Fayat DYNAPAC CT3000 User manual

Instructions Manual
Operation & Maintenance
4812325559EN
Tamping Roller
CT3000
Engine
Cummins QSB 6.7 ℓ, Tier III and Tier IV
From serial number
10000505xxB005408
10000513xxB005408
Reserves the right to introduce modifications
Printed in Brazil

24812325559EN 2018-02-20

2018-02-20 4812325559EN
CONTENT
OPERATION Page
Introduction..............................................................................................................................1
Safety - General instructions....................................................................................................2
Safety-During operation...........................................................................................................3
Safety - General instructions....................................................................................................4
Safety decals –Location and description.................................................................................5
Technical specifications...........................................................................................................7
Identification plates..................................................................................................................8
Operator's instruments and controls.......................................................................................10
Instruments and controls –Description and function..............................................................13
Emergency procedures..........................................................................................................23
Before starting the engine......................................................................................................29
Starting the engine.................................................................................................................33
Operation...............................................................................................................................34
Braking ..................................................................................................................................38
Stopping ................................................................................................................................40
Parking ..................................................................................................................................41
Lifting.....................................................................................................................................42
Towing...................................................................................................................................43
Transportation........................................................................................................................44
General instructions of operation - Summary.........................................................................48
Introduction............................................................................................................................49
Symbols and Lubricants.........................................................................................................50
Specifications ........................................................................................................................52
Lubrication and maintenance points.......................................................................................55
Lubrication and maintenance procedures ..............................................................................56
Daily (Every 10 hours of operation)........................................................................................60
Weekly (Every 50 hours of operation)....................................................................................70
Biweekly (Every 100 hours of operation)................................................................................75
Monthly (Every 250 hours of operation) .................................................................................77
Quarterly (Every 500 hours of operation)...............................................................................82
Biannually (Every 1,000 hours of operation) ..........................................................................83
Annually (Every 2,000 hours of operation).............................................................................91
Long lasting intervals.............................................................................................................94
Special instructions................................................................................................................95
Electrical system..................................................................................................................100

Introduction
2018-02-20 4812325559EN 1
Introduction
Warning symbols
ATTENTION! Damage to the machine and its
components.
CAUTION! Your safety might be involved.
Safety manual
The operator should read the safety manual
that comes with the machine. Always follow
the safety instructions and do not remove the
manual from the machine.
Main
This manual has information about the operation and usage
of the machine. For instructions and information about
lubrication and maintenance, please refer to the respective
Maintenance Section.
When releasing the emergency/parking brake
check that the warning lamp has turned off after
10 seconds, if not, check the cause of the
abnormality before operating the equipment.
NEVER release the emergency brake/parking
brake without knowing the conditions of braking.

Safety –General instructions
24812325559EN 2018-02-20
Safety - General instructions
(Read also the Safety Manual)
1. Read and understand this Manual before starting the engine and operating the
machine. The operator should be completely familiarized with the machine before
usage.
2. Observe and follow all the instructions of lubrication and maintenance contained
in the Maintenance Manual.
3. Do not operate the machine if you are not qualified, by training or experience.
NEVER allow passengers and always operate the machine seated.
4. Do not operate the machine if it needs repair or adjustments.
5. When entering or exiting the machine, use the stairs and the handrail. NEVER enter
or exit the machine while moving.
6. In the case of the ground stability is irregular or dangerous, use the Roll Over
Protective Structure (ROPS). Always use the seat belt with ROPS cabs.
7. In closed turns, maintain the lowest speed possible.
8. Avoid moving near cliffs or locations with high side inclination. Operate the
machine in low speed and always check the functionality of the brakes.
9. Beware of obstacles above your head. Always look up and down.
10. Take special attention when operating on rough terrain. Never exceed the speed
of 12.4 mph (20 km/h).
11. Obey all the safety rules and use the proper protection equipment according to
the work that will be done.
12. Maintain the machine always clean. Clean immediately dirt, grease or oil present
on the operator’s platform. Keep all the signals, lanterns, headlights and decals
clean and clearly readable and visible.
13. Observe the following safety measures when refueling the machine:
- Turn off the engine;
- Do not smoke or allow others to smoke;
- Do not allow sparks or flames near the equipment;
- Level the nozzle of fueling, as well as the fueling nipple.
14. Before performing any maintenance operation, cleat the tamping cylinders and
pull the emergency/parking brake.
15. If the noise level of the machine is superior to 85 dB (A), use proper auricular
protectors. The level of noise can fluctuate according to the kind of work the
equipment is being subjected to.
16. Do not modify the machine under any pretext, because this action can affect
personal safety and equipment safety. Any modification on the machine requires
a previous approval by writing from DYNAPAC.
17. Always keep the doors closed when operating machinery equipped with cab.

Safety –Operation
2018-02-20 4812325559EN 3
Safety-During operation
Operation near edges
While operating near to edges or holes, make sure that at least
half of the tamping rollers are on a compacted ground.
Remember that the center of gravity of the machine
shifts to the external side when operating the
steering wheel. As an example: move to the right
when the steering wheel is shifted to the left.
It is recommended to use the Roll Over Protective
Structure (ROPS) while operating on slopes or
irregular ground.
Always avoid when possible to operate
transversally on slopes. When on slopes, preferably
operate up and down.
Always use the first speed when operating on
slopes.
Always operate the machine with doors closed and
seat belt fastened.
Fig. Positioning of the tamping rollers
while operating near edges or holes.

Safety –General instructions
44812325559EN 2018-02-20
Safety - General instructions
Air conditioning
The system contains coolant under pressure. It is
forbidden by law to release the coolant into the
atmosphere.
The maintenance services in the air conditioning
system should only be performed by trained
personnel with proper equipment and tools.
The air conditioning system is under pressure. The
incorrect handling may cause severe personal
injuries. Do not release or loose hoses or fittings
with the system loaded.
Working Lights - Xenon
CAUTION! High voltage!
The working lights are Xenon-type, which have a secondary high
voltage power source.
Any maintenance procedure in the lighting system must only be
performed by qualified personnel and the main power source
must be shut off.
CAUTION! Dangerous residue for human being and
environment.
The working lights Xenon lamps contain mercury (Hg).
A damaged lamp is considered as a toxic and dangerous
residue, thus must be disposed properly and according to the
applicable law.
Fig. Air conditioning
Fig. Xenon Working Lights

Safety decals –Location and description
2018-02-20 4812325559EN 5
Safety decals –Location and description
1
1
3
2
3
2
5
5
6
7
4
6
8
9
9
7
10
10
10
10
11
12
13
14
15
16

Safety decals –Location and description
64812325559EN 2018-02-20
1.
WARNING. Zone subjected to
crushing of articulate direction.
Keep safe distance from this
area.
7.
WARNING. During
elevation, block the
articulation, read
instruction manual.
12.
Main battery switch.
2.
WARNING. Be careful! Engine
rotating components! Keep your
hands away from this risk area.
8.
Fuel.
13.
Hydraulic oil level.
3.
WARNING. Extremely hot
surface, danger! Do not touch
these surfaces.
8.
Fuel (Tier IV engine)
14.
Engine coolant.
4.
WARNING. Before operating the
machinery, it is recommended to
the operator to read the Safety
and Engine Manuals, as well as
the instructions of operation and
maintenance.
9.
Lifting position.
15.
Hydraulic oil.
5.
WARNING. Danger for hands
and arms, rotating belts. Keep
distance from this risk area.
10.
Fixation position.
16.
Fuel filter.
6.
Information plate of the lifting
capacity of the equipment.
11.
Manual compartment.

Technical specifications
2018-02-20 4812325559EN 7
Technical specifications
Vibrations –Operator station
(ISO 2631)
Vibration levels have been measured according to the operational cycle
described in the EU directive 2000/14/EC on machines equipped for the EU
market with operator seat in transport position.
Measured whole-body vibrations are below the action value of 0.5 m/s² as specified in
Directive 2002/44/EC. (Limit is 1.15 m/s²)
Measured hand/arm vibrations also were below the action level of 2.5 m/s² specified
in the same directive. (Limit is 5 m/s²)
Noise level
Sound levels have been measured according to the operational cycle described
in the EU directive 2000/14/EC on machines equipped for the EU market with
operator seat in transport position.
Guaranteed sound power level, LwA 103 dB (A)
Sound pressure level at the operator's ear (platform),LpA 85 ±3 dB (A)
Sound pressure level at the driver's ear (cab),LpA 80 ±3 dB (A)
During operation the above values may differ because of the actual operational
conditions.
Electrical system
Machines are EMC tested in accordance with EN
13309:2000 'Construction machinery'

Identification plates
84812325559EN 2018-02-20
Identification plates
Machine identification plate
The identification plate (1) is located on the left side of the
machine, in the lower chassis below the fuel tank.
This plate indicates the name of the manufacturer and its
address, type of machine, serial number and other important
information about the product.
When ordering replacement parts, always inform the serial
number and the machine model.
NOTE: When ordering replacement parts, always inform the
serial number and the machine model.
Product Identification Number (PIN) on the
chassis
The product identification number - PIN (2) is engraved on the
front chassis on the right side right below the fuel tank (1).
1
1
Fig. Location of identification plate on the
machine.
1 –Identification plate
Fig. Front chassis
2 –PIN

Identification plates
2018-02-20 4812325559EN 9
Explanation about the Product Identification
Number (PIN) with 17 characters
A –Manufacturer's code (100 = Dynapac)
B –Family/model code (00505 or 00513 = CT3000)
C –Checking code
D –Year of manufacturing (E = 2014, F=2015...)
E –Unit code (B = Sorocaba, Brasil)
F –Sequential serial number (from 000001 to 999999)
Engine identification plate
The engine identification plate (1) is located in the middle of the
engine valve cover. This plate has information such as serial
number, model and other information about the engine.
NOTE: When ordering replacement parts, always inform
the serial number and machine model.
100
00505
V
E
B
123456
A
B
C
D
E
F
1
Fig. Engine
1 –Engine identification plate

Operator´s instruments and controls
10 4812325559EN 2018-02-20
Operator's instruments and controls
Multifunction display, side control panel and
operator's control keyboard
1. Multifunction display
2. Operator's Control Keyboard
3. Warning lights switch
4. Parking brake switch
5. Starter key switch
6. Beacon warning light switch (Optional)
7. Emergency stop button
8. "Go Home" switch
9. Blade control joystick
3
4
5
6
7
8
2
1
9

Operator's instruments and controls
2018-02-20 4812325559EN 11
Operator's Control Keyboard
10. Steering turning light
11. Machine warning light –yellow
12. Machine warning light –red
13. High beam
14. Working lights
15. Rear working lights
16. Front working lights
17. Night working lights (Optional)
18. Rear working lights (Optional)
19. Front working lights (Optional)
20. Enable the regeneration (Tier IV Engine)
21. Empty
22. Engine radiators assembly cleaning
23. Disable the regeneration (Tier IV Engine)
24. Brake test
25. Horn
Speed lever
The equipment has four speeds forward and four speeds
backwards completely automatic. (Powershift).
Position the lever forward or backward, according to the desired
direction. On middle position, the transmission will be neutral.
Fig. –Speed lever
12
13
11
25
23
24
20
21
17
18
19
15
16
10
14
22
Gears
Forward
Reverse

Operator's instruments and controls
12 4812325559EN 2018-02-20
Cab instruments
Fig. –Rear right column.

Emergency Procedures
2018-02-20 4812325559EN 13
Instruments and controls –Description and function
No.
Designation
Symbol
Function
1
Multifunction display
-
Shows the transmission and engine
functions. Refer to the "Before Starting the
Engine" Section.
2
Operator's Control Keyboard
-
Refer to page 10
3
Beacon warning light switch
Press the switch to light on the beacon
warning lights.
4
Parking brake switch
When pressed, the parking brake is
activated.
To release the parking brake, slide the red
side backwards (towards the operator) and
change the switch's position.
NOTE: The parking brake must be activated
before turning on the machine.
5
Engine starter key switch
Turn the switch to the left to turn off the
electric system.
In the middle position the switch turn on all
the electric system.
Turn the switch to the right to activate the
starter motor.
6
Beacon warning light switch
(Optional)
Press the switch to activate the beacon
warning light, if equipped.
7
Emergency stop button
-
When this button is pressed the machine is
stopped and the engine is turned off. All
electric system will be also turned off.
8
“Go Home” Switch
In the occurrence of a failure, press the
switch in order to send the machine to be
repaired.
9
Blade control joystick
-
Perform the blade control functions Refer to
the "Blade Operation" Section.

Emergency Procedures
14 4812325559EN 2018-02-20
Instruments and controls –Description and function (cont.)
No.
Designation
Symbol
Function
10
Steering turning light
Indicates that the steering turning lights
are activated.
11
Machine warning light –yellow
Indicates that there is failure in the
machine. Refer to the multifunction
display (1) in order to check the failure.
12
Machine warning light –red
Indicates that there is failure in the
machine. Refer to the multifunction
display (1) in order to check the failure.
13
High beam warning light
Indicates that the high beams are
activated (steering column switch).
14
Working lights button
Press to turn ON/OFF all working lights.
15
Rear working lights button
Press to turn ON/OFF all rear working
lights.
16
Front working lights button
Press to turn ON/OFF all front working
lights.
17
Night working lights button
(Optional)
Press to turn ON/OFF all night working
lights, if equipped.
18
Rear night working lights button
(Optional)
Press to turn ON/OFF all rear night
working lights, if equipped.
19
Front night working lights button
(Optional)
Press to turn ON/OFF all front night
working lights, if equipped.
20
Button to enable the regeneration
(Tier IV Engine)
Press to enable the regeneration Refer
to the “Operation” section (Tier IV
Engine).
21
Empty
-
-
22
Engine radiators assembly
cleaning button
Press to turn on the fan in order to clean
the radiators assembly. Refer to the
"Operation" section.
23
Button to disable the regeneration
(Tier IV Engine)
Press to disable the regeneration. Refer
to the “Operation” section (Tier IV
Engine).
24
Brake test button
Press to test the brake drive mechanism.

Emergency Procedures
2018-02-20 4812325559EN 15
Instruments and controls –Description and function (cont.)
No.
Designation
Symbol
Function
25
Horn button
Press to activate the horn.
26
Automatic Climate Control
-
Air conditioning automatic control (see
A/C operation for detail).
27
Front wiper, intermittent
-
Intermittent function for front wiper.
28
Front wiper switch
Press to operate the front windshield
wiper.
29
Rear wiper switch
Press to operate the rear windshield
wiper.
30
Front and rear windshield washers
switch
Press the top to activate the front
washers. Press the bottom to activate
the rear washers.
31
Asymmetric front wiper switch
Press to operate the front side
windshield wiper.
32
Asymmetric rear wiper switch
Press to operate the rear side windshield
wiper.
33
Asymmetric side windshield
washers switch
Press the top to activate the front side
washers. Press the bottom to activate
the rear side washers.
34
Fuse box
Contains fuses from the electric system
in the cab.
35
Hammer for emergency exit
If it is necessary to leave the cab during
an emergency, release the hammer and
break the right side windows.
36
Defroster nozzle
-
Turn the defroster nozzle to direct the
air flow.

Emergency Procedures
16 4812325559EN 2018-02-20
A/C –System operation
Power/Enter
By feeding the panel with 24VDC, the screen will be on,
indicating that the product is in standby mode.
Press to turn on the A/C, it will show the software version and
then the temperature. To return to standbymode you must press
the button for 3s.
Set point Up/Down
Set point is the desired temperature inside the vehicle. To set it
up press or . The set point temperature will flash on the
display; press until reaches desired temperature.
Display
The display shows set point value, bar graph evaporator speed,
active function and other information. It also serves to allow the
operator to view the coil and return temperature, as well as the
parameters. It also serves to alert when there is some system
flaws.
Operation Mode
To change the operation mode, press the button
(operation mode), select the desired mode:
The controller has 4 operation modes that are:
- Only ventilation
- Only cooling
- Only heating
- Automatic mode
Press the button to confirm or wait a few seconds to cancel.
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