Fayat Group DYNAPAC CA2500 User manual

Instruction manualInstruction manual
Operating & MaintenanceOperating & Maintenance
4812162601_G.pdf4812162601_G.pdf
Vibratory rollerVibratory roller
CA2500/3500CA2500/3500
CA2500/3500 HCCA2500/3500 HC
CA4000CA4000
EngineEngine
Cummins QSF 3.8 (IV/T4F)Cummins QSF 3.8 (IV/T4F)
Cummins F 3.8 (V/T4F)Cummins F 3.8 (V/T4F)
Serial numberSerial number
10000167xxA015825 -10000167xxA015825 -
10000168xxA018468 -10000168xxA018468 -
10000187xxA031260 -10000187xxA031260 -
10000188xxA026250 -10000188xxA026250 -
10000189xxA025398 -10000189xxA025398 -
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
Training ....................................................................................................... 1
Signal symbols and meaning ...................................................................... 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 ................................................................................................ 8
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

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Dimensions, top view ................................................................................ 17
Weights and volumes................................................................................ 18
Working capacity....................................................................................... 18
General ..................................................................................................... 23
CO2-emission............................................................................................ 23
Fluid filled tires (Ballasted tires).................................................. 24
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

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Control panel and controls ........................................................................ 37
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

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Fuses at the master switch. ...................................................................... 64
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
Vibration .................................................................................................................. 78
Manual/Automatic vibration....................................................................... 78
Manual vibration - Switching on ................................................................ 79

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Amplitude - Changeover ........................................................................... 79
Seismic - (Optional)................................................................................... 80
Adjustable (Variable) frequency - (Optional) ............................................. 80
Dynapac Compaction Meter (DCM) including Active Bouncing Control
(ABC) - Optional........................................................................................ 81
Setting limit................................................................................................ 82
Operation CMV ......................................................................................... 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

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Short distance towing with the engine running.......................................... 91
Short distance towing when the engine is inoperative. ............................. 92
Towing the roller........................................................................................ 93
Transport ................................................................................................................. 93
Securing CA2500-CA4600 for loading ...................................................... 94
Operating instructions - Summary ......................................................................................... 97
Preventive maintenance ........................................................................................................ 99
Acceptance and delivery inspection.......................................................... 99
Warranty.................................................................................................... 99
Maintenance - Lubricants and symbols ............................................................................... 101
Maintenance symbols ............................................................................. 102
Maintenance - Maintenance schedule ................................................................................. 103
Service and maintenance points ............................................................. 103
General ................................................................................................... 103
Periodic service (service message) - Optional........................................ 104
Every 10 hours of operation (Daily)......................................................... 105
After the FIRST 50 hours of operation .................................................... 105
Every 50 hours of operation (Weekly)..................................................... 105
Every 250 / 750 / 1250 / 1750 hours of operation ................................... 106
Every 500 / 1500 hours of operation ....................................................... 106
Every 1000 hours of operation ................................................................ 107
Every 2000 hours of operation ................................................................ 108
Every other year...................................................................................... 109
Maintenance, 10h ................................................................................................................ 111
Scrapers - Check, adjustment................................................................. 111
Scrapers, Pad-drum ................................................................................ 112
Scrapers (Heavy duty), Pad drum........................................................... 112
Flexible scrapers (Optional) .................................................................... 113
Air circulation - Check ............................................................................. 113
Coolant level - Check .............................................................................. 114

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Diesel engine Check oil level ................................................................. 114
Fuel tank - Filling..................................................................................... 115
Urea tank - Refilling................................................................................. 115
Hydraulic reservoir - Check fluid level..................................................... 116
Maintenance, first 50h.......................................................................................................... 117
Hydraulic filter - Replacement ................................................................. 117
Drum cartridge - Oil change .................................................................... 118
Tires - Air pressure - Wheel nuts - Tightening ........................................ 119
Drum gearbox - Oil change ..................................................................... 120
Steering hitch - Tightening ...................................................................... 120
Maintenance - 50h ............................................................................................................... 121
Air cleaner
- Check hoses and connections .............................................................. 121
Pre-fuel filter - Draining ........................................................................... 122
Maintenance measures - 250 h ........................................................................................... 123
Drum cartridge - Checking the oil level ................................................... 123
Drum cartridge - Cleaning the ventilation screw ..................................... 124
Rear axle differential - Check oil level..................................................... 124
Rear axle planetary gears - Check oil level............................................. 125
Drum gearbox - Checking the oil level .................................................... 125
Radiator - Check/Cleaning ...................................................................... 126
Rubber elements and fastening screws - Check..................................... 126
Battery
- Check condition .................................................................................... 127
Air conditioning (Optional)
- Inspection.............................................................................................. 127
Automatic Climate Control (Optional) - Inspection .................................. 128
Maintenance measures - 500 h ........................................................................................... 129
Drum cartridge - Checking the oil level ................................................... 129
Drum cartridge - Cleaning the ventilation screw ..................................... 130

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Air cleaner
Checking - Change the main air filter...................................................... 130
Backup filter - Change............................................................................. 131
Air cleaner
- Cleaning................................................................................................ 131
Rear axle differential - Check oil level..................................................... 132
Rear axle planetary gears - Check oil level............................................. 132
Drum gearbox - Checking the oil level .................................................... 133
Radiator - Check/Cleaning ...................................................................... 133
The engine fuel filter - replacement/cleaning .......................................... 134
Diesel engine - Oil and Filter change ...................................................... 135
Hood, hinges - Lubrication ...................................................................... 135
Seat bearing - Lubrication ....................................................................... 136
Maintenance - 1000h ........................................................................................................... 137
Hydraulic filter - Replacement ................................................................. 137
Drum cartridge - Checking the oil level ................................................... 138
Drum cartridge - Cleaning the ventilation screw ..................................... 139
Drum cartridge - Oil level glass ............................................................... 139
Air cleaner
Checking - Change the main air filter...................................................... 140
Backup filter - Change............................................................................. 140
Air cleaner
- Cleaning................................................................................................ 141
Rear axle differential - Oil change........................................................... 142
Rear axle planetary gear - Oil change .................................................... 142
Drum gearbox - Oil change ..................................................................... 143
Radiator - Check/Cleaning ...................................................................... 143
The engine fuel filter - replacement/cleaning .......................................... 144
Diesel engine - Oil and Filter change ...................................................... 145
Seat bearing - Lubrication ....................................................................... 146
Hydraulic reservoir - Draining.................................................................. 146

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Fuel tank - Draining (Optional) ................................................................ 147
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 147
Steering hitch - Tightening ...................................................................... 148
Maintenance - 2000h ........................................................................................................... 149
Hydraulic reservoir - Oil change.............................................................. 149
Hydraulic filter - Replacement ................................................................. 150
Drum cartridge - Oil change .................................................................... 151
Drum cartridge - Cleaning the ventilation screw ..................................... 152
Drum cartridge - Oil level glass ............................................................... 152
Air cleaner
Checking - Change the main air filter...................................................... 152
Backup filter - Change............................................................................. 153
Air cleaner
- Cleaning................................................................................................ 154
Rear axle planetary gear - Oil change .................................................... 154
Rear axle differential - Oil change........................................................... 155
Drum gearbox - Oil change ..................................................................... 156
Radiator - Check/Cleaning ...................................................................... 156
The engine fuel filter - replacement/cleaning .......................................... 157
Diesel engine - Oil and Filter change ...................................................... 158
Seat bearing - Lubrication ....................................................................... 159
Hydraulic reservoir - Draining.................................................................. 159
Fuel tank - Draining (Optional) ................................................................ 160
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 160
Automatic Climate Control (Optional)
- Overhaul ............................................................................................... 161
Drying filter - Check................................................................................. 161
Steering hitch - Tightening ...................................................................... 162
Replacing the urea tank suction filter ...................................................... 162
Replacing the urea pump filter ................................................................ 163

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Introduction
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Introduction
The machine
CA2500/3500/4000 are models of Dynapac's
medium-heavy earth 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
tachographs, "Optimizer" (DCO) and "Dyn@lyzer" are
described in separate instructions.
Training
The purpose of operator training is to impart the
operator the knowledge and skills necessary for
proper operation and routine maintenance of the roller
according to this manual.
Note to trainer: Further information on operator training can be
found in ISO 7130.
Signal symbols and meaning
WARNING ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in death or serious injury.
WARNING ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in death or serious injury.
CAUTION ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in minor or moderate injury, damage to
the machine or property.
CAUTION ! Indicates potential hazardous
situation/procedure which, if not avoided, could
result in minor or moderate injury, damage to
the machine or property.
Safety information
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.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Replace immediately the instruction manuals if
lost, damaged or unreadable.
Only the operator is allowed to be on the roller.Only the operator is allowed to be on the roller.
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.
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Introduction
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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.
If faults or suspected damage are detected on the
roller, contact the responsible supervisor for any action.
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 manufacturer's engine manual.
Additional instructions for the engine can be
found in the manufacturer's engine manual.
Specific maintenance and checks on diesel
engines must be performed by engine supplier
authorized personnel.
Specific maintenance and checks on diesel
engines must be performed by engine supplier
authorized 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 the drum outside the edge, the substrate might not have
full bearing strength or the edge 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 the drum outside the edge, the substrate might not have
full bearing strength or the edge 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
footsteps or operator platform to avoid slipping risk. Keep all signs and
decals clean and legible.
•Keep the roller clean. Clean any dirt or grease that accumulates on the
footsteps or operator platform to avoid slipping risk. 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 by keeping it in contact 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 by keeping it in contact 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, edge
cutter/compactor 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, edge
cutter/compactor and chip spreader.
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Safety - General instructions
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•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.
•Modifications to the roller, including the use of any attachment/equipment,
not approved by Dynapac that might compromise safety (including visibility)
are not allowed. Any modifications are only to be made after written approval
has been given by Dynapac.
•Modifications to the roller, including the use of any attachment/equipment,
not approved by Dynapac that might compromise safety (including visibility)
are not allowed. Any modifications 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.
•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.
•For your own protection always wear:
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
Also wear:
- helmet if no cab or FOPS, or if required by worksite management
- working gloves if no cab and for work outside operator´s platform.
•For your own protection always wear:
- working boots with steel toecaps
- ear protectors
- reflecting clothing/high visibility jacket
Also wear:
- helmet if no cab or FOPS, or if required by worksite management
- working gloves if no cab and for work outside operator´s platform.
•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 risk zone, 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 risk zone, 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 the drum outside the edge, the
substrate might not have full bearing strength or
the edge is close to a slope.
Never operate with the drum outside the edge, the
substrate might not have full bearing strength or
the edge 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.
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Safety - when operating
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Work driving
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.
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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