................................................................................................... 5
Driving near edges ...................................................................................... 6
Special instructions .................................................................................................................. 7
Standard lubricants 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 .................... 8
Battery handling .......................................................................................... 8
Jump starting............................................................................................... 9
Technical specifications ......................................................................................................... 11
Vibrations - Operator station ..................................................................... 11
Noise level................................................................................................. 11
Dimensions, side view............................................................................... 12
Dimensions, top view ................................................................................ 13
Weights and volumes................................................................................ 13
Working capacity....................................................................................... 14
General ..................................................................................................... 14
Hydraulic system....................................................................................... 15
ROPS - bolts ............................................................................................. 15
Tightening torque ...................................................................................... 16

2000h-Maintenance
ICA250i-IN3EN1.pdf 2013-06-24
Machine description ............................................................................................................... 17
Identification ............................................................................................................ 17
Product identification number on the frame .............................................. 17
Machine plate............................................................................................ 17
Explanation of 17PIN serial number.......................................................... 18
Engine plates ............................................................................................ 18
Decals...................................................................................................................... 19
Location - decals ....................................................................................... 19
Safety decals............................................................................................. 20
Info 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 ............................................................................................................................... 29
Before starting ......................................................................................................... 29
Master switch - Switching on.................................................................... 29
Driver seat (Std.) - Adjustment.................................................................. 29
Driver seat (Option)- Adjustment............................................................... 30
Instruments and lamps - Checking............................................................ 30
Operator position....................................................................................... 31
View .......................................................................................................... 31
Interlock..................................................................................................... 32
Starting .................................................................................................................... 32
Start of diesel motor .................................................................................. 32
Operating................................................................................................................. 34

2000h-Maintenance
ICA250i-IN3EN1.pdf2013-06-24
Operating the roller ................................................................................... 34
Vibration .................................................................................................................. 35
Vibration On/Off ........................................................................................ 35
Vibration - Activation ................................................................................. 35
Braking .................................................................................................................... 36
Normal braking.......................................................................................... 36
Emergency braking ................................................................................... 36
Switching off.............................................................................................. 37
Parking .................................................................................................................... 37
Master switch ............................................................................................ 37
Chocking the drums .................................................................................. 38
Long-term 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
Locking the articulation ............................................................................. 41
Lifting the roller.......................................................................................... 41
Unlocking the articulation .......................................................................... 42
Towing/Recovering.................................................................................................. 42
Alternative 1 .............................................................................................. 42
Short distance towing with the engine running.......................................... 42
Alternative 2 .............................................................................................. 43
Towing short distances when the engine is inoperative............................ 43

2000h-Maintenance
ICA250i-IN3EN1.pdf 2013-06-24
Rear axle brake......................................................................................... 43
Releasing the parking brake in the drum .................................................. 44
Towing the roller........................................................................................ 45
Re-activating the rear axle brake .............................................................. 46
Roller prepared for transport ..................................................................... 46
Operating instructions - Summary ......................................................................................... 47
Preventive maintenance ........................................................................................................ 49
Acceptance and delivery inspection.......................................................... 49
Warranty.................................................................................................... 49
Maintenance - Lubricants and symbols ................................................................................. 51
Maintenance symbols ............................................................................... 52
Maintenance - Maintenance 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 operation (Monthly) .................................................... 55
Every 500 hours of operation (Every three months) ................................. 55
Every 1000 hours of operation (Every six months) ................................... 56
Every 2000 hours of operation (Yearly) .................................................... 56
Maintenance, 10h .................................................................................................................. 57
Scrapers - Check, adjustment................................................................... 57
Steel scrapers (Optional) .......................................................................... 58
Soften scrapers (Optional) ........................................................................ 58
Coolant level - Check ................................................................................ 59
Air circulation - Check ............................................................................... 60
Fuel tank - Filling....................................................................................... 60
Diesel engine Check oil level ................................................................... 61
Brakes - Check.......................................................................................... 61

2000h-Maintenance
ICA250i-IN3EN1.pdf2013-06-24
Hydraulic reservoir - Check fluid level....................................................... 62
Steering cylinder - Lubrication................................................................... 63
Maintenance - 50h ................................................................................................................. 65
Air cleaner
Checking - Change the main air filter........................................................ 65
Backup filter - Change............................................................................... 66
Air cleaner
- Cleaning.................................................................................................. 66
Articulation - Lubrication............................................................................ 67
Steering joint - Lubrication ........................................................................ 67
Tires - Air pressure - Wheel nuts - Tightening .......................................... 68
Maintenance - 250h ............................................................................................................... 69
Rear axle differential - Check oil level....................................................... 69
Rear axle transmission box - Check oil level ............................................ 70
Rear axle planetary gears - Check oil level............................................... 70
Drum - Checking the oil level .................................................................... 71
Radiator - Check/Cleaning ........................................................................ 71
Bolted joints - Checking tightening torque................................................. 72
Rubber elements and fastening screws - Check....................................... 72
Battery - Check electrolyte level................................................................ 73
Battery cell ................................................................................................ 73
Maintenance - 500h ............................................................................................................... 75
Bleeder filter - Inspection/Cleaning ........................................................... 75
Diesel engine - Oil and Filter change ........................................................ 76
Maintenance - 1000h ............................................................................................................. 77
Hydraulic fluid filter - Replacement ........................................................... 77
Hydraulic fluid reservoir - Draining ............................................................ 78
Fuel tank - Drainage.................................................................................. 79
Rear axle differential - Oil change............................................................. 80
Rear axle transmission - Oil change ......................................................... 81

2000h-Maintenance
ICA250i-IN3EN1.pdf 2013-06-24
Rear axle's planetary gears - Draining the oil ........................................... 81
Rear axle's planetary gears - Oil change - Oil filling ................................. 82
Maintenance - 2000h ............................................................................................................. 83
Hydraulic reservoir - Changing the fluid .................................................... 83
Drum - Oil change ..................................................................................... 84
Steering hitch - Check............................................................................... 84
Controls - Lubrication ................................................................................ 85

Introduction
ICA250i-IN3EN1.pdf2013-06-24
Introduction
The machine
CA250i is one of Dynapac's medium-heavy soil
compaction rollers. It is available in STD and D
versions.
Intended use
All types of base courses and subbase courses can be
compacted deeper and the interchangeable drums, D
to PD, and vice versa, facilitate even greater variety in
the range of application.
The cab and safety-related accessories are described
in this manual. Other accessories, such as compaction
meter, tachograph and field computer, are described
in separate instructions.
Warning symbols
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
WARNING ! Marks a danger or a hazardous
procedure that can result 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 ! 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 machine
in accordance with the instruction manual.
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
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Introduction
ICA250i-IN3EN1.pdf 2013-06-24
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
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 entire machine so that any leakages or
other faults are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
THINK ENVIRONMENT ! Do not release oil,
fuel and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
This manual contains instructions for periodic
maintenance normally carried out by the operator.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
Additional instructions for the engine can be
found in the manufactuer's engine manual.
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