Dynapac CA250 i User manual

Instructions manualInstructions manual
Operating & MaintenanceOperating & Maintenance
ICA250i-IN2EN1.pdfICA250i-IN2EN1.pdf
Vibratory rollerVibratory roller
CA250 iCA250 i
EngineEngine
KOEL 4R1040TAKOEL 4R1040TA
Serial numberSerial number
10000154x0E000866 -10000154x0E000866 -
Original instructionOriginal instruction
Reservation for changesReservation for changes
Printed in IndiaPrinted in India

2000h-Maintenance
ICA250i-IN2EN1.pdf2012-12-19
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-IN2EN1.pdf 2012-12-19
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-IN2EN1.pdf2012-12-19
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-IN2EN1.pdf 2012-12-19
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-IN2EN1.pdf2012-12-19
Hydraulic reservoir - Check fluid level....................................................... 62
Maintenance - 50h ................................................................................................................. 63
Air cleaner
Checking - Change the main air filter........................................................ 63
Backup filter - Change............................................................................... 64
Air cleaner
- Cleaning.................................................................................................. 64
Articulation - Lubrication............................................................................ 65
Steering joint - Lubrication ........................................................................ 65
Tires - Air pressure - Wheel nuts - Tightening .......................................... 66
Maintenance - 250h ............................................................................................................... 67
Rear axle differential - Check oil level....................................................... 67
Rear axle transmission box - Check oil level ............................................ 68
Rear axle planetary gears - Check oil level............................................... 68
Drum - Checking the oil level .................................................................... 69
Radiator - Check/Cleaning ........................................................................ 69
Bolted joints - Checking tightening torque................................................. 70
Rubber elements and fastening screws - Check....................................... 70
Battery - Check electrolyte level................................................................ 71
Battery cell ................................................................................................ 71
Maintenance - 500h ............................................................................................................... 73
Bleeder filter - Inspection/Cleaning ........................................................... 73
Diesel engine - Oil and Filter change ........................................................ 74
Maintenance - 1000h ............................................................................................................. 75
Hydraulic fluid filter - Replacement ........................................................... 75
Hydraulic fluid reservoir - Draining ............................................................ 76
Fuel tank - Drainage.................................................................................. 77
Rear axle differential - Oil change............................................................. 78
Rear axle transmission - Oil change ......................................................... 79
Rear axle's planetary gears - Draining the oil ........................................... 79

2000h-Maintenance
ICA250i-IN2EN1.pdf 2012-12-19
Rear axle's planetary gears - Oil change - Oil filling ................................. 80
Maintenance - 2000h ............................................................................................................. 81
Hydraulic reservoir - Changing the fluid .................................................... 81
Drum - Oil change ..................................................................................... 82
Steering hitch - Check............................................................................... 82
Controls - Lubrication ................................................................................ 83

Introduction
ICA250i-IN2EN1.pdf2012-12-19
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.
1

Introduction
ICA250i-IN2EN1.pdf 2012-12-19
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.
2

Safety - General instructions
ICA250i-IN2EN1.pdf2012-12-19
Safety - General instructions
(Also read the safety manual)
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
1. The operator must be familiar with the contents of the OPERATION section
before starting the roller.
2. Ensure that all instructions in the MAINTENANCE section are followed.2. Ensure that all instructions in the MAINTENANCE section are followed.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
3. Only trained and/or experienced operators are to operate the roller.
Passengers are not permitted on the roller. Remain seated at all times when
operating the roller.
4. Never use the roller if it is in need of adjustment or repair.4. Never use the roller if it is in need of adjustment or repair.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
5. Only mount and dismount the roller when it is stationary. Use the intended
grips and rails. Always use the three-point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine.
Never jump down from the machine.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
6. The ROPS (Roll Over Protective Structure) should always be used when the
machine is operated on unsafe ground.
7. Drive slowly in sharp bends.7. Drive slowly in sharp bends.
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, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
9. When driving close to edges, ditches or holes, make sure that at least 2/3 of
the drum width is on previously compacted material (solid surface).
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
11. Drive particularly carefully on uneven ground.11. Drive particularly carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
12. Use the safety equipment provided. The seat belt must be worn on machines
fitted with ROPS/ROPS-cab.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
14. Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
14. Safety measures before refueling:
- Stop the engine
- Do not smoke.
- No naked flames in the vicinity of the roller.
- Earth the filling equipment nozzle to the tank opening to avoid sparks.
15. Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
15. Before repairs or service:
- Chock the drums/wheels and under the strike-off blade.
- Lock the articulation if necessary
3

Safety - General instructions
ICA250i-IN2EN1.pdf 2012-12-19
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The
noise level can vary depending on the equipment on the machine and the
surface the machine is being used on.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac.
17. Do not make any changes or modifications 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
working temperature. Braking distances can be longer than normal when the
fluid is cold. See instructions in the STOP section.
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when the
fluid is cold. See instructions in the STOP section.
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
19. For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
4

Safety - when operating
ICA250i-IN2EN1.pdf2012-12-19
Safety - when operating
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
The operator may allow a person to remain in
the danger area, but should then observe
caution and operate the machine only when the
person is visible or has given clear indications
of where he or she is.
Slopes
Fig. Operating on slopes
Max 20° or 36%
This angle has been measured on a hard, flat surface
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, machine speed
across the ground and raising the center of gravity can
all cause the machine to topple at smaller slope
angles than those specified here.
To exit the cab in an emergency, release the
hammer on the rear right post and break the rear
window.
To exit the cab in an emergency, release the
hammer on the rear right post and break the rear
window.
It is recommended that ROPS (Roll Over Protective
Structure) or a ROPS-approved cab is always used
when driving on slopes or unsafe ground. Always
wear a seat belt.
It is recommended that ROPS (Roll Over Protective
Structure) or a ROPS-approved cab is always used
when driving on slopes or unsafe ground. Always
wear a seat belt.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
Where possible, avoid driving across slopes.
Drive instead straight up and down sloping
ground.
5

Safety - when operating
ICA250i-IN2EN1.pdf 2012-12-19
Driving near edges
Fig. Position of drum when driving near
an edge
Minimum
2/3
When driving near an edge, minimum 2/3 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 left.
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 left.
6

Special instructions
ICA250i-IN2EN1.pdf2012-12-19
Special instructions
Standard lubricants and other recommended
oils and fluids
Before leaving the factory, the systems and
components are filled with the oils and fluids specified
in the lubricant specification. These are suitable for
ambient temperatures in the range -15°C to +40°C
(5°F - 105°F).
Higher ambient temperatures, 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
normal oil. However, the following fluids must be used
for other components:
Hydraulic system - mineral oil Shell Tellus T100 or
similar.
Temperatures
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 ranges.
High pressure cleaning
Do not spray water directly onto electrical components
or the instrument panels.
Place a plastic bag over the fuel filler cap and secure
with a rubber band. This is to avoid 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 important when using a
high-pressure cleaner.
Never aim the water jet directly at the fuel tank
cap. This is particularly important when using a
high-pressure cleaner.
Fire fighting
If the machine catches fire, use an ABC-class powder
fire extinguisher.
A BE-class carbon dioxide fire extinguisher can also
be used.
7

Special instructions
ICA250i-IN2EN1.pdf 2012-12-19
Roll Over Protective Structure (ROPS), ROPS
approved cab
If the machine is fitted with a Roll Over
Protective Structure (ROPS, or ROPS approved
cab) never carry out any welding or drilling in
the structure or cab.
If the machine is fitted with a Roll Over
Protective Structure (ROPS, or ROPS approved
cab) never carry out any welding or drilling in
the structure or cab.
Never attempt to repair a damaged ROPS
structure or cab. These must be replaced with
new ROPS structure or cabs.
Never 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 removing batteries, always disconnect the
negative cable first.
When fitting batteries, always connect the
positive cable first.
When fitting batteries, always connect the
positive cable first.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
8

Special instructions
ICA250i-IN2EN1.pdf2012-12-19
Jump starting
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.
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 the same voltage as the dead battery.
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 the machine which is
providing jump start power.
First connect the jump start battery's positive terminal
(1) to the flat battery's positive terminal (2).Then
connect the jump start battery's negative terminal (3)
to, for example, a bolt (4) or the lifting eye on the
machine with the flat battery.
Start the engine on the power providing machine. Let it
run for a while. Now try to start the other machine.
Disconnect the cables in the reverse order.
9

Special instructions
ICA250i-IN2EN1.pdf 2012-12-19
10

Technical specifications
ICA250i-IN2EN1.pdf2012-12-19
Technical specifications
Vibrations - Operator station
(ISO 2631)
The vibration levels are measured in accordance with the operational cycle described in
EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched
on, on soft polymer material and with the operator’s seat in the transport position.
The vibration levels are measured in accordance with the operational cycle described in
EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched
on, on soft polymer material and with the operator’s seat in the transport position.
Measured whole-body vibrations are below the action value of 0.5 m/s² as specified in Directive
2002/44/EC. (Limit is 1.15 m/s²)
Measured whole-body vibrations are below the action value of 0.5 m/s² as specified in Directive
2002/44/EC. (Limit is 1.15 m/s²)
Measured hand/arm vibrations also were below the action level of 2.5 m/s² specified in the same
directive. (Limit is 5 m/s²)
Measured hand/arm vibrations also were below the action level of 2.5 m/s² specified in the same
directive. (Limit is 5 m/s²)
Noise level
The noise level is measured in accordance with the operational cycle described in EU
directive 2000/14/EC on machines equipped for the EU market, on soft polymer material
with vibration switched on and the operator's seat in the transport position.
The noise level is measured in accordance with the operational cycle described in EU
directive 2000/14/EC on machines equipped for the EU market, on soft polymer material
with vibration switched on and the operator's seat in the transport position.
Guaranteed sound power level, LwA 107 dB (A)Guaranteed sound power level, LwA 107 dB (A)
Sound pressure level at the operator's ear (platform), LpA 90 ±3 dB (A)Sound pressure level at the operator's ear (platform), LpA 90 ±3 dB (A)
Sound pressure level at the operator's ear (cab), LpA 85 ±3 dB (A)Sound pressure level at the operator's ear (cab), LpA 85 ±3 dB (A)
During operation the above values may differ because of the actual operational
conditions.
During operation the above values may differ because of the actual operational
conditions.
11

Technical specifications
ICA250i-IN2EN1.pdf 2012-12-19
Dimensions, side view
Dimensions mm inDimensions mm in
A Wheelbase, drum and wheel 2887 133.7A Wheelbase, drum and wheel 2887 133.7
L Length, standard equipped roller 5550 218.5L Length, standard equipped roller 5550 218.5
H1 Height, with ROPS (STD, D) 2905 114.4H1 Height, with ROPS (STD, D) 2905 114.4
H3 Height, without ROPS/cab (STD, D) 2266 89.2H3 Height, without ROPS/cab (STD, D) 2266 89.2
D Diameter, drum 1523 60D Diameter, drum 1523 60
S Thickness, drum sweep, nominal 25 1S Thickness, drum sweep, nominal 25 1
K1 Clearance, tractor frame 453 17.8K1 Clearance, tractor frame 453 17.8
K2 Clearance, drum frame (STD, D) 400 15.7K2 Clearance, drum frame (STD, D) 400 15.7
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