Fayat Group DYNAPAC CA4600 User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812163801.pdf4812163801.pdf
Vibratory rollerVibratory roller
CA4600/5000/5500/6000/6500CA4600/5000/5500/6000/6500
EngineEngine
Cummins B4.5 (stage V/T4f)Cummins B4.5 (stage V/T4f)
Serial numberSerial number
10000173xxA024508 -10000173xxA024508 -
10000174xxA023601 -10000174xxA023601 -
10000175xxA024527 -10000175xxA024527 -
10000176xxA023681 -10000176xxA023681 -
10000177xxA023604 -10000177xxA023604 -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in SwedenPrinted in Sweden

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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
Work driving ................................................................................................ 7
Safety (Optional) ...................................................................................................................... 9
Air conditioning............................................................................................ 9
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
Welding ..................................................................................................... 12
Battery handling ........................................................................................ 12
Jump starting (24V)................................................................................... 13
Technical specifications ......................................................................................................... 15
Vibrations - Operator station ..................................................................... 15
Noise level................................................................................................. 15
Electrical system ....................................................................................... 15
Slopes ....................................................................................................... 15
Dimensions, side view............................................................................... 16
Dimensions, top view ................................................................................ 17

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Weights and volumes................................................................................ 18
Working capacity....................................................................................... 18
General ..................................................................................................... 23
CO2-emission............................................................................................ 23
Liquid-filled tyres (Ballastade tyres)............................................ 23
Hydraulic system....................................................................................... 24
Air Conditioning / Automatic Climate Control (ACC) (Optional) ................ 24
Tightening torque ...................................................................................... 25
Machine description ............................................................................................................... 27
Diesel engine ............................................................................................ 27
Electrical system ....................................................................................... 27
Propulsion system/Transmission .............................................................. 27
Brake system ............................................................................................ 27
Steering system ........................................................................................ 27
Vibration system........................................................................................ 28
Cab............................................................................................................ 28
FOPS and ROPS ...................................................................................... 28
Identification ............................................................................................................ 29
Product and component plates ................................................................. 29
Product identification number on the frame .............................................. 29
Machine plate............................................................................................ 30
Explanation of 17PIN serial number.......................................................... 30
Engine plates ............................................................................................ 31
Decals...................................................................................................................... 32
Location - decals ....................................................................................... 32
Location - decals, CALIFORNIA ............................................................... 33
Safety decals............................................................................................. 33
Info decals................................................................................................. 36
Instruments/Controls ............................................................................................... 37
Control panel and controls ........................................................................ 37

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Function descriptions ................................................................................ 38
Warning indication - membrane panel (Keypad)....................................... 41
Display explanations ................................................................................. 41
Machine alarm........................................................................................... 45
DEF-displays (Urea tank level) ................................................................. 46
DEF-displays (Urea quality) ...................................................................... 47
DEF displays (EAT - Tampering) .............................................................. 48
DEF displays (Exhaust cleaning lamp) ..................................................... 49
DEF displays (Exhaust cleaning lamp disabled (inhibit) ........................... 50
Dynapac Sub System (DSS)..................................................................... 51
"MAIN MENU" ........................................................................................... 52
"USER SETTINGS" .................................................................... 52
"MACHINE SETTINGS".............................................................. 53
"SERVICE MENU"...................................................................... 53
"ABOUT"..................................................................................... 54
Operator help when starting...................................................................... 55
Operator help Workmode.......................................................................... 55
Display when activating choice via the button set..................................... 56
Instruments and controls, cab ................................................................... 57
Function description of instruments and controls in the cab ..................... 58
Using the cab controls............................................................................... 59
Defroster ..................................................................................... 59
Heat ............................................................................................ 59
AC/ACC ...................................................................................... 59
ACC - Control panel .................................................................................. 60
Main display screen .................................................................................. 60
ACC - Operation menus............................................................................ 60
Electrical system...................................................................................................... 62
Fuses in the main switchbox. .................................................................... 63
Fuses at the master switch. ...................................................................... 64

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Fuse box at master switch ........................................................................ 64
Electricity for Urea system ........................................................................ 65
Fuses in cab.............................................................................................. 65
Operation ............................................................................................................................... 67
Before starting ......................................................................................................... 67
Master switch - Switching on..................................................................... 67
Operator's seat - Adjustment..................................................................... 67
Belt reminder............................................................................................. 68
Operator's seat, comfort - Adjustments..................................................... 68
Control panel, adjustments ....................................................................... 69
Parking brake ............................................................................................ 69
Display - Control........................................................................................ 70
Interlock..................................................................................................... 71
Operator position....................................................................................... 71
View .......................................................................................................... 72
Starting .................................................................................................................... 73
Starting the engine .................................................................................... 73
Driving ..................................................................................................................... 74
Operating the roller ................................................................................... 74
Machine with gear change in separate spring-return switch
(gear position switch).................................................................. 74
Machine with speed limiter (speed potentiometer) - Optional..... 75
Slopes......................................................................................... 76
Machine with TC (Anti-Spin) ....................................................... 77
Slopes (TC (Anti-Spin))............................................................... 77
Interlock/Emergency stop/Parking brake - Check ..................................... 78
Dynapac Compaction Meter (DCM) including Active Bouncing Control
(ABC) - Optional........................................................................................ 78
Setting limit................................................................................................ 79
Operation CMV ......................................................................................... 80

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Vibration .................................................................................................................. 81
Manual/Automatic vibration....................................................................... 81
Manual vibration - Switching on ................................................................ 81
Amplitude - Changeover ........................................................................... 82
Adjustable (Variable) frequency - (Optional) ............................................. 82
Braking .................................................................................................................... 83
Normal braking.......................................................................................... 83
Emergency braking ................................................................................... 83
Switching off.............................................................................................. 84
Parking .................................................................................................................... 84
Chocking the drums .................................................................................. 84
Master switch ............................................................................................ 85
Long-term parking.................................................................................................................. 87
Engine ....................................................................................................... 87
Battery....................................................................................................... 87
Air cleaner, exhaust pipe........................................................................... 87
Fuel tank ................................................................................................... 87
Hydraulic reservoir .................................................................................... 87
Tires (All-weather)..................................................................................... 87
Hoods, tarpaulin ........................................................................................ 88
Urea tank (DEF tank) ................................................................................ 88
Miscellaneous ........................................................................................................................ 89
Lifting ....................................................................................................................... 89
Locking the articulation ............................................................................. 89
Lifting the roller.......................................................................................... 89
Lifting the roller with jack:.......................................................................... 90
Unlocking the articulation .......................................................................... 90
Towing/Recovering.................................................................................................. 90
Short distance towing with the engine running.......................................... 91
Short distance towing when the engine is inoperative. ............................. 92

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Towing the roller........................................................................................ 93
Transport ................................................................................................................. 93
Securing CA2500-CA4600 for loading ...................................................... 94
Securing CA5000/5500/6000/6500 for loading ......................................... 96
Operating instructions - Summary ......................................................................................... 99
Preventive maintenance ...................................................................................................... 101
Acceptance and delivery inspection........................................................ 101
Warranty.................................................................................................. 101
Maintenance - Lubricants and symbols ............................................................................... 103
Maintenance symbols ............................................................................. 104
Maintenance - Maintenance schedule ................................................................................. 105
Service and maintenance points ............................................................. 105
General ................................................................................................... 105
Periodic service (service message) - Optional........................................ 106
Every 10 hours of operation (Daily)......................................................... 107
After the FIRST 50 hours of operation .................................................... 107
Every 50 hours of operation (Weekly)..................................................... 107
Every 250 / 750 / 1250 / 1750 hours of operation ................................... 108
Every 500 / 1500 hours of operation ....................................................... 108
Every 1000 hours of operation ................................................................ 109
Every 2000 hours of operation ................................................................ 110
Every other year...................................................................................... 111
Maintenance, 10h ................................................................................................................ 113
Scrapers - Check, adjustment................................................................. 113
Scrapers, Pad-drum ................................................................................ 114
Scrapers (Heavy duty), Pad drum........................................................... 114
Flexible scrapers (Optional) .................................................................... 115
Air circulation - Check ............................................................................. 115
Coolant level - Check .............................................................................. 116
Diesel engine Check oil level ................................................................. 116

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Fuel tank - Filling..................................................................................... 117
Urea tank - Refilling................................................................................. 118
Hydraulic reservoir - Check fluid level..................................................... 118
Maintenance, first 50h.......................................................................................................... 119
Hydraulic filter - Replacement ................................................................. 119
Drum cartridge - Oil change .................................................................... 120
Tires - Air pressure - Wheel nuts - Tightening ........................................ 121
Drum gearbox - Oil change ..................................................................... 122
Steering hitch - Tightening ...................................................................... 122
Maintenance - 50h ............................................................................................................... 123
Air cleaner
- Check hoses and connections .............................................................. 123
Pre-fuel filter - Draining ........................................................................... 124
Maintenance measures - 250 h ........................................................................................... 125
Drum cartridge - Checking the oil level ................................................... 125
Drum cartridge - Cleaning the ventilation screw ..................................... 126
Rear axle differential - Check oil level..................................................... 126
Rear axle planetary gears - Check oil level............................................. 127
Drum gearbox - Checking the oil level .................................................... 127
Radiator - Check/Cleaning ...................................................................... 128
Rubber elements and fastening screws - Check..................................... 128
Battery
- Check condition .................................................................................... 129
Air conditioning (Optional)
- Inspection.............................................................................................. 129
Automatic Climate Control (Optional) - Inspection .................................. 130
Maintenance measures - 500 h ........................................................................................... 131
Drum cartridge - Checking the oil level ................................................... 131
Drum cartridge - Cleaning the ventilation screw ..................................... 132
Air cleaner
Checking - Change the main air filter...................................................... 132

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Backup filter - Change............................................................................. 133
Air cleaner
- Cleaning................................................................................................ 133
Rear axle differential - Check oil level..................................................... 134
Rear axle planetary gears - Check oil level............................................. 134
Drum gearbox - Checking the oil level .................................................... 135
Radiator - Check/Cleaning ...................................................................... 135
The engine fuel filter - replacement/cleaning .......................................... 136
Diesel engine - Oil and Filter change ...................................................... 137
Hood, hinges - Lubrication ...................................................................... 137
Seat bearing - Lubrication ....................................................................... 138
Maintenance - 1000h ........................................................................................................... 139
Hydraulic filter - Replacement ................................................................. 139
Drum cartridge - Checking the oil level ................................................... 140
Drum cartridge - Cleaning the ventilation screw ..................................... 141
Air cleaner
Checking - Change the main air filter...................................................... 141
Backup filter - Change............................................................................. 142
Air cleaner
- Cleaning................................................................................................ 143
Rear axle differential - Oil change........................................................... 144
Rear axle planetary gear - Oil change .................................................... 144
Drum gearbox - Oil change ..................................................................... 145
Radiator - Check/Cleaning ...................................................................... 145
The engine fuel filter - replacement/cleaning .......................................... 146
Diesel engine - Oil and Filter change ...................................................... 147
Seat bearing - Lubrication ....................................................................... 148
Hydraulic reservoir - Draining.................................................................. 148
Fuel tank - Draining (Optional) ................................................................ 149
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 149

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Steering hitch - Tightening ...................................................................... 150
Maintenance - 2000h ........................................................................................................... 151
Hydraulic reservoir - Oil change.............................................................. 151
Hydraulic filter - Replacement ................................................................. 152
Drum cartridge - Oil change .................................................................... 153
Drum cartridge - Cleaning the ventilation screw ..................................... 154
Air cleaner
Checking - Change the main air filter...................................................... 154
Backup filter - Change............................................................................. 155
Air cleaner
- Cleaning................................................................................................ 155
Rear axle planetary gear - Oil change .................................................... 156
Rear axle differential - Oil change........................................................... 157
Drum gearbox - Oil change ..................................................................... 157
Radiator - Check/Cleaning ...................................................................... 158
The engine fuel filter - replacement/cleaning .......................................... 158
Diesel engine - Oil and Filter change ...................................................... 159
Seat bearing - Lubrication ....................................................................... 160
Hydraulic reservoir - Draining.................................................................. 160
Fuel tank - Draining (Optional) ................................................................ 161
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 161
Automatic Climate Control (Optional)
- Overhaul ............................................................................................... 162
Drying filter - Check................................................................................. 162
Steering hitch - Tightening ...................................................................... 163
Replacing the urea pump filter ................................................................ 164
Replacing the urea tank suction filter ...................................................... 165

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Introduction
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Introduction
The machine
CA4600/5000/5500/6000/6500 are models of
Dynapac's heavy soil compaction rollers. They are
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. PD-shell or 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
tachograph, "Optimizer" (DCO) and "Analyzer"
(Dyn@lyzer) 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.
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Introduction
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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
Decal and location of decal shown in section
Machine description.
Proposition 65
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
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Introduction
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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, where maintenance after every 10 and
50 hours of operation can be performed by the
machine operator. Other maintenance intervals must
be carried out by accredited (Dynapac) service
personnel.
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.
Specific maintenance and checks on diesel
engines must be carried out by the engine
supplier’s certified personnel.
Specific maintenance and checks on diesel
engines must be carried out by the engine
supplier’s certified personnel.
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 regulations and directives
applicable for this machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable regulations
and directives with supplements, as well as the
harmonized standards and other regulations that are
applied and according to the regulations must be
declared in writing.
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Safety - General instructions
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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 the operator is allowed to be on the roller. Remain seated at all times
when operating the roller.
3. Only the operator is allowed to be 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 ascend and descend the roller when it is stationary. Use the intended
footsteps, grips and rails. Always use the three-point grip (both feet and one
hand, or one foot and both hands) when ascending or descending the
machine. Never jump down from the machine.
5. Only ascend and descend the roller when it is stationary. Use the intended
footsteps, grips and rails. Always use the three-point grip (both feet and one
hand, or one foot and both hands) when ascending or descending the
machine. Never jump down from the machine.
6. The ROPS (Roll Over Protective Structure) shall be used.6. The ROPS (Roll Over Protective Structure) shall be used.
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. Never operate with roller outside the edge, if the substrate does not have full
bearing strength or is close to a slope. Avoid operating close to edges and
ditches and the like as well as on poor ground conditions that influence the
bearing strength and capacity to support the roller.
9. Never operate with roller outside the edge, if the substrate does not have full
bearing strength or is close to a slope. Avoid operating close to edges and
ditches and the like as well as on poor ground conditions that influence the
bearing strength and capacity to support the roller.
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.
- Lock the articulation if necessary.
- Place blocks under overhanging equipment, such as strike-off blade and
chip spreader.
15. Before repairs or service:
- Chock the drums/wheels.
- Lock the articulation if necessary.
- Place blocks under overhanging equipment, such as strike-off blade and
chip spreader.
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16. Hearing protection is recommended if the noise level exceeds 80 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 80 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
20. If the machine seems to be responding abnormally during travel, stop and
check it.
20. If the machine seems to be responding abnormally during travel, stop and
check it.
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Safety - when operating
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Safety - when operating
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
Prevent persons from entering or remaining in
the danger area, i.e. a distance of at least 7 m
(23 ft) in all directions from operating machines.
The operator may allow a person to remain in
the risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
The operator may allow a person to remain in
the risk zone, however he/she must be attentive
and operate the machine only when the person
is fully visible or has given a clear indication of
where he or she is.
Avoid driving across a slope. Drive straight up
and down sloping ground.
Avoid driving across a slope. Drive straight up
and down sloping ground.
Driving near edges
Never operate with roller outside the edge, if the
substrate does not have full bearing strength or is
close to a slope.
Never operate with roller outside the edge, if the
substrate does not have full bearing strength or is
close to a slope.
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.
Work driving
Avoid operating close to edges and ditches and the
like as well as on poor ground conditions that influence
the bearing strength and capacity to support the roller.
Pay attention to potential obstacles above the
machine, such as overhead cables and the branches
of trees etc.
Pay particular attention to the stability of the substrate
when compacting close to edges and holes. Do not
compact with a large overlap from the previous track in
order to maintain roller stability. Consider other
compaction methods such as remote-control or a
walk-behind roller close to steep slopes or where the
bearing strength of the substrate is unknown.
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Safety - when operating
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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.
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