Dynapac CA 150 User manual

DYNAPAC
CA 150
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
O150EN2
OPERATION

19
ILF015WO1

VibratoryRoller
CA150
Operation
O150EN2, August 2002
Diesel engine:
CA 150: Cummins 4BT 3.3C
These instructions apply from:
CA 150 PIN (S/N) *73X20150*
Reservation for alterations.
Printed in Sweden
CA 150 is Dynapac’s light vibratory soil compactor. Available in D (smooth drum) and
PD (padfoot) versions. The PD version has its widest range of application on cohesive
material and rockfill materials.
All types of supporting and reinforcement courses can be compacted, and the
interchangeable drums, ie, D to PD and vice versa, give enhanced versatility in the
choice of application.
The cab and safety-related accessories are described in this manual. Other accessories,
such as the compaction meter, etc. are described in separate instructions.
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2CA 150 O150EN2
CONTENTS
WARNING SYMBOLS
SAFETY MANUAL
GENERAL
Safety instructions – Personal safety
Special caution – Machine or component damage
The safety manual, which accompanies each
machine, must be studied by each operator of
the roller. Always follow the safety rules and
do not remove the manual from the roller.
This manual contains instructions concerning operation
and use of the roller. For information regarding care and
maintenance, see the manual, “MAINTENANCE, CA 150”.
When starting up and driving a cold machine,
which implies cold hydraulic fluid, the braking
distance will be longer than normal until the
machine reaches normal working temperature.
WARNING
CAUTION
WARNING
WARNING
Page
Safety instructions (Read the Safety Manual also) .......... 3
Safety when driving .......................................................... 4
Safety decals, location/description ............................... 5, 6
Machine and engine plates ............................................... 7
Instruments and controls .................................................. 8
Instruments and controls, functional description ........ 9, 10
Controls in the cab ......................................................... 11
Before starting ...........................................................13-15
Starting ........................................................................... 16
Operation ....................................................................... 17
Driving/Vibration ............................................................. 18
Braking ........................................................................... 19
Parking ........................................................................... 20
Lifting .............................................................................. 21
Towing ............................................................................ 22
Instructions for towing .................................................... 23
Towing/Retrieval ............................................................ 24
Transport ........................................................................ 24
Operating instructions - Summary ................................. 25
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.

3
CA 150 O150EN2
SAFETY INSTRUCTIONS (Read the Safety Manual also)
1. The operator must be familiar with the contents of the OPERATION MAN-
UAL before starting the roller.
2. Make sure that all instructions in the MAINTENANCE MANUAL are fol-
lowed.
3. Only trained and/or experienced operators may drive the roller. Passen-
gers are not allowed on the roller. Remain seated during all operation.
4. Never use the roller if it is in need of adjustment or repairs.
5. Board and leave the roller only when it is stationary. Use the grips and rail-
ings that are provided. Always use a ”three-point grip” - both feet and one
hand or one foot and both hands - when boarding or exiting the machine.
6. The ROPS (Roll Over Protective Structure) should always be used when
the machine is operated on risky ground.
7. Drive slowly in sharp bends.
8. Avoid driving at an angle on slopes; drive straight up or down.
9. When driving close to unsafe edges or holes, make sure that at least two
thirds of the drum width is firmly on material that has already been com-
pacted.
10. Make sure that there are no obstacles in the direction of travel, on the
ground or overhead.
11. Drive extra carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on ma-
chines fitted with ROPS.
13. Keep the roller clean. Clean dirt and grease from the operator’s platform
without delay. Keep all signs and decals clean and clearly legible.
14. Safety measures before refueling:
– Stop the engine.
– Do not smoke.
– No naked flame in the vicinity.
– Ground the nozzle of the filling device against the tank to prevent sparks.
15. Before repairs or service:
– Place chocks against the drums/wheels and against the strike-off blade.
– Lock the articulation if required.
16. Hearing protectors are recommended if the noise level exceeds 85 dB(A).
The noise level may vary depending on what material the machine is oper-
ating on.
17. Make no changes or modifications on the roller that could affect safety.
Changes may only be made following written consent by Dynapac.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Remember that the braking distance will be longer if
the fluid is cold. See starting instructions in the OPERATION MANUAL.
WARNING

4CA 150 O150EN2
SAFETY WHEN DRIVING
Max 20°
or 36%
Driving near an edge
When you drive near an edge, at least two thirds of the
drum width must be on solid ground.
Remember that the machine’s center of
gravity is displaced outward when you
steer to one side. For example, it shifts to
the right when you steer to the left.
The ROPS (Roll Over Protective Structure)
is always recommended when driving on
slopes or insecure ground.
Where possible, avoid all driving
across a
slope. Instead, drive up and down on slop-
ing ground.
The tilting angle is measured on a hard, level surface
with the machine stationary, steering angle zero, vibra-
tion switched OFF and all tanks full. Remember that
loose ground, steering of the machine, vibration
switched ON, driving speed and raising the center of
gravity (for example, with accessories) may cause the
machine to topple even on a smaller slope than that
stated here.
To leave the cab in an emergency, release
the hammer located on the rear right post
and break the rear window.
Fig.1 Position of drum when driving near
an edge
Fig.2 Tippingangleonside slopes
At least
2/3
Slopes
WARNING
WARNING
WARNING
WARNING

5
CA 150 O150EN2
SAFETY DECALS, LOCATION/DESCRIPTION
327 16 12 6
14 512141498 17
15 723
1251441914
11
1713

6CA 150 O150EN2
SAFETY DECALS, LOCATION/DESCRIPTION
Crush zone, articulation/
Drum. Maintain a safe dis-
tance from the crush zone.
Warning - hot surfaces in
the engine compartment.
Do not touch.
Warning - rotating engine
components. Keep your
hands at a safe distance from
the danger zone.
The operator is urgently
requested to read the safety
manual, and the operation
and maintenance instruc-
tions before using the
machine.
1.
2.
3.
4.
903424
903459
903423
903422
The articulation must be
interlocked when lifting.
Read the instruction manual.
5.
Lifting point
Diesel fuel
Tire pressure
110 kPa
16psi
9.
8.
357587
991658
991990
908229
16.
10.
Battery
disconnector
11.
904835
Securing
point
14.
382751
7.
15.
Handbook
compartment
903425
Mass Kg
904870
12.
Lifting plate
Emergency exit
6.
Tires filled with ballast
(Optional).
Read the instruction manual.
17.
903985
Hydraulic
fluid Biological
hydraulic
fluid
272372 904601
Alt. 1 Alt. 2
791277
13.
Sound Power
level
107

7
CA 150 O150EN2
MACHINE AND ENGINE PLATES
Machine plate
PIN on frame
Fig.3 Operator’s platform
1. Machine plate
Fig.4 Front frame
1. PIN
Fig.5 Engine
1. Engine plate
2. EPA sign (USA)
1
Engine plate
The PIN (1) of the machine is punched on the front right
edge of the forward frame beam.
The engine plate (1) is affixed to the right side of the
engine under the injection pump. The plate indicates the
type of engine, serial number and engine data. Please
state the engine serial number when ordering spares.
See also the Engine Manual.
1
1
Cummins Engine Company, Inc
Columbus,IndianaUSA
47202-3005 www.Cummins.com
WARNING: Injurymayresultandwarrantyisvoided
if fuel rate, rpm or altitude exceed published
maximum values for this model and application.
Timing-BTDC 8 degrees
This engine conforms to YYYY U.S. EPA and California
regulations for large non-road compression ignition
engines as applicable. This engine is certified to
operate on diesel fuel.
Valve Lash Intake 0.014in/0.35mm
(cold engine) Exhaust 0.020in/0.50mm
Fuel rate at rated HP/kW 61mm3/st
S.O. # SO94678
Made in Japan 6204-81-2411
Important Engine Information
Model B3.3 ESN 68006011
Gross rated HP/kW 80 /60 at 2200 rpm
Low Idle RPM 800 RPM
Fuel Rating FR30004
CPL
Displacement: 3.261L/1991
Displacement: 3.261L/1991
European Approval Number:
e11*97/68CA*00/000*0069*00
Date of Manufacture 20010219
The machine plate (1) is affixed on the front left side of
the frame, by the steering joint. The plate shows the
manufacturer’s name and address, type of machine,
product identification number (PIN), weight in working
order, engine power and year of manufacture (the year
of manufacture is not specified if the machine is
delivered outside the EU).
Please state the roller PIN when ordering spares.

8CA 150 O150EN2
INSTRUMENTS AND CONTROLS
61011
5
4
20
3
2
1
21
16
15
18
19
17
12
13
14 78 9
1. Horn
2. Starter switch
3. Hazard beacon
4. Working lights
5. Reserve/parking brake knob
6. Instrument protection
7. Warning lamp, charging
8. Brake warning lamp
9. Warning lamp, engine oil
pressure/Engine temperature
10. Warning lamp, hydraulic filter
11. Warning lamp, air filter
Fig.6 Instruments and control panel
12. Warning lamp, hydraulic temperature
13. Amplitude selector Low/0/High
14. Speed selector, rear axle
15. Engine revs control
16. Fuel gauge
17. Fuse box
18. Vibration ON/OFF
19. Forward/Reverse lever
20. Test button for warning lamps
21 . Handbook compartment
= Optional

9
CA 150 O150EN2
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
1 Horn, switch
2 Starter switch
3 Hazard beacon, switch
(Optional)
4 Working lights, switch
(Optional)
5 Reserve brake/Parking brake
6 Instrument protection
7 Warning lamp, battery
charging
8 Brake warning lamp
9 Warning lamp, oil pressure
10 Warning lamp, hydraulic filter
11 Warning lamp, air filter
12 Warning lamp, hydraulic
temperature
Items.in Designation Symbol Function
fig. 6
Press to sound the horn.
In position the electric circuit is broken.
In position all instruments and electric
controls are powered.
In position the start motor is activated.
Turn right to switch on the hazard beacon.
Turn right to switch on the working lights.
Press to activate the reserve brake. Press
when the machine is stationary to activate the
parking brake.
Pull out to release both brakes.
Fold down over the instruments to protect
from weather and damage.
If this lamp lights while the engine is running,
the alternator is not charging.
Stop the engine and remedy the fault.
The lamp lights when the parking or reserve
brake knob is pushed in and the brakes are
applied.
The lamp lights if engine oil pressure is too
low. Stop the engine immediately and locate
the fault.
If this lamp lights while the engine is running at
full rev, the hydraulic filters must be changed.
If this lamp lights while the engine is running at
full rev, the air cleaner must be cleaned or
replaced.
If this lamp lights, the hydraulic fluid is too hot.
Do not drive the roller; cool the fluid by
allowing the engine to idle and locate the fault.
STOP

10 CA 150 O150EN2
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
13 Amplitude selector
14 Speed selector, rear axle
(Optional)
15 Revs control, diesel engine
16 Fuel gauge
17 Fuse box
18 Vibration ON/OFF, switch
19 Forward/Reverse lever
20 Test button for warning lamps
21 Handbook compartment
Itemsin Designation Symbol Function
fig. 6
The left mode gives low amplitude.
The right mode gives high amplitude.
Vibration is OFF in the Omode.
Transportation speed (High)
Working speed (Low)
Working revs in the upper position.
Idling in the lower position.
Indicates fuel tank level.
Contains fuses for the electrical system.
Press once and release to switch vibration
ON, press again to switch vibration OFF.
The above applies only when the amplitude
selector (13) is in the High or Low mode.
The lever must be in neutral to start the
engine, it cannot be started with the forward/
reverse lever in any other position.
Direction of travel and speed of the roller is
regulated with the forward/reverse lever. The
roller moves forward when the lever is
moved forward, etc. Speed of the roller is
regulated in proportion to how far the lever is
moved from neutral. The further from neutral,
the higher the speed.
The lamps 10, 11, 12 are checked when the
switch is pressed.
Stowage space for safety manual and
operator’s manuals.

11
CA 150 O150EN2
CONTROLS IN THE CAB
Fig. 7a Cab roof, front Fig. 7b Cab roof, rear
14
Fig. 7c Cab, left side Fig. 7d Cab, right side
23
56 7
Fig. 7e Cab, rear
8
Fig.7f Cab, left side
9

12 CA 150 O150EN2
CONTROLS IN THE CAB, FUNCTIONAL DESCRIPTION
Itemsin Designation Symbol Function
fig. 7
1 Wiper front, switch
2 Wiper rear, switch
3 Screenwash front and rear
panes, switch
4 Hammer for emergency
evacuation
5 Handbook compartment
6 Heater (Optional)
7 Air fan, switch
(Optional)
8 Cab lighting,
switch
9 Windshield washer fluid
Press to turn on the front wiper.
Press to turn on the rear wiper.
Press at the top to spray the windscreen.
Press at the bottom to spray the rear screen.
To evacuate the cab in an emergency,
release the hammer and break the REAR
window.
Stowage space for safety manual and
operator’s manuals.
Left mode, maximum heating.
Right mode, heating turned off.
Left mode, fan turned off. Right mode, cab
ventilation increases in three steps.
Press to turn on the cab lights.
Fill with new fluid as needed.

13
CA 150 O150EN2
BEFORE STARTING
2
1
1
1
2
The engine hood must be unlocked during
operation, so that battery power can be
disconnected quickly if necessary.
Battery disconnecter
– Switching ON
Fig.8 Engine compartment
1. Battery disconnecter
2. Hourmeter
Remember to carry out daily service. See maintenance
manual.
The battery disconnecter is located in the engine
compartment. Open the engine cover and set the key
(1) to the ON position. The entire roller will be powered.
The hourmeter (2) records the number of hours so long
as the engine is running.
WARNING
Operator’s seat – Setting
Adjust the operator’s seat to ensure a comfortable
posture and so that all controls are within easy reach.
The seat can be adjusted as follows:
Length adjustment (1)
Always make sure that the seat is secure
before beginning operation.
Fig.9 Operator’s seat
1. Locking lever - length adjustment
WARNING
Operator’s seat in cab (Optional)
– Setting
Fig.10 Operator’s seat
1. Locking lever – length adjustment
2. Lever – weight adjustment
Set the operator’s seat in a comfortable position and so
that the controls are easily accessible.
The seat has the following adjustment facilities:
• Length adjustment (1).
• Weight adjustment (2).
Always make sure that the seat is secure
before beginning operation.
WARNING

14 CA 150 O150EN2
BEFORE STARTING
1
2
3
4
7812
20
2
16
58
Turn the starter switch (2) to position I. Press the
button (20) and make sure that all the control lamps
light.
Check that the fuel gauge (16) gives a reading.
Check that the warning lamps for charging (7), oil
pressure (12), and parking brake (8) light.
Instruments, lamps and
field of view – Check
Reserve/parking brake
– Control
Fig.12 Controlpanel
5. Reserve/parking brake knob
8. Brake lamp
Ensure that the reserve/parking brake knob
(5) is pressed down.
If the parking brake is not applied, the
roller may start to roll when you start the
engine on sloping ground.
Fig. 11 Instrument panel
2. Starter switch
7. Charging lamp
8. Brake lamp
12. Oil pressure lamp
16. Fuel gauge
20. Test button for warning lamps
WARNING
Operator’sstation
Fig.13 Operator’s station
1. Seat belt 3. Rubber element
2. ROPS 4. Anti-slip
If the roller is equipped with a ROPS (2) (Roll Over
Protective Structure) or a cab, always use the seat belt
(1) and wear a hard hat.
Replace the seat belt (1) if it shows signs
of wear or has been subjected to severe
force.
Check that the 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 condition; replace with new anti-slip if
friction is poor.
CAUTION
WARNING
WARNING If the machine is fitted with a cab, make sure
that the door is closed when in motion.
CAUTION

15
CA 150 O150EN2
BEFORE STARTING
Field of view
Fig. 14 Field of view
Before starting, make sure that the field of view is
unobstructed, both in front and behind. All cab windows
must be clean and rearview mirrors properly adjusted.

16 CA 150 O150EN2
STARTING
789
2
13
15 19
Starting the engine
Set the forward/reverse lever (19) in neutral. The
engine cannot be started if the lever is in any other
position.
Set the amplitude selector (13) for Low/High vibration to
Omode.
Set the revs control (15) to idling mode.
Turn the starter switch (2) to the right to the starting
mode and release the knob immediately when the
engine starts.
Do not run the starter motor too long. If the
engine does not start immediately, wait a
minute or so before making a new attempt.
Warm up the engine for a few minutes with the rev
control in the idling mode, longer if the ambient
temperature is below +10°C (+50°F).
Check while warming up that the warning lamps for oil
pressure (9) and charging (7) are out. The warning
lamp (8) for the parking brake should still light.
When you start up and drive a cold machi-
ne, the hydraulic fluid is cold, and the
braking distance will be longer than normal
until the machine reaches normal working
temperature.
Ensure that ventilation (extraction) is
adequate if the engine is run indoors.
Risk of carbon monoxide poisoning.
Fig. 15 Instrument panel
2. Starter switch
7. Charging lamp
8. Brake lamp
9. Oil pressure lamp/temperature
lamp
13. Amplitude selector
15. Revs control
19. Forward/Reverse lever
WARNING
WARNING
CAUTION

17
CA 150 O150EN2
OPERATION
511
14
15 19
Turn the rev control (15) upward and latch it at its limit.
The engine speed should be about 2300 r/min.
Check that the steering is working by turning the
steering wheel once to the right and once to the left,
while the roller is stationary.
Ensure that the area in front of and behind
the roller is clear.
Pull up the reserve/parking brake knob (5)
and check that the warning lamp for the
parking brake is out. When starting the
roller on a slope, be prepared that it may
begin to roll.
Driving the roller
Fig. 16 Instrument panel
5. Reserve/parking brake knob
11. Warning lamp, air filter
14. Speed selector, rear axle
15. Rev control
19. Forward/Reverse lever
Check occasionally while driving that no lamps light. If
the oil pressure lamp lights, stop the roller and the
engine immediately. Check and remedy any fault; see
also the maintenance manual and the engine manual.
If the warning lamp (11) for the air cleaner
lights during operation (at full engine revs), the
main filter must be cleaned or replaced; see
Maintenance Manual.
Set the High/Low speed selector (14) to the desired
mode (optional feature), see decal on the instrument
panel.
The high mode may only be used for trans-
port runs on an even surface.
Carefully move the forward/reverse lever (19) in the
desired direction of travel.
Speed increases as the lever is moved farther from the
neutral position.
Always regulate speed with the forward/
reverse lever and never by changing the
engine speed.
Check operation of the reserve/parking
brake by pressing the reserve/parking
brake knob (5) while the roller is running
slowly forward.
Under no circumstances may the machine
be operated from the outside. The operator
must remain seated inside the machine
during all operation.
WARNING
WARNING
WARNING
WARNING
CAUTION
CAUTION
Max-speeds, km/h (mph)
Std/P D PD
7,5 (4.7) 5 (3.1) 5 (3.1)
Dualspeed, rear axle
Std/P D PD
7,5 (4.7) 5 (3.1) 5 (3.1)
18,5 (11.5) 9 (5.6) 9 (5.6)
WARNING

18 CA 150 O150EN2
18
13
DRIVING/VIBRATION
Engagement and disengagement of vibration is made
with the switch (18) on top of the forward/reverse lever.
Always switch off vibration before the roller comes to a
complete standstill.
Never allow vibration to be on when the roller
is stationary; this may damage the surface
and the machine.
Drum vibration can be set in two modes, selected using
the switch (13). Turn the knob to the left mode for low
amplitude, to the right mode for high amplitude.
Never alter the amplitude setting while the
vibration is running. Switch vibration off first
and wait until it has ceased before altering the
amplitude.
Fig. 17 Instrument panel
13. Amplitude selector
18. Vibration ON/OFF
Low/High amplitude
– Setting
CAUTION
CAUTION