Download
Share
Print this page
Dynapac REDLINE DRA90 Instruction Manual
  1. Manuals
  2. Brands
  3. Dynapac Manuals
  4. Construction Equipment
  5. REDLINE DRA90
  6. Instruction manual
Dynapac REDLINE DRA90 Instruction Manual

Dynapac REDLINE DRA90 Instruction Manual

Asphalt roller
Hide thumbs

Advertisement

Quick Links

Download this manual
I
INSTRUCTION MANUAL
DRA90
Asphalt Roller
SERIAL NUMBER:
10300612CME010544
ENGINE:
Dynapac- 4R1040T
Part Number:
4812331115_B-EN
DRA90 Asphalt Roller

Advertisement

loading
Need help?

Need help?

Do you have a question about the REDLINE DRA90 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Dynapac REDLINE DRA90

Summary of Contents for Dynapac REDLINE DRA90

  • Page 1 INSTRUCTION MANUAL DRA90 Asphalt Roller SERIAL NUMBER: 10300612CME010544 ENGINE: Dynapac- 4R1040T Part Number: 4812331115_B-EN DRA90 Asphalt Roller...

  • Page 2: Manual Revisions

    June 2022 Revised with new branding guideline Customer Acknowledgment • Dynapac reserves the right to make any changes or modifications without prior notice and without incurring any liability to retrofit machines previously shipped from the factory. • Dynapac will not be held responsible for any damages caused by unauthorized modification of the machine and its associated equipment.

  • Page 3: Table Of Contents

    Table of Contents Section 1: Introduction 1.1 General Information ................... Instruction Manual Location ..................Receiving the Roller ....................Identification Data ....................Roller Identification ....................Engine Identification ....................1.2 Roller Description ....................Identification of Major Components ................ Diesel Engine ......................Electrical System ....................Main and Light Fuses ......................
  • Page 4 Table of Contents Section 3: Special Instructions 3.1 Operational Limitations ..................Standard Lubricants and Other Recommended Oils and Fluids ......Higher Ambient Temperatures ................Lower Ambient Temperature - Freeze Risk ............Temperatures ....................... High Pressure Cleaning ..................Ambient Temperature Range ................Operating Conditions For Stability ................
  • Page 5 Hazard Warning Lights Switch ................29 Rotating Beacon Switch (Optional) ..............29 Direction Indicator Switch ..................Parking Brake On/Off Switch ................Control Panel ....................... Control Panel Warnings Symbols .................. 31 Control Panel Notification Symbols ................32 Section 6: Inspections and Operations 6.1 General Information ..................
  • Page 6 Table of Contents 6.6 Transporting the Roller..................Transportation Procedures ................... Safety Precautions ......................44 Operator Checklist ......................44 Start Up ......................... 44 Before Driving ....................... 44 Roller preparation for Transport ................... 45 6.7 Special Conditions ................... Cold Weather Conditions ..................Hot Weather Conditions..................
  • Page 7 Table of Contents Fuel Tank ......................Water Tank ............................63 Brakes ........................Sprinkler System ....................7.6 Lubrication and Filters ..................Hydraulic Reservoir ....................Check Hydraulic Oil Level ..................... 65 Steering Cylinder and Steering Joint ..............Drum - Oil Level ....................Check Drum Gear Oil Level ..................
  • Page 8 This page is intentionally blank...

  • Page 9: Section 1:Introduction

    Perform the necessary pre-operational and post-operational checks on the roller. If any part of this manual cannot be understood, contact the supervisor or local Dynapac distributor. This is an essential condition for working safely with the roller. The correct roller operation, use, and regular maintenance are also essential elements to provide the highest performance and safety.

  • Page 10: Instruction Manual Location

    Figure 1-1: Instruction manual Location Provide the model type and serial number while contacting the local Dynapac service or parts office. Enter the roller data on the following lines to maintain the roller and engine information...

  • Page 11: Roller Identification

    Roller Identification The roller product identification number (PIN) plate is located on left hand side of the engine frame. The PIN number is a 17 digit number which provides information about manufacturer, family model, check letter, no coding, production unit, and serial number. Figure 1-2: Location PIN Manufacturer Family/Model...

  • Page 12: Engine Identification

    Engine Identification Figure 1-4: Identification Plate Engine identification plate The engine identification plate is affixed to the right side of the engine. The engine identification plate provides model identification and other important data about the engine. Refer to the engine operation and maintenance manual for further information on the identification information.

  • Page 13: Roller Description

    1.2 Roller Description The roller is a two self-propelled vibratory tandem rollers in the nine-metric tons class featuring 1690-mm wide drums. The roller is equipped with drive, brakes, and vibration on both drums. To permit optimum performance on a wide range of applications and site requirements, the roller is equipped with: •...

  • Page 14: Diesel Engine

    Figure 1-6: Major Components Right Side Head light Fuel tank Cylinder Water tank Hydraulic tank Drum Seat Rear light Drive motor Platform Scrapper Engine Vibration motor Steering hitch Diesel Engine The roller is equipped with the water-cooled, straight four cylinder BS II diesel engine. Introduction...

  • Page 15: Electrical System

    Figure 1-8: Fuses-View A Electrical System The roller is equipped with 12-V electrical system and 90-A AC alternator. Figure 1-7: Electric System 10-A Fuse D and E 40-A Main and Light fuse 30-A Mini Relay Battery Disconnector switch 75-A Starter Relay 100 –A Fuel Solenoid Battery disconnector 30-A Mini Relay...
  • Page 16 Figure 1-9: Fuses- View B Figure 1-10: Fuse Boxes in Switch Box Fuse box Fuse for Driving Lights Fuse The flat pin, type C (medium) fuses and 20-A fuse are used for driving lights. Table 1-2:Fuse Function and Amperage Sl.No Function Amperage Main fuse 15 A...

  • Page 17: Propulsion System/Transmission

    Propulsion System/ Designated Applications Transmission The roller is designed primarily to compact thin The propulsion system is a hydrostatic system and thick asphalt layers with respect to dual with a hydraulic pump supplying two motors vibration amplitudes optimized for this purpose. It with gear box connected in parallel.
  • Page 18 This page is intentionally left blank...

  • Page 19: Section 2: Safety First

    Section 2: Safety First 2.1 General Information This information is intended as a guide for trained and qualified personnel who are aware of the dangers involved in handling potentially hazardous equipment. It is not intended to contain a complete list of all safety precautions which should be observed by personnel using this equipment.

  • Page 20: Warnings And Cautions

    Further Do not make any unauthorized modifications to information can be found in the respective this roller. Dynapac cannot be held responsible for component descriptions and/ or fitting and any accidents, incidents, or damage to persons or removal instructions.

  • Page 21: Operating Safety

    Operating Safety Driving Near Edges Know the working area. Familiarize with work site While driving near an edge make sure to maintain obstructions and any other potential hazards in 2/3 of the drum width on the solid ground. the area. N o t e The roller's center of gravity moves outwards when steering.

  • Page 22: Slopes

    Hydraulic Maintenance Slopes Safety The slope angle is measured on a hard, flat The normal operating temperature of hydraulic oil surface with the roller stationary. The steering is hot enough to cause serious burns. Use angle was zero, the vibration was switched OFF precautions when working on any hot fluid lines or and all tanks were full.

  • Page 23: Transporting

    Transporting • Use only appropriate means of transport and lifting gear of adequate capacity. • Fastening of loads and instructing the crane operators should be entrusted to the experienced persons only. The person giving the instructions must be within sight or sound of the operator.

  • Page 24: Equipment Safety Decals

    2.2 Equipment Safety Decals Before you operate, maintain, work around, or in any other way use this roller, read and understand the safety decals and safety labels located on the roller. Follow all directions on the labels. Do not remove or deface the labels.

  • Page 25: Section 3: Special Instructions

    For operation of the roller at higher ambient temperatures, however maximum +50°C (122°F). The diesel engine can be run at this temperature using normal oil. Hydraulic system - mineral oil Dynapac Hydraulic 300. Lower Ambient Temperature - Freeze Risk Make sure that the watering system is empty/drained of water (sprinkler, hoses, tank/s) or that anti-freeze has been added, to prevent the system freezing.

  • Page 26: High Pressure Cleaning

    Travel at a safe speed relevant to contain toxic lead. surrounding conditions. Do not use a quick charger for charging the Contact the local Dynapac distributor, dealer, or battery. This may shorten the battery life. service office for further information. Special Instructions...

  • Page 27: Jump Starting

    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. Check the battery used for jump starting has the same voltage as the dead battery. 1.
  • Page 28 This page is intentionally left blank...

  • Page 29: Section 4: Specifications

    Section 4: Specifications 4.1 Weight and Dimensions Figure 4-1: Dimensions, Side View Table 4-1: Weight and Dimensions Side View Wheelbase 2785 mm (109.6 in) Length 4340 mm (170.9 in) Height, with canopy 3060 mm (120.5 in) Height, without canopy 2400 mm (94.5 in) Thickness 17 mm (0.7 in) Operating mass...

  • Page 30: Diesel Engine

    6500 mm (255.9 in) Turning radius inner 4800 mm (188.9 in) Drum width 1690 mm (66.5 in) Steering angle +/- 28 degree Diesel Engine Table 4-3: Diesel Engine Engine Model HP (kW) rpm Dynapac 4R1040 NA 76HP (56kW) @ 2200 rpm Specifications...

  • Page 31: Fluid Volume

    Fluid Volume Table 4-4: Fluid Volumes Fuel tank 180 L (47.55 gal) Water tank Front side 400 L (105.6 gal) Rear side 400 L (105.6 gal) Hydraulic Oil 75 L (17.1 gal) Hydraulic tank 62 L (16.4 gal) Hydraulic system 13 L (3.4 gal) Drum oil 14 L (3.7 gal) each...
  • Page 32 This page is intentionally left blank...

  • Page 33: Section 5: Operation Controls

    Section 5: Operation Controls 5.1 Instruments and Controls This section provides basic information about the operating controls, instruments, and indicators located on the consoles and around the roller. The operator console is located in front of the operator seat under the steering wheel. The slim profile and quick opening side panels provide easy access for maintenance and service.

  • Page 34: Starter Switch

    Starter Switch Throttle Lever The Starter switch starts and stops the engine. The Throttle lever regulates the speed of the There are three positions in the starter switch: engine. In the forward position, the engine idles and in the backward position the engine runs at •...

  • Page 35: Emergency Stop

    Emergency Stop Sprinkler Switch Figure 5-7: Sprinkler Switch The Emergency stop button is used to stop the engine in an emergency situation which cannot be shut off in a usual manner. It switches off the Upper position engine and activates the brakes. The emergency stop aborts the entire control operation in a Intermediate position quicker way for the personnel safety.

  • Page 36: Horn Button

    Horn Button Vibration Selector Switch Depending on the Vibration selector switch The Horn button is located on the switch position, the vibration is activated in the following assembly. places. Press the button to activate the horn. Upper position Activates vibration on front drum.

  • Page 37: Working Light Switch(Optional)

    Working Light Switch Depress the switch to turn on the rotating beacon. Depress the Working light switch to turn on the Figure 5-15: Rotating Beacon Switch working lights. Figure 5-13: Working Lights Direction Indicator Switch The direction indicators are blinking lamps mounted near the left and right, front, and rear Hazard Warning Lights Switch...

  • Page 38: Control Panel

    Control Panel Figure 5-18: Control Panel Oil pressure indicator Hydraulic oil temperature indicator Fuel level indicator Hour meter Parking brake indicator Battery/charging indicator Air filter indicator Low fuel level indicator Glow plug indicator Engine water temperature indicator Operation Controls...

  • Page 39: Control Panel Warnings Symbols

    Control Panel Warnings Symbols Warning lights turn on when the starter switch is turned to the on position and turn off when the engine is started. If the lights turn on even when the engine is running indicates a faulty condition. Table 5-1: Warning Lights Designation Function...

  • Page 40: Control Panel Notification Symbols

    Control Panel Notification Symbols Notifications are displayed when the starter switch is turned to the on position and notifies those corresponding systems are operating. Table 5-2: Notification Lights Designation Function Description Parking brake indicator The lamp illuminates when the parking brake is activated.

  • Page 41: Section 6: Inspections And Operations

    Section 6: Inspections and Operations 6.1 General Information N o t e If you are not experienced with the roller controls, read and understand Section 5 - Operation Controls. The following operational hints should be observed: • Do not speed the engine when it is cold. •...

  • Page 42: Check Engine Oil Level

    Check Engine Oil Level Check Engine Coolant Level • Hot oil and hot components can cause Check the coolant level through level plug of personal injury. Do not allow hot oil or expansion tank. Fill the cooling system when hot components to contact the skin. coolant is empty.

  • Page 43: Check Fuel Level

    Check Fuel Level Check Batteries Fuel is flammable and may cause serious Batteries contain an acid and can cause injury or death. Shut off the engine, injury. Battery fumes can ignite and extinguish all open flames, and do not explode. Do not smoke when observing smoke while filling the tank.

  • Page 44: Before Starting The Engine

    6.2 Before Starting the If any controls, instruments, or devices do Engine not function correctly report the defects to the proper personnel. Defects must be corrected before starting and operating the Remember to carry out daily maintenance before roller. starting the engine. Seat (Standard) Adjustment Refer to Section 7 - Maintenance.

  • Page 45: Check The Instruments And Lamps

    Check the Instruments and Lamps N o t e Make sure that the Emergency stop is pulled out and the parking brake is activated. If the forward/reverse lever is in neutral, the automatic brake function is engaged. 1. Turn on the switch. 2.

  • Page 46: Operating The Roller

    6.3 Operating the Roller 6. Make sure the Throttle lever is turned to backward position. Operation Figure 6-5: Throttle Lever 1. Before the roller startup, a pre-operational general inspection of the roller must be performed in accordance with those instructions previously mentioned and, in the instructions, found in Section 7 - Maintenance.

  • Page 47: Vibration On Selected Drum

    N o t e Vibration on Selected Drum As a general rule, do not operate the starter motor more than 30 seconds at a 1. Activate the Vibration selector switch to time without pausing to allow the starter activate vibration for the front drum, rear drum, motor to cool for at least two minutes.

  • Page 48: Switching Off

    Switching Off 1. Press the Vibration control button to the off position. 2. Set the FNR lever to the neutral position. 3. Turn the Throttle lever to forward position and allow the engine to idle for a few minutes to cool.

  • Page 49: Lifting And Handling

    6.4 Lifting and Handling Lifting the Roller • Use a crane/forklift to lift the equipment. Locking the Articulation • Pay attention when lifting and balancing the N o t e Lock the steering joint, before lifting equipment. the roller. • Seek a person to guide the way when lifting 1.

  • Page 50: Towing The Roller

    6.5 Towing the Roller Towing The roller can be moved up to 300 meters Towing Information (1,000 ft) using the instructions below. Proper equipment must be used to prevent N o t e Chock the drum to prevent the roller damage to the vehicle and the roller during any from moving when the brakes are tow.
  • Page 51 4. Tighten the knob clockwise Engaging the Brakes 1. Turn knob 3 counter clockwise after towing. Figure 6-11: Tighten Step 2. Tighten the Allen screw 2 to original position and then tighten nut 3. Figure 6-13: Towing Knob 5. Operate the lever for 10 to 12 times to manually release the brake.

  • Page 52: Transporting The Roller

    6.6 Transporting the Start Up Roller 1. Before starting the engine, check inside, outside, and underneath the roller for people or obstructions. Transportation Procedures 2. Always horn before starting the roller to alert Safety Precautions everyone in the area. Before moving the roller on public roads, check for 3.

  • Page 53: Roller Preparation For Transport

    Roller preparation for Transport Figure 6-14: Securing for Loading Lashing wire Chocks 1. Chock the drums securely. 2. Support the drum frame firmly to prevent overloading of the rubber suspension of the drum. 3. Anchor the roller securely with lashing wire at all the four corners. Inspections and Operations...
  • Page 54 Figure 6-15: Securing the Vibratory Roller for Transport Table 6-1: Lashings' Permitted Distance The lashings' permitted distance interval in meters (1 - 4: Double lashings, LC at least 1.7 tons (1700 daN), STF 300 kg (300daN)) Double L Double L 0,6 - 3,0 0,1 - 3,0 The distance L...

  • Page 55: Special Conditions

    6.7 Special Conditions Cold Weather Conditions • Refer to Section 7 - 7.3 Refill Capacities/Lubricants in the maintenance section for information regarding cold weather lubricants, hydraulic fluids, coolants, fuel, and the like. • Use winter grade diesel fuel for operation at subzero temperatures. •...
  • Page 56 • Lubricate the steering joint bearings and both bearings on the steering cylinder with grease. Grease the steering cylinder piston with conservation grease. Grease the hinges on the doors to the engine compartment and the cab. Grease both ends of the forward/reverse control (bright parts).

  • Page 57: Section 7: Maintenance

    Section 7: Maintenance 7.1 General Information Safety should be the main concern for anyone working on or around the roller. Do not perform any function that could put someone in danger. Always wear proper safety gear while working on or around the roller. This includes an approved hard hat, safety glasses, steel toe shoes, gloves, respirator, and ear protection.

  • Page 58: Maintenance Schedule

    7.2 Maintenance Schedule Maintenance Schedule Information The maintenance schedule shows those items requiring regular service and the interval at which they are performed. A regular service program is geared to the items listed under each interval. These intervals are based on average operating conditions. Before each consecutive interval is performed, all of the maintenance requirements from the previous interval must also be performed.
  • Page 59 Table 7-3: Maintenance at 50 Hours or Weekly Description Action Lubrication Drum gear oil Check level Air cleaner element Check Leakages at hose and adopter Check Maintenance...
  • Page 60 Table 7-4: Maintenance at 250 Hours/750 Hours/Three Months Description Action Lubrication Battery and lead connection Check Engine Oil Change Drum Oil Check level Table 7-5: Maintenance at 500 Hours/Six Months Description Action Lubrication Engine oil filter Change See engine manual Engine oil Change See engine manual...
  • Page 61 Table 7-7: Maintenance at 2,000 Hours/Two Years Description Action Lubrication Engine oil filter Change See engine manual Engine oil Change See engine manual Fuel filter Change See engine manual Water separator Change See engine manual Engine primary air filter Change Safety filter Change Valve cover gasket...

  • Page 62: Refill Capacities/Lubricants

    Spot check the several cap screws and the nuts for proper torque. If any are found loose, a more thorough investigation must be made. • If a defect is detected, that requires special service, stop the roller operation until the defect has been corrected. If necessary, contact the Dynapac representative for assistance. Maintenance...

  • Page 63: Lubrication Chart

    Periodic lubrication requirements are listed in the following Lubrication Chart. These requirements include lubricant checks and greasing designated areas of the roller. Description Part Number Remarks Quantity Engine oil 4812161855 Dynapac engine oil 200 5 L (1.3 gallons) Hydraulic oil 4812161868 Dynapac hydraulic 300 20 L (5.3 gallons) Drum oil 4812161887 Dynapac Drum oil 1000 5L (1.3 gallons)
  • Page 64 Table 7-8: Maintenance Symbols Symbol Description Symbol Description Engine oil level Air filter Engine oil filter Battery Hydraulic reservoir level Sprinkler Hydraulic fluid filter Sprinkler water Drum oil level Recycling Lubrication oil Fuel filter Maintenance...

  • Page 65: Standard Torque Values

    7.4 Standard Torque Values Use only the proper tools (inches) on hardware. Other tools may not fit properly and may slip and cause injury. Head Markings Fasteners should be replaced with the same grade or a higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original grade fastener.
  • Page 66 Metric coarse screw thread, bright galvanized (fzb): M-thread Size 12.9, 8.8 Oiled 8.8 Dry 10.9 Oiled 10.9, Dry 12.9, Dry Oiled 1080 1130 1260 1580 1770 1900 2100 Metric coarse thread, zinc treated (Dacromet/GEOMET) M-thread Size 10.9 Oiled 10.9 Dry 12.9 Oiled 12.9 Dry 1010...

  • Page 67: Maintenance As Required

    7.5 Maintenance as Loose Bolted Connections Required If any loose nuts or bolts are found during the frequent walk-around and the daily inspections, Service as Required make sure they are properly torqued. Refer to 7.4 Standard Torque Values for the required torque The preventive maintenance and service in this for all bolt sizes and grades.

  • Page 68: Air Cleaner Pre-Cleaner

    Air Cleaner Pre- Cleaner Figure 7-2: Air Cleaner Elements Wipe clean the inside of the cover and the filter housing. Wipe also both surfaces for the outlet pipe. N o t e Check that the hose clamps between the filter housing and the suction hose are tight and that the hoses are intact.

  • Page 69: Cleaning The Filter Element

    N o t e 8. Carefully install the cleaned or new main Replace air filter element after two filter. cleaning intervals Air Circulation Figure 7-3: Air Filter Check that the engine has free circulation of cooling air through the grille in the engine compartment.

  • Page 70: Engine

    Engine Batteries Refer to the engine service and maintenance The following battery maintenance must be manuals for specific information on the engine carried out as part of the 250-hour routine maintenance. maintenance schedule. N o t e Switch off the engine before filling the oil. Batteries contain an acid and can cause N o t e Care must be taken while draining the...

  • Page 71: Check Electrolyte Level

    Fuel Tank Check Electrolyte Level 1. Shut off the engine. Refuel the tank every day before starting the roller. 2. Lockout/tagout the roller as per the site-specific procedure. 1. Unscrew the lockable tank cap. 3. Check the electrolyte level and keep the electrolyte level above the plates.

  • Page 72: Coolant System

    Coolant System Water Tank Unscrew the tank cap and fill with clean water. Do Check that all hoses/hose connectors are intact not remove the strainer. See technical and tight. Fill with coolant as specified in the specifications for the tank volume. lubricant’s specification.

  • Page 73: Brakes

    Sprinkler System 4. Tighten all the screws after adjustment. Start the sprinkler system and make sure that no Figure 7-11: Drum nozzles are clogged. If necessary, clean clogged nozzles and the coarse filter located by the water pump. The sprinkler system should be drained if there is a risk of freezing.

  • Page 74: Lubrication And Filters

    7.6 Lubrication and Check Hydraulic Oil Level Filters If the hydraulic oil level is low, add hydraulic oil. Hydraulic Reservoir 1. Level the roller. 2. Check the reservoir oil level by viewing the The hydraulic reservoir oil level must be checked sight gauge.

  • Page 75: Steering Cylinder And Steering Joint

    Steering Cylinder and Drum - Oil Level Steering Joint 1. Run the roller slowly until the oil plug is opposite to one of the inspection holes. The steering cylinder is located under the operator platform. There is a grease fitting near the base 2.

  • Page 76: Check Drum Gear Oil Level

    Check Drum Gear Oil Level Housekeeping 1. Move the roller until the inspection/filling The complete roller must be given a weekly holes are in position for filling. cleaning. Daily cleaning will be required if material is adhering to the roller working parts. 2.
  • Page 77 This page is intentionally left blank...
  • Page 78 Dynapac road construction India Pvt ltd. Pune, India.