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