Dynapac ICA362 User manual

Instructions manualInstructions manual
ICA362-4EN3.pdfICA362-4EN3.pdf
Driving & MaintenanceDriving & Maintenance
Vibratory rollerVibratory roller
CA362CA362
EngineEngine
Cummins QSB 6.7CCummins QSB 6.7C
Serial numberSerial number
*72X21159*-*72X21159*-
10000117x0A000001 -10000117x0A000001 -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in SwedenPrinted in Sweden

2000h-Maintenance
ICA362-4EN3.pdf2012-06-12
Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Warning symbols......................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
CE marking and Declaration of conformity.................................................. 3
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Driving near edges ...................................................................................... 7
Slopes ......................................................................................................... 7
Safety (Optional) ...................................................................................................................... 9
Strike-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 cleaning ............................................................................. 11
Fire fighting ............................................................................................... 12
Roll Over Protective Structure (ROPS), ROPS approved cab .................. 12
Battery handling ........................................................................................ 12
Jump starting............................................................................................. 13
Technical specifications ......................................................................................................... 15
Vibrations - Operator station ..................................................................... 15
Noise level................................................................................................. 15
Electrical system ....................................................................................... 15
Dimensions, side view............................................................................... 16
Dimensions, top view ................................................................................ 17
Weights and volumes................................................................................ 18

2000h-Maintenance
ICA362-4EN3.pdf 2012-06-12
Working capacity....................................................................................... 18
General ..................................................................................................... 19
Tightening torque ...................................................................................... 20
ROPS - bolts ............................................................................................. 21
Hydraulic system....................................................................................... 21
Automatic Climate Control (ACC) (Optional)............................................. 21
Machine description ............................................................................................................... 23
Identification ............................................................................................................ 23
Product identification number on the frame .............................................. 23
Machine plate............................................................................................ 23
Explanation 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 controls...................................................... 30
Function descriptions ................................................................................ 31
Controls in the cab .................................................................................... 34
Function description of instruments and controls in the cab ..................... 35
Electrical system...................................................................................................... 36
Fuses ........................................................................................................ 36
Fuses in cab.............................................................................................. 38
Main fuses................................................................................................. 38
Fuses at battery master disconnect switch ............................................... 39
Relays ....................................................................................................... 39
Relays in cab............................................................................................. 40
Operation ............................................................................................................................... 41

2000h-Maintenance
ICA362-4EN3.pdf2012-06-12
Before starting ......................................................................................................... 41
Master switch - Switching on..................................................................... 41
Operator’s seat - Adjusting....................................................................... 41
Control unit - Setting ................................................................................. 42
Operator’s seat in cab - Adjusting ............................................................. 42
Instruments and lamps - Checking........................................................... 43
Parking brake - Check............................................................................... 43
Interlock..................................................................................................... 44
Operator position....................................................................................... 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).................................................. 50
Drive, drum/wheels ................................................................................... 50
Vibration .................................................................................................................. 50
Amplitude/frequency - Changeover........................................................... 50
Manual vibration - Switching on ................................................................ 51
Braking .................................................................................................................... 51
Emergency braking ................................................................................... 51
Normal braking.......................................................................................... 52
Switching off.............................................................................................. 52
Parking .................................................................................................................... 53
Chocking the drums .................................................................................. 53
Master switch ............................................................................................ 53
Long-term parking.................................................................................................................. 55
Engine ....................................................................................................... 55

2000h-Maintenance
ICA362-4EN3.pdf 2012-06-12
Battery....................................................................................................... 55
Air cleaner, exhaust pipe........................................................................... 55
Fuel tank ................................................................................................... 55
Hydraulic reservoir .................................................................................... 55
Tires (All-weather)..................................................................................... 55
Steering cylinder, hinges, etc. ................................................................... 56
Hoods, tarpaulin ........................................................................................ 56
Miscellaneous ........................................................................................................................ 57
Lifting ....................................................................................................................... 57
Locking the articulation ............................................................................. 57
Lifting the roller.......................................................................................... 57
Unlocking the articulation .......................................................................... 58
Towing/Recovering.................................................................................................. 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 ................................................................................. 59
Drum gearbox brake (Option) ................................................................... 60
Towing the roller........................................................................................ 61
Roller prepared for transport ..................................................................... 61
Operating instructions - Summary ......................................................................................... 63
Preventive maintenance ........................................................................................................ 65
Acceptance and delivery inspection.......................................................... 65
Warranty.................................................................................................... 65
Maintenance - Lubricants and symbols ................................................................................. 67
Maintenance symbols ............................................................................... 69
Maintenance - Maintenance schedule ................................................................................... 71

2000h-Maintenance
ICA362-4EN3.pdf2012-06-12
Service and maintenance points ............................................................... 71
General ..................................................................................................... 71
Every 10 hours of operation (Daily)........................................................... 72
After the FIRST 50 hours of operation ...................................................... 72
Every 50 hours of operation (Weekly)....................................................... 73
Every 250 hours of operation (Monthly) .................................................... 73
Every 500 hours of operation (Every three months) ................................. 74
Every 1000 hours of operation (Every six months) ................................... 74
Every 2000 hours of operation (Yearly) .................................................... 75
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 reservoir - Check fluid level....................................................... 80
Fuel tank - Filling....................................................................................... 81
Brakes - Check.......................................................................................... 82
Maintenance - 50h ................................................................................................................. 83
Air cleaner
Checking - Change the main air filter........................................................ 83
Backup filter - Change............................................................................... 84
Air cleaner
- Cleaning.................................................................................................. 84
Articulation - Lubrication............................................................................ 85
Steering joint - Lubrication ........................................................................ 85
Tires - Air pressure - Wheel nuts - Tightening .......................................... 86
Automatic Climate Control (Optional) - Inspection .................................... 86
Strike-off blade (Optional)
- Lubrication .............................................................................................. 87

2000h-Maintenance
ICA362-4EN3.pdf 2012-06-12
Maintenance - 250h ............................................................................................................... 89
Rear axle differential - Check oil level....................................................... 89
Rear axle planetary gears - Check oil level............................................... 90
Drum gearbox - Checking the oil level ...................................................... 90
Drum cartridge - Checking the oil level ..................................................... 91
Drum cartridge - Cleaning the ventilation screw ....................................... 92
Radiator - Check/Cleaning ........................................................................ 92
Bolted joints - Checking tightening torque................................................. 92
Rubber elements and fastening screws - Check....................................... 93
Battery - Check electrolyte level................................................................ 93
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 Filter change ........................................................ 97
Steering chain and seat bearing - Lubrication........................................... 97
Seat bearing - Lubrication ......................................................................... 98
Maintenance - 1000h ............................................................................................................. 99
Hydraulic filter - Replacement ................................................................... 99
Hydraulic reservoir - Draining.................................................................. 100
Fuel tank - Drainage................................................................................ 101
Rear axle differential - Oil change........................................................... 101
Rear axle's planetary gears - Draining the oil ......................................... 102
Rear axle's planetary gears - Oil change - Oil filling ............................... 103
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 103
Maintenance - 2000h ........................................................................................................... 105

2000h-Maintenance
ICA362-4EN3.pdf2012-06-12
Hydraulic reservoir - 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 - Check (Optional) .............................................................. 109
Drying filter - Check................................................................................. 109

2000h-Maintenance
ICA362-4EN3.pdf 2012-06-12

Introduction
ICA362-4EN3.pdf2012-06-12
Introduction
The machine
CA362 is one of Dynapac's medium-heavy soil
compaction rollers. It is available in a D (smooth drum)
and PD (padfoot) version.
Intended use
The D-version is intended for the compaction of
rockfill. The main area of application for the PD
version is on cohesive material and weathered stone
material.
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.
1

Introduction
ICA362-4EN3.pdf 2012-06-12
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.
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.
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.
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.
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.
2

Introduction
ICA362-4EN3.pdf2012-06-12
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.
CE marking and Declaration of conformity
(Applies to machines 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 2006/42/EC and that it also
complies with other directives applicable for this
machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable directives and
supplements, as well as the harmonized standards
and other regulations that are applied.
3

Introduction
ICA362-4EN3.pdf 2012-06-12
4

Safety - General instructions
ICA362-4EN3.pdf2012-06-12
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
5

Safety - General instructions
ICA362-4EN3.pdf 2012-06-12
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
6

Safety - when operating
ICA362-4EN3.pdf2012-06-12
Safety - when operating
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.
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.
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Safety - when operating
ICA362-4EN3.pdf 2012-06-12
8

Safety (Optional)
ICA362-4EN3.pdf2012-06-12
Safety (Optional)
Strike-off blade
Fig.Strike-off blade
1. Locking pin
1
The operator must make sure that nobody is in
the area of operation while the machine is in
use.
The operator must make sure that nobody is in
the area of operation while the machine is in
use.
Ensure always 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 ground before leaving or
parking the roller.
Ensure always 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 ground before leaving or
parking the roller.
The strike-off blade must be retracted to the
transport position (1) at the end of each
working period.
The strike-off blade must be retracted to the
transport position (1) at the end of each
working period.
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Safety (Optional)
ICA362-4EN3.pdf 2012-06-12
Air conditioning
The system described in this manual is type ACC
(Automatic Climate Control)
Fig. Cab
The system contains pressurized refrigerant. It
is forbidden to release refrigerants into the
atmosphere.
The system contains pressurized refrigerant. It
is forbidden to release refrigerants into the
atmosphere.
The cooling system is pressurized. Incorrect
handling can result in serious personal injury.
Do not disconnect or undo the hose couplings.
The cooling system is pressurized. Incorrect
handling can result in serious personal injury.
Do not disconnect or undo the hose couplings.
The system must be refilled with an approved
refrigerant by authorized personnel when
necessary.
The system must be refilled with an approved
refrigerant by authorized personnel when
necessary.
Fig. Air conditioning
10