Dynapac CA 602 Instruction Manual

DYNAPAC
CA 602
Box 504, SE-371 23 Karlskrona, Sweden
Telephone [phone]
Telefax [phone]
Web www.dynapac.com
O602EN1
OPERATION

19
ILF015WO1

Vibratory Roller
CA602
Operation
O602EN1, June 2002
Diesel engine:
CA 602: Cummins QSB 5.9-C
These instructions apply from:
CA 602 PIN (S/N) *71420603*
Reservation for changes.
Printed in Sweden.
The Dynapac CA 602 is available in D (smooth drum) and PD (padfoot) versions, of which the CA
602D is designed for compacting rock fill. The main range of application for the PD versions 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.
Certain accessories, such as the compaction meter, tachograph and the CCS/RA field computer,
are described in separate instructions.
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2CA 602 O602EN1
This manual contains instructions concerning
operation and use of the roller. For information
regarding care and maintenance, see the manual,
“MAINTENANCE, 602".
When starting up and driving a cold machine,
which implies cold hydraulic fluid, the braking
distance will be longer than normal until the
machine reaches normal working temperature.
The safety manual, which accompanies each
machine, must be studied by each operator of
the roller. Always follow the safety rules and
do not remove the manual from the roller.
CONTENTS
Safety instructions – Personal safety
Special caution – Machine or component damage
WARNING SYMBOLS
SAFETY MANUAL
GENERAL
WARNING
CAUTION
WARNING
WARNING
Page
Safety instructions (Read the Safety Manual also) ......... 3
Safety when driving ......................................................... 4
Safety (optional) .............................................................. 5
Safety decals, location/description ............................... 6-7
Machine and engine plates .............................................. 8
Instruments and controls ................................................. 9
Instruments and controls, functional description ...... 10-13
Controls in the cab ........................................................ 14
Controls in the cab, functional description ..................... 15
Before starting.......................................................... 16-18
Starting .......................................................................... 19
Driving ........................................................................... 20
Driving on difficult courses ............................................ 21
Vibrating/driving ............................................................. 21
Braking .......................................................................... 22
Parking .......................................................................... 23
Instructions for lifting ..................................................... 24
Instructions for towing .............................................. 25-26
Towing/Retrieval ............................................................ 27
Transport ....................................................................... 27
Operating instructions - Summary ................................ 28
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.

3CA 602 O602EN1
SAFETY INSTRUCTIONS (Read the Safety Manual also)
1. The operator must be familiar with the contents of the OPERATION MAN-
UAL before starting the roller.
2. Make sure that all instructions in the MAINTENANCE MANUAL are fol-
lowed.
3. Only trained and/or experienced operators may drive the roller. Passen-
gers are not allowed on the roller. Remain seated during all operation.
4. Never use the roller if it is in need of adjustment or repairs.
5. Board and leave the roller only when it is stationary. Use the grips and
railings that are provided. Always use a ”three-point grip” - both feet and
one hand or one foot and both hands - when boarding or exiting the machine.
6. The ROPS (Roll Over Protective Structure) should always be used when
the machine is operated on risky ground.
7. Drive slowly in sharp bends.
8. Avoid driving at an angle on slopes; drive straight up or down.
9. When driving close to unsafe edges or holes, make sure that at least two
thirds of the drum width is firmly on material that has already been com-
pacted.
10. Make sure that there are no obstacles in the direction of travel, on the
ground or overhead.
11. Drive extra carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on ma-
chines fitted with ROPS.
13. Keep the roller clean. Clean dirt and grease from the operator’s platform
without delay. Keep all signs and decals clean and clearly legible.
14. Safety measures before refueling:
– Stop the engine.
– Do not smoke.
– No naked flame in the vicinity.
– Ground the nozzle of the filling device against the tank to prevent sparks.
15. Before repairs or service:
– Place chocks against the drums/wheels and against the strike-off blade.
– Lock the articulation if required.
16. Hearing protectors are recommended if the noise level exceeds 85 dB(A).
The noise level may vary depending on what material the machine is oper-
ating on.
17. Make no changes or modifications on the roller that could affect safety.
Changes may only be made following written consent by Dynapac.
18. Do not use the roller until the hydraulic fluid has reached its normal work-
ing temperature. Braking distance can be longer than usual if the fluid is
cold. See starting instructions in the OPERATION MANUAL.
WARNING

4CA 602 O602EN1
SAFETY WHEN DRIVING
Fig.2 Tipping angle onsideslopes
Max 20°
or 36%
At least
2/3
Fig.1 Position of drum when driving near
an edge
Driving near an edge
When you drive near an edge, at least two thirds of the
drum width must be on solid ground.
Remember that the machine’s center of
gravity is displaced outward when you
steer to one side. For example, it shifts to
the right when you steer to the left.
The ROPS (Roll Over Protective Structure)
is always recommended when driving on
slopes or insecure ground.
Where possible, avoid all driving
across a
slope. Instead, drive up and down on slop-
ing ground.
The tilting angle is measured on a hard, level surface
with the machine stationary, steering angle zero, vibra-
tion switched OFF and all tanks full. Remember that
loose ground, steering of the machine, vibration
switched ON, driving speed and raising the center of
gravity (for example, with accessories) may cause the
machine to topple even on a smaller slope than that
stated here.
To leave the cab in an emergency, release
the hammer located on the rear right post
and break the rear window.
Slopes
WARNING
WARNING
WARNING
WARNING

5CA 602 O602EN1
SAFETY (OPTIONAL)
Fig.3 Airconditioning
Air conditioning The system contains pressurized refriger-
ant. Releasing refrigerants into the air is
prohibited. The refrigerant circuit may only
be repaired by an authorized company.
The cooling system is pressurized.
Incorrect handling can result in serious
personal injury. Do not disconnect the
hose coupling.
Recharge the system with approved refriger-
ant when required.
WARNING
WARNING
CAUTION

6CA 602 O602EN1
SAFETY DECALS, LOCATION/DESCRIPTION
11 12 614
2, 3 17
17 15
1
5
79
8
14
10 4
1
6147 9
10416
13
1214

7CA 602 O602EN1
SAFETY DECALS, LOCATION/DESCRIPTION
Crush zone, articulation/
Drum. Maintain a safe dis-
tance from the crush zone.
Warning - hot surfaces in
the engine compartment.
Do not touch.
Warning - rotating engine
components. Keep your
hands at a safe distance from
the danger zone.
The operator is urgently
requested to read the safety
manual, and the operation
and maintenance instructions
before using the machine.
1.
2.
3.
6.
903424
903459
903423
903422
The articulation must be
interlocked when lifting.
Read the instruction manual.
7.
Lifting point
Diesel fuel
Tire pressure
110 kPa
16psi
12.
11.
357587
991658
991990
908229
17.
8.
904165
Toxic gas. Read the instruc-
tion manual.
Hydraulic
fluid Biological
hydraulic
fluid
272372 904601
13.
Alt. 1 Alt. 2
Battery
disconnector
16.
904835
Securing
point
14.
382751
10.
15.
Handbook
compartment
903425
Tires filled with ballast.
Read the instruction manual.
4.
Mass Kg
904870
9.
Lifting plate
Emergency exit
5.
903985

8CA 602 O602EN1
MACHINE AND ENGINE PLATES
Machine plate
PIN on frame
Fig.4 Operator’s platform
1. Machine plate
Fig.5 Front frame
1. PIN
Fig.6 Engine
1. Engine plate
2. EPA sign (USA)
1
1
Engine plate
1
The engine plate (1) is affixed to the right side of the
engine under the injection pump. The plate indicates the
type of engine, serial number and engine data. Please
state the engine serial number when ordering spares.
See also the Engine Manual.
The machine plate (1) is affixed on the front left side of
the frame, by the steering joint. The plate shows the
manufacturer’s name and address, type of machine,
product identification number (PIN), weight in working
order, engine power and year of manufacture (the year
of manufacture is not specified if the machine is
delivered outside the EU).
Please state the roller PIN when ordering spares.
The PIN (1) of the machine is punched on the front right
edge of the forward frame beam.
IMPORTANT ENGINE INFORMATION
This engine conforms to YYYY U.S. EPA
and California Tier 2 regulations for
heavy duty non-road compression
ignition diesel cycle engines as
applicable.
THIS ENGINE IS CERTIFIED TO OPERATE
ON DIESEL FUEL 3939196
2
Cummins Engine Company, Inc
Columbus, Indiana
47202-3005
Warning Injury may result and warranty is voided
if fuel rate, rpm or altitude exceed published
maximumvalues forthis model andapplication.
Dateof MFG.
Made in Great Britain.
3284907
CID/L. CPL Engine Serial No.
Family Cust. Spec.
Engine Model
Valve lash Timing-TDCInch Int. Exh.
MM Int. Exh. Fuel rate at rated HPcold
#
Firing Order
RatedHP/KW at RPM
FR

9CA 602 O602EN1
INSTRUMENTS AND CONTROLS
10 11 12 13 14 15 16 17 18 19 20
9 8 7 6 5 4 3 2 1 25 24 23 22 21
31 32 33 34
30 29 28 27 26
35 36 37 38 39
40
Fig.7 Instruments and control panel
1. Starter switch
2. Revs/Frequency selector
3. Working lights
4. Hazard beacon
5. Direction indicator switch
6. Hazard flashers
7. Main beam switch
8. Parking/dipped beam switch
9. Anti-spin, Fault Indication
10. Voltmeter
11. Hydraulic temperature
12. Engine temperature
13. Engine revs/Vibration frequency
14. Compaction meter/
Speedometer (see item 21)
15. Fuel gauge
16. Preheating, diesel engine
17. Service indicator lamp
18. Fault alarm lamp
19. Diagnostics ”ON”
20. Scroll through error codes
21. Speedometer (If compaction
meter is included in item14)
22. Fault alarm lamp
23. Rev selector
24. Amplitude selector Low/0/High
25. CMV selector
26. Hourmeter
27. Brake warning lamp
28. Warning lamp, engine oil pressure
29. Warning lamp, hydraulic filter
30. Warning lamp, air filter
31. Warning lamp, charging
32. Warning lamp, hydraulic
temperature
33. Warning lamp, engine
temperature
34. Warning lamp, fuel level
35. Speed selector, drum
36. Speed selector, rear axle
37. Reserve/Parking brake knob
38. Vibration ON/OFF
39. Forward/Reverse lever
40. Horn
41. Anti-spin function
= Optional
41

10 CA 602 O602EN1
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
Item in Designation Symbol Function
fig. 7
1 Starter switch In mode the electric circuit is broken.
In mode all instruments and electric controls
are powered.
In mode the starter motor is energized.
2 Engine revs/Frequency In mode the engine revs are shown on
selector (Optional) instrument 13.
In the right mode the vibration frequency is
shown on instrument 13.
(The left mode has no function.)
3 Working lights rear, switch Turn to the right to switch on the working
(Optional) lights.
4 Hazard beacon, switch Turn to the right to switch on the hazard
(Optional) beacon.
5 Direction indicator, switch Turn to the left to make the left direction
(Optional) indicator flash, etc.
The flashing function is switched off in the
middle mode.
6 Hazard flashers, switch Turn to the right to switch on the hazard
(Optional) flashers.
7 Main/Dipped beam, switch Turn to the right to switch on the main beam
with control lamp (Optional) and to illuminate the switch.
Turn to the left to switch on the dipped beam.
8 Driving lighting, switch When turned right, the first setting switches
(Optional) on the parking light, the second setting
activates low beam.
9 Warning lamp, malfunctioning The hydraulic propulsion system is not
anti-spin function working satisfactorily if the lamp flashes.
(Optional) Locate and remedy the fault.
10 Voltmeter, (Optional) Indicates voltage of the electrical system.
Normally 12–15 volt.
11 Temperature gauge, Indicates temperature of hydraulic fluid.
hydraulic fluid, (Optional) Normal temperature range 65°C to 80°C
(149°F to 176°F). Stop the engine if the
meter reading exceeds 85°C (185°F).
Locate and remedy the fault.

11CA 602 O602EN1
Item in Designation Symbol Function
fig. 7
12 Temperature gauge, Indicates engine temperature.
meter, (Optional) Normal temperature is about 90°C (194°F).
Stop the engine if the gauge indicates a
temperature higher than 103°C (217°F).
Locate and remedy the fault.
13 Engine revs/Frequency The inner scale shows the actual engine
meter, (Optional) speed. The outer scale shows the vibration
frequency.
14 Compaction meter (Optional) See separate instructions.
15 Fuel gauge Indicates fuel level.
16 Preheating of diesel engine Green Lights when preheating temperature is not right.
17 Service indicator lamp White If the lamp lights for a few seconds, it is time
for the 250-hour service.
18 Fault alarm lamp, Yellow Indicates fault and displays error code
not serious fault together with 19. See error codes under
brace 7 in the machine binder.
19 Diagnostic "ON" Checks error code together with lamp 18
and 20.
20 Scroll through error codes. Turn right to scroll forward.
Turn left to scroll backward.
21 Speedometer (Optional) The outer scale shows roller speed in km/h.
The inner scale shows roller speed in mph.
22 Fault alarm lamp, serious fault Red Stop the engine.
23 Rev selector, diesel engine 900 = Idling revs
1500 = Revs for loading/unloading
2200 = Working and transport revs
24 Amplitude selector Left mode gives low amplitude.
Right mode gives high amplitude.
Vibration switched OFF in O mode.
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION

12 CA 602 O602EN1
Item in Designation Symbol Function
fig. 7
25 CMV selector (Optional) Mode 150 gives reading on outer scale.
Mode 50 gives reading on inner scale.
26 Hourmeter Engine running time is indicated in hours.
27 Brake warning lamp This lamp will light when the parking or re
serve brake knob is pressed and the brakes
are applied.
28 Warning lamp, oil pressure This lamp lights if lubricating pressure in the
engine is too low.
Stop the engine immediately and locate the fault.
29 Warning lamp, hydraulic filter If the lamp lights up when the diesel engine is
running at full speed, the hydraulic fluid filters
must be replaced.
30 Warning lamp, air filter The air filter should be cleaned or replaced if
this lamp lights when the engine is running at
full speed.
31 Warning lamp, battery The alternator is not charging if this lamp
charging lights when the engine is running.
Stop the engine and locate the fault.
32 Warning lamp, hydraulic This lamp lights if the hydraulic fuel is too hot.
temperature Stop the roller, and allow the fluid to cool
down by idling the engine. Locate and remedy
the fault.
33 Warning lamp, This lamp lights if the engine is too hot. Stop
engine temperature the engine immediately and locate and
remedy the fault. See also the engine manual.
34 Warning lamp, low fuel level This lamp lights when there is only sufficient
fuel left for a short period. Refuel without
delay.
35 Speed selector, drum Transport speed (High)
(Optional)
Working speed (Low)
36 Speed selector, rear axle Transport speed (High)
Working speed (Low)
37 Reserve brake/Parking brake Push in to activate the reserve brake. Parking
brake is applied if pushed in when machine is
stationary. Both brakes are released when
knob is pulled out.
STOP
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION

13CA 602 O602EN1
Item in Designation Symbol Function
fig. 7
38 Vibration ON/OFF, switch Push and release the switch to engage vibra
tion, push once more to disengage vibration.
The above applies only when the amplitude
selector (24) is in position High or Low.
39 Forward/Reverse control The lever must be in neutral to start the
engine, it cannot be started with the forward/
reverse lever in any other position.
Direction of travel and speed of the roller is
regulated with the forward/reverse lever. The
roller moves forward when the lever is moved
forward, etc. Speed of the roller is regulated in
proportion to how far the lever is moved from
neutral. The further from neutral, the higher
the speed.
40 Horn, switch Press to sound the horn.
41 Anti-spin function Set the knob to the left for forward anti-spin
function.
Set the knob in the middle for reverse anti-spin
function.
Set the knob to the right for transport driving.
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION

14 CA 602 O602EN1
CONTROLS IN THE CAB
11
Fig. 8a Cab roof, front
Fig. 8d Cab, rear Fig. 8e Cab roof, rear
Fig. 8c Cab, right side (with AC option)
10
1 2 3
4
Fig. 8b Cab, right side
5
6
7
5
6
7
9

15CA 602 O602EN1
CONTROLS IN THE CAB, FUNCTIONAL DESCRIPTION
Item in Designation Symbol Function
fig. 8
1 Wiper front, switch Press to turn on the front wiper.
2 Wiper rear, switch Press to turn on the rear wiper.
3 Screenwash front and rear Press at the top to spray the windscreen.
panes, switch
Press at the bottom to spray the rear screen.
4 Fuse box (cab) Contains fuses for the electrical system.
See the “Electrical system” section in the
Maintenance Manual for functional
descriptions of the fuses.
5 Heater Right mode, maximum heating.
Left mode, heating turned off.
6 Air fan, switch Left mode, fan turned off.
Right mode, cab ventilation increases in three
steps.
7 Recirculation of cab air, Left mode, maximum recirculation of air.
slide control Right mode, minimum.
8 Temperature sensor Senses the interior temperature.
Must not be covered.
9 Air conditioning switch Starts and stops the air conditioner.
10 Handbook compartment Stowage space for safety manual and
operator’s manuals.
11 Hammer for emergency To evacuate the cab in an emergency, re
evacuation lease the hammer and break the REAR
window.

16 CA 602 O602EN1
BEFORE STARTING
Battery disconnecter
– Switching ON
Fig.9 Engine compartment
1. Battery disconnecter
2
Operator’s seat – Setting
1
43
5
Fig.11 Operator’s station
1. Locking lever - rotation (Optional)
2. Locking lever - slope of steering
wheel
3. Locking lever - length adjustment
4. Lever - seat back slope
5. Lever - weight adjustment
1
Fig.10 Operator’s seat
1. Locking lever - length adjustment
2. Lever - weight adjustment
3. Locking lever - slope of steering
wheel
Control unit (Optional) – Setting
2
1
3
The engine hood must be unlocked during
operation, so that battery power can be
disconnected quickly if necessary.
Remember to carry out daily service. See maintenance
manual.
The battery disconnecter is located in the engine
compartment. Open the engine cover and set the key
(1) to the ON position. The entire roller will be powered.
WARNING
Adjust the operator’s seat to ensure a comfortable
posture and so that all controls are within easy reach.
The seat can be adjusted as follows:
Length adjustment (1)
Cushioning to suit weight of operator (2)
Release the locking lever (3) to adjust the steering
column to the desired slope and then lock the steering
column in its new position.
Always make sure that the seat is secure
before beginning operation.
WARNING
Always make sure that the seat is secure
before beginning operation.
The control unit has two modes of adjustment, ie,
rotation and slope of steering wheel.
Pull the lever (1) upwards to allow rotation.
Release the locking lever (2) to adjust the steering
column to the desired slope and then lock the steering
column in its new position.
The seat can be adjusted as follows:
• Length adjustment (3).
• Seat back slope (4).
• Cushioning to suit weight of operator (5).
WARNING

17CA 602 O602EN1
BEFORE STARTING
Turn the starter switch (1) to position I. All warning
lamps should light for about 5 seconds and the buzzer
should sound. Make sure that the warning lamps light.
Check that the voltmeter (10) goes up to at least 12
volts, and also check that the level gauges (15) give a
reading.
Check that the warning lamps for charging (31), oil
pressure (28) and parking brake (27) light.
The hourmeter (26) records the number of hours so
long as the engine is running.
10 15
1 31 28 27 26
Instruments and lamps
– Checking
Fig.13 Instrument panel
1. Starter switch
10. Voltmeter (Optional)
15. Fuel gauge
26. Hourmeter
27. Brake lamp
28. Oil pressure lamp
31. Charging lamp
Parking brake – Check
Fig.14 Controls panel
37. Reserve/Parking brake knob
Operator’s seat in cab – Setting
Fig.12 Operator’s seat
1. Lever - length adjustment
2. Knob - height adjustment
3. Knob - seat cushion slope
4. Knob - seat back slope
5. Knob - armrest slope
6. Knob - lumbar adjustment
5
4
6
23
1
37
Make sure that the reserve/parking brake
knob (37) is really pushed in.
The roller can start to move if the engine is
started on sloping ground if the parking
brake is not applied.
WARNING
Interlock(optional)
The engine switches off 7 seconds after the operator
rises from the seat. This will occur regardless of
whether the forward/reverse lever is in neutral or the
drive mode. The engine will not stop if the parking
brake is activated.
Adjust the operator’s seat to ensure a comfortable
posture and so that all controls are within easy reach.
The seat can be adjusted as follows:
• Length adjustment (1).
• Height adjustment (2).
• Slope of seat cushion (3).
• Seat back slope (4).
• Slope of armrests (5).
• Lumbar support (6).
WARNING Always make sure that the seat is secure
before beginning operation.

18 CA 602 O602EN1
BEFORE STARTING
Field of view
Fig.16 Field of view
Operator’sstation
Fig.15 Operator’s station
1. Sitsbälte
2. ROPS
3. Rubber element
4. Anti-slip
3
2
4
1
If the machine is fitted with a cab, make
sure that the door is closed when in mo-
tion.
Before starting, make sure that the field of view is
unobstructed, both in front and behind. All cab windows
must be clean and rearview mirrors properly adjusted.
If the roller is equipped with a ROPS (Roll Over
Protective Structure) or a cab, always use the seat
belt (1) and wear a hard hat.
Replace the seat belt (1) if it shows signs
of wear or has been subjected to severe
force.
Check that the rubber elements (3) on the
platform are intact. Worn elements will impair
comfort.
Ensure that the anti-slip (4) on the platform
is in good condition; replace with new anti-
slip if friction is poor.
CAUTION
WARNING
WARNING
WARNING