Fayat Group DYNAPAC CA1500 User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812159201_F.pdf4812159201_F.pdf
Vibratory rollerVibratory roller
CA1500/1800CA1500/1800
EngineEngine
Cummins QSB 3.3 (IIIA/T3)Cummins QSB 3.3 (IIIA/T3)
Cummins QSB 3.3 (IIIB/T4i)Cummins QSB 3.3 (IIIB/T4i)
Deutz TD3.6 (IIIB/T4)Deutz TD3.6 (IIIB/T4)
Serial numberSerial number
10000155xxA012706 -10000155xxA012706 -
10000156xxA010304 - 01688210000156xxA010304 - 016882
10000160xxA012491 -10000160xxA012491 -
10000162xxA015871 - 01600410000162xxA015871 - 016004
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 ..................................................................................................... 20
Hydraulic system....................................................................................... 21
Air Conditioning / Automatic Climate Control (ACC) (Optional) ................ 21
Tightening torque ...................................................................................... 22
Machine description ............................................................................................................... 23
Diesel engine ............................................................................................ 23
Electrical system ....................................................................................... 23
Propulsion system/Transmission .............................................................. 23
Brake system ............................................................................................ 23
Steering system ........................................................................................ 23
Vibration system........................................................................................ 24
Cab............................................................................................................ 24
FOPS and ROPS ...................................................................................... 24
Identification ............................................................................................................ 25
Product and component plates ................................................................. 25
Product identification number on the frame .............................................. 25
Machine plate............................................................................................ 26
Explanation of 17PIN serial number.......................................................... 26
Engine plates ............................................................................................ 27
Decals...................................................................................................................... 28
Location - decals ....................................................................................... 28
Location - decals, CALIFORNIA ............................................................... 29
Safety decals............................................................................................. 29
Info decals................................................................................................. 32
Instruments/Controls ............................................................................................... 33
Control panel and controls ........................................................................ 33
Function descriptions ................................................................................ 34
Warning indication - membrane panel (Keypad)....................................... 37

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Display explanations ................................................................................. 37
Machine alarm........................................................................................... 40
Dynapac Sub System (DSS)..................................................................... 41
"MAIN MENU" ........................................................................................... 42
"USER SETTINGS" .................................................................... 42
"SERVICE MENU"...................................................................... 43
"ABOUT"..................................................................................... 44
Operator help when starting...................................................................... 45
Operator help Workmode.......................................................................... 45
Display when activating choice via the button set..................................... 46
Instruments and controls, cab ................................................................... 47
Function description of instruments and controls in the cab ..................... 48
Using the cab controls............................................................................... 49
Defroster ..................................................................................... 49
Heat ............................................................................................ 49
AC/ACC ...................................................................................... 49
ACC - Control panel .................................................................................. 50
Main display screen .................................................................................. 50
ACC - Operation menus............................................................................ 50
Electrical system...................................................................................................... 52
Fuses in the main switchbox ..................................................................... 53
Fuses at master switch (Cummins)........................................................... 54
Fuses at master switch (Deutz)................................................................. 54
Fuse box at master switch ........................................................................ 55
Fuses in cab.............................................................................................. 55
Operation ............................................................................................................................... 57
Before starting ......................................................................................................... 57
Master switch - Switching on..................................................................... 57
Operator's seat - Adjustment..................................................................... 57
Belt reminder............................................................................................. 58

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Operator's seat, comfort - Adjustments..................................................... 58
Control panel, adjustments ....................................................................... 59
Parking brake ............................................................................................ 59
Display - Control........................................................................................ 60
Interlock..................................................................................................... 61
Operator position....................................................................................... 61
View .......................................................................................................... 62
Starting .................................................................................................................... 63
Starting the engine .................................................................................... 63
Driving ..................................................................................................................... 64
Operating the roller ................................................................................... 64
Machine with gear change in separate spring-return switch
(gear position switch).................................................................. 64
Machine with speed limiter (speed potentiometer) - Optional..... 65
Slopes......................................................................................... 66
Machine with TC (Anti-Spin) ....................................................... 67
Slopes (TC (Anti-Spin))............................................................... 67
Interlock/Emergency stop/Parking brake - Check ..................................... 68
Vibration .................................................................................................................. 68
Manual/Automatic vibration....................................................................... 68
Manual vibration - Switching on ................................................................ 69
Amplitude - Changeover ........................................................................... 69
Seismic - (Optional)................................................................................... 70
Adjustable (Variable) frequency - (Optional) ............................................. 70
Dynapac Compaction Meter (DCM) including Active Bouncing Control
(ABC) - Optional........................................................................................ 71
Setting limit................................................................................................ 72
Operation CMV ......................................................................................... 72
Braking .................................................................................................................... 73
Normal braking.......................................................................................... 73

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Emergency braking ................................................................................... 73
Switching off.............................................................................................. 74
Parking .................................................................................................................... 74
Chocking the drums .................................................................................. 74
Master switch ............................................................................................ 75
Long-term parking.................................................................................................................. 77
Engine ....................................................................................................... 77
Battery....................................................................................................... 77
Air cleaner, exhaust pipe........................................................................... 77
Fuel tank ................................................................................................... 77
Hydraulic reservoir .................................................................................... 77
Tires (All-weather)..................................................................................... 77
Hoods, tarpaulin ........................................................................................ 78
Miscellaneous ........................................................................................................................ 79
Lifting ....................................................................................................................... 79
Locking the articulation ............................................................................. 79
Lifting the roller.......................................................................................... 79
Lifting the roller with jack:.......................................................................... 80
Unlocking the articulation .......................................................................... 80
Towing/Recovering.................................................................................................. 80
Short distance towing with the engine running.......................................... 81
Short distance towing when the engine is inoperative. ............................. 82
Towing the roller........................................................................................ 83
Transport ................................................................................................................. 83
Securing CA1500-CA1800 for loading ...................................................... 84
Operating instructions - Summary ......................................................................................... 87
Preventive maintenance ........................................................................................................ 89
Acceptance and delivery inspection.......................................................... 89
Warranty.................................................................................................... 89
Maintenance - Lubricants and symbols ................................................................................. 91

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Maintenance symbols ............................................................................... 93
Maintenance - Maintenance schedule ................................................................................... 95
Service and maintenance points ............................................................... 95
General ..................................................................................................... 95
Periodic service (service message) - Optional.......................................... 96
Every 10 hours of operation (Daily)........................................................... 97
After the FIRST 50 hours of operation ...................................................... 97
Every 50 hours of operation (Weekly)....................................................... 97
Every 250 / 750 / 1250 / 1750 hours of operation ..................................... 98
Every 500 / 1500 hours of operation ......................................................... 98
Every 1000 hours of operation .................................................................. 99
Every 2000 hours of operation ................................................................ 100
Maintenance, 10h ................................................................................................................ 101
Scrapers - Check, adjustment................................................................. 101
Scrapers, Pad-drum ................................................................................ 102
Flexible scrapers (Optional) .................................................................... 102
Air circulation - Check ............................................................................. 103
Coolant level - Check .............................................................................. 103
Diesel engine Check oil level ................................................................. 104
Fuel tank - Filling..................................................................................... 104
Hydraulic reservoir - Check fluid level..................................................... 105
Maintenance, first 50h.......................................................................................................... 107
Hydraulic filter - Replacement ................................................................. 107
Tires - Air pressure - Wheel nuts - Tightening ........................................ 109
Drum gear - Oil change........................................................................... 109
Drum gear - Oil filling .............................................................................. 110
Steering hitch - Tightening ...................................................................... 110
Maintenance - 50h ............................................................................................................... 111
Air cleaner
- Check hoses and connections .............................................................. 111

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Maintenance measures - 250 h ........................................................................................... 113
Radiator - Check/Cleaning ...................................................................... 113
Rear axle differential (No Spin) - Check oil level..................................... 114
Rear axle planetary gears (No Spin) - Check oil level ............................ 114
Drum - Checking the oil level .................................................................. 115
Drum gearbox - Checking the oil level .................................................... 116
Rubber elements and fastening screws - Check..................................... 116
Battery
- Check condition .................................................................................... 117
Air conditioning (Optional)
- Inspection.............................................................................................. 117
Automatic Climate Control (Optional) - Inspection .................................. 118
Maintenance measures - 500 h ........................................................................................... 119
Radiator - Check/Cleaning ...................................................................... 119
Air cleaner
Checking - Change the main air filter...................................................... 119
Backup filter - Change............................................................................. 120
Air cleaner
- Cleaning................................................................................................ 121
Rear axle differential (No Spin) - Check oil level..................................... 122
Rear axle planetary gears (No Spin) - Check oil level ............................ 122
Drum - Checking the oil level .................................................................. 123
Drum gearbox - Checking the oil level .................................................... 124
Diesel engine - Oil and Filter change ...................................................... 125
Fuel pre-filter - Replacement................................................................... 125
Replacing the fuel filter............................................................................ 126
Hood, hinges - Lubrication ...................................................................... 126
Seat bearing - Lubrication ....................................................................... 127
Maintenance - 1000h ........................................................................................................... 129
Hydraulic filter - Replacement ................................................................. 129
Air cleaner
Checking - Change the main air filter...................................................... 130

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Backup filter - Change............................................................................. 131
Air cleaner
- Cleaning................................................................................................ 132
Rear axle differential (No Spin) - Oil change........................................... 133
Rear axle planetary gear (No Spin) - Oil change .................................... 133
Drum - Checking the oil level .................................................................. 134
Drum gear - Oil change........................................................................... 135
Drum gear - Oil filling .............................................................................. 135
Steering hitch - Tightening ...................................................................... 136
Radiator - Check/Cleaning ...................................................................... 136
Diesel engine - Oil and Filter change ...................................................... 137
Fuel pre-filter - Replacement................................................................... 137
Replacing the fuel filter............................................................................ 138
Hood, hinges - Lubrication ...................................................................... 138
Seat bearing - Lubrication ....................................................................... 139
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 139
Maintenance - 2000h ........................................................................................................... 141
Hydraulic filter - Replacement ................................................................. 141
Air cleaner
Checking - Change the main air filter...................................................... 142
Backup filter - Change............................................................................. 143
Air cleaner
- Cleaning................................................................................................ 144
Rear axle differential (No Spin) - Oil change........................................... 145
Rear axle planetary gear (No Spin) - Oil change .................................... 145
Drum - Checking the oil level .................................................................. 146
Drum - Oil change ................................................................................... 146
Drum gear - Oil change........................................................................... 147
Drum gear - Oil filling .............................................................................. 147
Steering hitch - Tightening ...................................................................... 148

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Diesel engine - Oil and Filter change ...................................................... 149
Radiator - Check/Cleaning ...................................................................... 150
Fuel pre-filter - Replacement................................................................... 150
Replacing the fuel filter............................................................................ 151
Hood, hinges - Lubrication ...................................................................... 151
Seat bearing - Lubrication ....................................................................... 152
Hydraulic reservoir - Draining.................................................................. 152
Fuel tank - Draining (Optional) ................................................................ 153
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 153
Automatic Climate Control (Optional)
- Overhaul ............................................................................................... 154
Drying filter - Check................................................................................. 154

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Introduction
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Introduction
The machine
CA1500/1800 are models of Dynapac's soil
compaction rollers. They are available in a D (smooth
drum) and PD (padfoot) version.
Intended use
All types of base courses and subbase courses can be
compacted. The PD version enables the use of either
D or PD drums, which ensures greater flexibility for a
wider range of applications.
The cab and safety-related accessories are described
in this manual. Other accessories, such as
tachograph, and "Analyzer" (DCA) 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.
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.
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Introduction
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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
more easily detected on the ground than on the
machine itself.
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Introduction
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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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Introduction
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Safety - General instructions
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Safety - General instructions
(Also read the safety manual)
•The operator must be familiar with the contents of the OPERATION section
before starting the roller.
•The operator must be familiar with the contents of the OPERATION section
before starting the roller.
•Ensure that all instructions in the MAINTENANCE section are followed. •Ensure that all instructions in the MAINTENANCE section are followed.
•Only the operator is allowed to be on the roller. Remain seated at all times
when operating the roller.
•Only the operator is allowed to be on the roller. Remain seated at all times
when operating the roller.
•Never use the roller if it is in need of adjustment or repair. •Never use the roller if it is in need of adjustment or repair.
•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.
•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.
•Dynapac always recommends mounted ROPS (Roll Over Protective
Structure), or a ROPS-approved cab and seat belt usage.
•Dynapac always recommends mounted ROPS (Roll Over Protective
Structure), or a ROPS-approved cab and seat belt usage.
•Drive slowly in sharp bends. •Drive slowly in sharp bends.
•Avoid driving across slopes. Drive straight up or straight down the slope. •Avoid driving across slopes. Drive straight up or straight down the slope.
•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 jeopardizes
the bearing strength and capacity to support the roller.
•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 jeopardizes
the bearing strength and capacity to support the roller.
•Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
•Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
•Drive particularly carefully on uneven ground. •Drive particularly carefully on uneven ground.
•Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
•Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
•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.
•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.
•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.
•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.
•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.
•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.
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Safety - General instructions
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•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.
•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.
•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.
•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.
•For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
•For your own protection always wear:
- helmet
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
- working gloves
•If the machine seems to be responding abnormally during travel, stop and
check it.
•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
jeopardizes 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.
Dynapac always recommends mounted ROPS
(Roll Over Protective Structure), or a
ROPS-approved cab and seat belt usage.
Dynapac always recommends mounted ROPS
(Roll Over Protective Structure), or a
ROPS-approved cab and seat belt usage.
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