Page 1 Instruction manual Instruction manual Operating & Maintenance Operating & Maintenance 4812160001_A.pdf 4812160001_A.pdf Vibratory roller Vibratory roller CA2500 CA2500 Engine Engine Cummins QSB 3.3 (IIIA/T3) Cummins QSB 3.3 (IIIA/T3) Cummins QSB 3.3 (IIIB/T4i) Cummins QSB 3.3 (IIIB/T4i) Serial number Serial number...
Page 3: Table Of Contents
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 Security Warning - machinery ..............
Page 4 Weights and volumes................17 Working capacity..................18 General ..................... 19 Hydraulic system..................19 Automatic Climate Control (ACC) (Optional)..........20 Tightening torque ..................21 Machine description ....................... 23 Diesel engine .................... 23 Electrical system ..................23 Propulsion system/Transmission .............. 23 Brake system .................... 23 Steering system ..................
Page 5 Machine alarm................... 39 Dynapac Sub System (DSS)..............40 "MAIN MENU" ................... 41 "USER SETTINGS" ..............41 "SERVICE MENU" ..............42 "ABOUT"..................43 Operator help when starting..............44 Operator help Workmode................44 Display when activating choice via the button set........45 Instruments and controls, cab ..............
Page 6 Display - Control..................58 Interlock..................... 59 Operator position..................59 View ......................60 Starting ........................61 Starting the engine ..................61 Driving ........................62 Operating the roller ................... 62 Machine with speed limiter (speed potentiometer) - Optional..62 Machine with gear change in separate spring-return switch (gear position switch)..............
Page 7 Tires (All-weather)..................71 Hoods, tarpaulin ..................72 Miscellaneous ........................73 Lifting ........................73 Locking the articulation ................73 Lifting the roller..................73 Lifting the roller with jack:................74 Unlocking the articulation ................74 Towing/Recovering....................74 Short distance towing with the engine running.......... 75 Short distance towing when the engine is inoperative.
Page 8 Every 2000 hours of operation ..............92 Every other year..................93 Maintenance, 10h ........................95 Scrapers - Check, adjustment..............95 Flexible scrapers (Optional) ..............96 Air circulation - Check ................96 Coolant level - Check ................97 Diesel engine Check oil level ..............97 Fuel tank - Filling..................
Page 9 Maintenance - 500 / 1500h ....................111 Air cleaner Checking - Change the main air filter............111 Backup filter - Change................112 Air cleaner - Cleaning....................112 Radiator - Check/Cleaning ..............113 Drum cartridge - Checking the oil level ........... 113 Rear axle differential (No Spin) - Check oil level........
Page 10 Hood, hinges - Lubrication ..............126 Seat bearing - Lubrication ............... 127 Hydraulic reservoir - Draining..............127 Fuel tank - Draining (Optional) ..............128 Air conditioning (Optional) Fresh air filter - Change ................128 Steering hitch - Tightening ..............129 Maintenance - 2000h ......................
Page 11 Steering hitch - Tightening ..............143 2014-08-25 4812160001_A.pdf...
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Page 13: Introduction
Introduction Introduction The machine CA2500 are models of Dynapac's soil compaction rollers. They are available in a D (smooth drum) version. Intended use All types of base courses and subbase courses can be compacted. The cab and safety-related accessories are described in this manual.
Page 14: General
Introduction Read the entire manual before starting the Read the entire manual before starting the machine and before carrying out any machine and before carrying out any maintenance. maintenance. Ensure good ventilation (extraction of air by fan) Ensure good ventilation (extraction of air by fan) where the engine is run indoors.
Page 15: Ce Marking And Declaration Of Conformity
Introduction 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 directives applicable for this machine.
Page 16 Introduction 4812160001_A.pdf 2014-08-25...
Page 17: Safety - General Instructions
Safety - General instructions Safety - General instructions (Also read the safety manual) The operator must be familiar with the contents of the OPERATION section The operator must be familiar with the contents of the OPERATION section before starting the roller. before starting the roller.
Page 18 Safety - General instructions 16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The 16. Hearing protection is recommended if the noise level exceeds 85 dB(A). The noise level can vary depending on the equipment on the machine and the noise level can vary depending on the equipment on the machine and the surface the machine is being used on.
Page 19: Safety - When Operating
Safety - when operating Safety - when operating Prevent persons from entering or remaining in Prevent persons from entering or remaining in the danger area, i.e. a distance of at least 7 m the danger area, i.e. a distance of at least 7 m (23 ft) in all directions from operating machines.
Page 20: Slopes
Safety - when operating Slopes This angle has been measured on a hard, flat surface with the machine stationary. The steering angle was zero, the vibration was switched OFF and all tanks were full. Always take into consideration that loose ground, steering the machine, vibration on, machine speed across the ground and raising the center of gravity can all cause the machine to topple at smaller slope...
Page 21: Safety (Optional)
Safety (Optional) Safety (Optional) Air conditioning The system described in this manual is an AC/ACC type (Automatic climate control) The system contains pressurized refrigerant. It is The system contains pressurized refrigerant. It is forbidden to release refrigerants into the forbidden to release refrigerants into the atmosphere.
Page 22 Safety (Optional) 4812160001_A.pdf 2014-08-25...
Page 23: Special Instructions
Special instructions Special instructions Standard lubricants and other recommended oils and fluids Before leaving the factory, the systems and components are filled with the oils and fluids specified in the lubricant specification. These are suitable for ambient temperatures in the range -15°C to +40°C (5°F - 105°F).
Page 24: Fire Fighting
Special instructions with a rubber band. This is to avoid high pressure water entering the vent hole in the filler cap. This could cause malfunctions, such as the blocking of filters. Place a plastic bag over the exhaust pipe and secure with a rubber band to avoid water in the muffler.
Page 25: Jump Starting (24V)
Special instructions Dispose of old batteries in an environmentally Dispose of old batteries in an environmentally friendly way. Batteries contain toxic lead. friendly way. Batteries contain toxic lead. Do not use a quick-charger for charging the Do not use a quick-charger for charging the battery.
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Page 27: Technical Specifications
Technical specifications Technical specifications Vibrations - Operator station (ISO 2631) The vibration levels are measured in accordance with the operational cycle described in The vibration levels are measured in accordance with the operational cycle described in EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched EU directive 2000/14/EC on machines equipped for the EU market, with vibration switched on, on soft polymer material and with the operator’s seat in the transport position.
Page 28: Dimensions, Side View
Technical specifications Dimensions, side view Dimensions Dimensions Wheelbase, drum and wheel Wheelbase, drum and wheel 2840 2840 Length, standard equipped roller Length, standard equipped roller 5560 5560 Height, with ROPS/cab Height, with ROPS/cab 2810 2810 Diameter, drum (D) Diameter, drum (D) 1500 1500 Thickness, drum amplitude, Nominal (D)
Page 29: Dimensions, Top View
Technical specifications Dimensions, top view Dimensions Dimensions Width, standard equipped roller Width, standard equipped roller 2300 2300 Width, tractor section Width, tractor section 1707 1707 Overhang, right frame side Overhang, right frame side Overhang, left frame side Overhang, left frame side Turn radius, external Turn radius, external 5200...
Page 30: Working Capacity
Technical specifications Working capacity Compaction data Compaction data Static linear load Static linear load CA2500 CA2500 26 (kg/cm) 26 (kg/cm) 146 (pli) 146 (pli) Amplitude Amplitude High High CA2500D CA2500D 0,9 (mm) 0,9 (mm) 0.07 0.07 0.035 (in) 0.035 (in)
Page 31: General
Technical specifications General Engine Engine Manufacturer/Model Manufacturer/Model Cummins QSB 3.3 Cummins QSB 3.3 Water-cooled turbo diesel Water-cooled turbo diesel Power output (SAE J1995), 2200 rpm 82kW Power output (SAE J1995), 2200 rpm 82kW (IIIA/T3, IIIB/T4i) (IIIA/T3, IIIB/T4i) Engine speed Engine speed - idling - idling 900 rpm...
Page 32: Automatic Climate Control (Acc) (Optional)
Technical specifications Automatic Climate Control (ACC) (Optional) The system described in this manual is an AC/ACC type (Automatic Climate Control), i.e. a system that maintains the set temperature in the cab, provided windows and doors are kept closed. Coolant designation: HFC-R134:A Coolant weight when full: 1350 gram (2.98 lbs) 4812160001_A.pdf 2014-08-25...
Page 33: Tightening Torque
Technical specifications Tightening torque Tightening torque in Nm for oiled or dry bolts tightened with a torque wrench. Metric coarse screw thread, bright galvanized (fzb): STRENGTH CLASS: 8.8, Oiled 8.8, Oiled 8.8, Dry 8.8, Dry 10.9, Oiled 10.9, Oiled 10.9, Dry 10.9, Dry 12.9, Oiled 12.9, Oiled...
Page 34 Technical specifications 4812160001_A.pdf 2014-08-25...
Page 35: Machine Description
Machine description Machine description Diesel engine The machine is equipped with a water-cooled, straight four cylinder, four-stroke, turbocharged diesel engine with direct injection and a charge air cooler. (IIIB/T4i) The engine is also equipped with cooled exhaust gas recirculation (CEGR) and electronically controlled exhaust gas recirculation valves (EGR) together with a Cummins ®...
Page 36: Vibration System
Machine description On certain markets, the machine is also equipped with an emergency steering system. Vibration system The vibration system is a hydrostatic system in which a hydraulic motor drives the eccentric shaft, which generates the drum's vibrations. High amplitude or low amplitude are determined by the hydraulic motor's direction of rotation.
Page 37: Identification
Machine description Identification Product and component plates 1, 2 Product plate - Product Identification Number (PIN), model/type designation Product plate - Product Identification Number (PIN), model/type designation Engine plate - Type description, product and serial numbers Engine plate - Type description, product and serial numbers Cab/ROPS plate - Certification, product and serial numbers Cab/ROPS plate - Certification, product and serial numbers Component plate, rear axle - Product and serial numbers...
Page 38: Machine Plate
Machine description Machine plate The machine type plate (1) is attached to the front left side of the frame, beside the steering joint. The plate specifies the manufacturer's name and address, the type of machine, the PIN product identification number (serial number), service weight, engine power and year of manufacture.
Page 39: Engine Plates
Machine description Engine plates The engine type plates (1) are affixed to the top and on the right side of the engine. The plates specify the type of engine, serial number and the engine specification. Please specify the engine serial number when ordering spares.
Page 40: Decals
Machine description Decals Location - decals 15,16 17,23 Fig. Location, decals and signs 1. Warning, Crush zone 1. Warning, Crush zone 4700903422 4700903422 12. Master switch 12. Master switch 4700904835 4700904835 2. Warning, Rotating engine 2. Warning, Rotating engine 4700903423 4700903423 13.
Page 41: Safety Decals
Machine description Safety decals Always make sure that all safety decals are completely legible, and remove dirt or order new decals if they have become illegible. Use the part number specified on each decal. 4700903422 Warning - Crush zone, articulation/drum. Maintain a safe distance from the crush zone.
Page 42 Machine description 4700904165 Warning - Toxic gas (option, ACC) Read the instruction manual. 4700903590 -Emergency exit 4812160001_A.pdf 2014-08-25...
Page 43: Info Decals
Machine description Info decals Noise power level Noise power level Diesel fuel Diesel fuel Lifting point Lifting point Hoisting plate Hoisting plate Handbook compartment Handbook compartment Master switch Master switch Hydraulic fluid Hydraulic fluid Biological hydraulic fluid Biological hydraulic fluid Securing point Securing point Tire pressure...
Page 44: Instruments/Controls
Machine description Instruments/Controls Control panel and controls Fig. Control panel Ignition switch Ignition switch Parking brake Parking brake Forward & Reverse lever Forward & Reverse lever Working mode / Transport Working mode / Transport Hazard lights Hazard lights mode mode Strike-off blade, floating position 15 Strike-off blade, floating position 15 Reserve...
Page 45: Function Descriptions
Machine description Function descriptions Designation Designation Symbol Symbol Function Function Ignition key Ignition key The electric circuit is broken. The electric circuit is broken. All instruments and electric controls are supplied with All instruments and electric controls are supplied with power.
Page 46 Machine description Designation Designation Symbol Symbol Function Function Working mode / Transport mode Working mode / Transport mode Activates working mode, which makes it possible to Activates working mode, which makes it possible to use vibration and lower the strike-off blade (optional). use vibration and lower the strike-off blade (optional).
Page 47: Warning Indication - Membrane Panel (Keypad)
Machine description Designation Designation Symbol Symbol Function Function Gear position switch, Dip Gear position switch, Dip Activates the four different gear positions. (1) Hare, (2) Activates the four different gear positions. (1) Hare, (2) Drum spin, (3) Wheelspin and (4) Tortoise. The current Drum spin, (3) Wheelspin and (4) Tortoise.
Page 48: Display Explanations
Machine description Display explanations When the ignition key is activated to position I, a start screen is visible in display. This is shown for a few seconds and then switches over to the status screen. Before activating the starter motor, wait until the start image has changed to the status image (the machine is performing a system check while the start image is being displayed).
Page 49 Machine description Example of menu field. Scroll/Selection buttons to choose Scroll/Selection buttons to choose between available functions. between available functions. Alarm log button to display engine and Alarm log button to display engine and machine alarms. machine alarms. Settings/Button select menu, which opens Settings/Button select menu, which opens the main menu.
Page 50 Machine description When an engine alarm is activated, the alarm is shown on the display. The engine alarm is sent out from the engine ECM, which handles the monitoring of the engine functions. The message, which consists of an SPN and FMI code, can be interpreted via the engine supplier error code list.
Page 51: Machine Alarm
Machine description Machine alarm Symbol Symbol Designation Designation Function Function Warning symbol, hydraulic fluid filter Warning symbol, hydraulic fluid filter If the symbol is shown when the diesel engine is running at If the symbol is shown when the diesel engine is running at full speed, the hydraulic fluid filter must be changed.
Page 52: Dynapac Sub System (Dss)
Machine description Dynapac Sub System (DSS) Description Description Note Note code code Speed sensor, front Speed sensor, front Optional Optional Speed sensor, rear Speed sensor, rear Inclination sensor Inclination sensor Optional Optional Optional Optional IO-Card IO-Card Cooling fan speed sensor Cooling fan speed sensor Vibration frequency meter Vibration frequency meter...
Page 53: Main Menu
Machine description "MACHINE ALARM" Logged machine alarms. These alarms come from the other systems on the machine. "MAIN MENU" In the main menu it is also possible to change some user and machine settings, access the service menu for calibration purposes (special service personnel only, requires pin code), and to see the version of installed software.
Page 54: Service Menu
Machine description "SERVICE MENU" The service menu is also accessible via the main menu for adjustments. "ADJUSTMENTS" "TESTMODES" - Installation personnel only, requires pin code. 4812160001_A.pdf 2014-08-25...
Page 55: About
Machine description "CALIBRATION" - service personnel only, requires password. "EDC Calibration" used to calibrate the joystick and speed potentiometer. "TX Program" only used to change software in the display and requires special equipment and know-how. "EDC CALIBRATION" To calibrate, move the joystick fully forward (F) and press in both black buttons on the top of the joystick.
Page 56: Operator Help When Starting
Machine description Operator help when starting When trying to start the machine without having set one, two or three of the conditions required to start machine, the missing conditions are shown in the display. The missing conditions must be set before it is possible to start the machine.
Page 57: Display When Activating Choice Via The Button Set
Machine description Display when activating choice via the button set. The parking symbol is shown when the parking brake is activated. = Vibration is enabled in the operating position. = Strike-off blade = High amplitude/Low amplitude = Automatic vibration control. If the function is activated via the red button on the control lever, an image of a sine curve appears and vibration is activated when the control lever is...
Page 58: Instruments And Controls, Cab
Machine description Instruments and controls, cab Radio/CD Fig. Cab roof, front Heater/AC Fig. Right rear cab post 15. Hammer for emergency exit 4812160001_A.pdf 2014-08-25...
Page 59: Function Description Of Instruments And Controls In The Cab
Machine description Function description of instruments and controls in the cab Designation Designation Symbol Symbol Function Function Heater control Heater control Turn to the right to increase heating. Turn to the right to increase heating. Turn to the left to reduce heating. Turn to the left to reduce heating.
Page 60: Using The Cab Controls
Machine description Using the cab controls Defroster To quickly remove ice or mist, make sure that only the front and rear air nozzles are open. Turn the heater and fan dial (1 and 2) to max. Adjust the nozzle so that it blows on the window to be de-iced, or to remove mist.
Page 61: Acc - Control Panel
Machine description ACC - Control panel 1. LCD Display During normal operation, the set-point temperature, blower speed, operation mode and fresh/re-circulated air selection are displayed. 2. SET / SELECT Button Under normal operation button is used for selecting between modes. (Also used in Test / diagnostics mode for different choices) 3.
Page 62 Machine description Climate Control mode settings: Press SET / SELECT button until the climate control mode icon appears, and then turn the button until the required mode is displayed. AUTO AUTO The system runs automatically to keep the temperature that is The system runs automatically to keep the temperature that is selected (set-point temperature).
Page 63: Electrical System
Machine description Turning HVAC system OFF: In the main screen, press the Power button to turn off the HVAC system. When the system is turned off, the backlight will turn off and the interior temperature will be displayed on the screen. To turn off the HVAC system from Defrost mode, press the Power button until the HVAC system returns to the AUTO mode, then press the Power button again...
Page 64: Fuses In The Main Switchbox
Machine description Fuses in the main switchbox The figure shows the position of the fuses. The table below gives fuse amperage and function. All fuses are flat pin fuses, type C (medium). Main relay (K2), 24V outlet engine Main relay (K2), 24V outlet engine Reserve Reserve compartment (X97)
Page 65: Fuses At Master Switch (Cummins)
Machine description Fuses at master switch (Cummins) The fuse box (1) is located inside the cover by the steps on the left-hand side of the roller. This is also where the batteries (2) are, and the starter relay (4) and preheating relay (5) are placed behind the battery disconnector plate (3).
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Page 67: Operation
Operation Operation Before starting Master switch - Switching on Remember to carry out daily maintenance. Refer to the maintenance instructions. The battery disconnector switch is located inside the cover by the steps on the left-hand side of the roller. Turn the key (1) to the On position. The roller is now supplied with power.
Page 68: Belt Reminder
Operation Belt reminder The machine can be equipped with seat belt with belt reminder. Unless the seat belt is used, a warning image appear in the display and a warning buzzer sounds to alert the driver to use the seat belt. Operator's seat, comfort - Adjustments Adjust the operator's seat so that the position is comfortable and so that the controls are within easy...
Page 69: Control Panel, Adjustments
Operation Control panel, adjustments The control unit has two adjustment options, rotation and steering column angle. For rotation, lift the lever (1). Ensure that the control unit locks in position before operating the machine. Release locking lever (2) to adjust the steering column angle.
Page 70: Display - Control
Operation Display - Control Sit down for all operations. Turn the ignition key (1) to position I, the start screen will be shown in display. Fig. Control panel 1. Ignition key 2. Status screen Check that the voltmeter (5) reads at least 24 volts, and that the fuel gauge (3) show a reading.
Page 71: Interlock
Operation Interlock The roller is equipped with Interlock. The diesel engine with switch off after 7 seconds if the operator gets off the seat when going forwards/backwards. If the control is in neutral when the operator stands up a buzzer will go on until the parking brake is activated. If the parking brake is activated, the diesel engine will not stop if the forward/reverse lever is moved out of neutral.
Page 72: View
Operation View Before starting, make sure that the view forwards and backwards is unobstructed. All cab windows should be clean and the rear view mirrors should be correctly adjusted. Fig. view 4812160001_A.pdf 2014-08-25...
Page 73: Starting
Operation Starting Starting the engine Make sure that the emergency stop is OFF and the parking brake ON. Set the forward/reverse lever (1) in neutral position, and set the speed selector (2) in the idling position (LO) or (ECO) if that option is installed on the machine. The diesel engine cannot be started in any other position of the controls.
Page 74: Driving
Operation Driving Operating the roller Under no circumstances is the machine to be Under no circumstances is the machine to be operated from the ground. The operator must be operated from the ground. The operator must be seated inside the machine during all operation. seated inside the machine during all operation.
Page 75: Machine With Gear Change In Separate Spring-Return Switch (Gear Position Switch)
Operation Carefully move the forward/reverse lever (2) forwards or backwards, depending on which direction of travel is required. Speed increases as the lever is moved away from the neutral position. Fig. The display shows the selection in the middle (tortoise, drum spin, wheelspin or hare).
Page 76 Operation The machine's gear position is shown in the center of the speedometer; select the gear/speed for the task. The machine does not need to be stopped to change gear position. Max. speed Max. speed = Rabbit (4) = Rabbit (4) 8 km/h 8 km/h 5 mph...
Page 77: Slopes
Operation Slopes To optimize available pulling force and protect the machine's engine against over-revving while working or during transport driving on steep slopes (>10%), you must select low gear. Never drive with a higher gear/at a faster speed that the machine requires to climb up the same slope! Interlock/Emergency stop/Parking brake - Check The interlock, emergency stop and parking brake must...
Page 78: Vibration
Operation Vibration Manual/Automatic vibration Activate the button for the Working mode (4). Manual or automatic vibration activation/deactivation is selected using button (1). In the manual position, the operator activates vibration using the switch (2) on the forward/reverse lever. In automatic mode (AVC), vibration is activated when the speed is ≥...
Page 79: Amplitude - Changeover
Operation Amplitude - Changeover The amplitude setting must not be change when The amplitude setting must not be change when vibration is in operation vibration is in operation Switch the vibration off and wait until vibration Switch the vibration off and wait until vibration stops before changing amplitude.
Page 80: Emergency Braking
Operation Emergency braking Braking is normally activated using the forward/reverse lever. The hydrostatic transmission retards and slows the roller when the lever is moved towards the neutral position. A disc brake in each drum motor/drum gear and the rear axle also acts a secondary brake when in motion, and as a parking brake when stationary.
Page 81: Parking
Operation Parking Chocking the drums Never disembark from the machine when the is Never disembark from the machine when the is engine running, unless the parking brake is engine running, unless the parking brake is activated. activated. Make sure that the roller is parked in a safe place Make sure that the roller is parked in a safe place with respect to other road users.
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Page 83: Long-Term Parking
Long-term parking Long-term parking The following instructions should be followed The following instructions should be followed when long term parking (more than one month). when long term parking (more than one month). These measures apply when parking for a period of up to 6 months.
Page 84: Hoods, Tarpaulin
Long-term parking Hoods, tarpaulin * Lower the instrument cover over the instrument panel. * Cover the entire roller with a tarpaulin. A gap must be left between the tarpaulin and the ground. * If possible, store the roller indoors and ideally in a building where the temperature is constant.
Page 85: Miscellaneous
Miscellaneous Miscellaneous Lifting Locking the articulation Articulation must be locked to prevent inadvertent Articulation must be locked to prevent inadvertent turning before lifting the roller. turning before lifting the roller. Turn the steering wheel to the straight ahead position. Activate the parking brake. Front frame shall be in line with the rear frame.
Page 86: Lifting The Roller With Jack
Miscellaneous Weight: refer to the hoisting plate on the roller Lifting the roller with jack: The machine’s gross weight is specified on the The machine’s gross weight is specified on the hoisting plate (1). Refer also to the Technical hoisting plate (1). Refer also to the Technical specifications.
Page 87: Short Distance Towing With The Engine Running
Miscellaneous Short distance towing with the engine running Activate the parking brake, and temporarily stop Activate the parking brake, and temporarily stop the engine. Chock the wheels to prevent the roller the engine. Chock the wheels to prevent the roller from moving.
Page 88: Short Distance Towing When The Engine Is Inoperative
Miscellaneous Short distance towing when the engine is inoperative. Chock the wheels to prevent the roller from Chock the wheels to prevent the roller from moving when the brakes are hydraulically moving when the brakes are hydraulically disengaged. disengaged. Fig. Propulsion pump - By-pass valves Open the hood and make sure that the propulsion 1.
Page 89: Towing The Roller
Miscellaneous Towing the roller When towing/recovering, the roller must be braked When towing/recovering, the roller must be braked by the towing vehicle. A towing bar must be used by the towing vehicle. A towing bar must be used as the roller has no brakes. as the roller has no brakes.
Page 90: Securing Ca1500-Ca4600 For Loading
Miscellaneous Securing CA1500-CA4600 for loading Securing the CA1500-4600D/PD vibratory roller from Dynapac for transport. Roller loaded in forward direction Direct of travel 1 - 3 = double lashings, i.e. one lashing with two parts secured to two different lashing mounts, 1 - 3 = double lashings, i.e.
Page 91 Miscellaneous Load carrier Load carrier When loaded, the vibratory roller is centered laterally on the platform (± 5 cm). When loaded, the vibratory roller is centered laterally on the platform (± 5 cm). The parking brake is applied and in good working condition, and the articulated joint lock is The parking brake is applied and in good working condition, and the articulated joint lock is closed.
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Page 93: Operating Instructions - Summary
Operating instructions - Summary Operating instructions - Summary Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. Ensure that all instructions in the MAINTENANCE section are followed. Ensure that all instructions in the MAINTENANCE section are followed. Turn the master switch to the ON position.
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Page 95: Preventive Maintenance
Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost. The Maintenance section includes the periodic maintenance that must be carried out on the machine. The recommended maintenance intervals assume that the machine is used in a normal environment and working conditions.
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Page 97: Maintenance - Lubricants And Symbols
Maintenance - Lubricants and symbols Maintenance - Lubricants and symbols Always use high-quality lubricants and the Always use high-quality lubricants and the amounts recommended. Too much grease or amounts recommended. Too much grease or oil can cause overheating, resulting in rapid oil can cause overheating, resulting in rapid wear.
Page 98: Maintenance Symbols
Maintenance - Lubricants and symbols BIOLOGICAL BIOLOGICAL Air temperature -10°C - +35°C Air temperature -10°C - +35°C PANOLIN HLP Synth 46 PANOLIN HLP Synth 46 HYDRAULIC HYDRAULIC (14°F-95°F) (14°F-95°F) (www.panolin.com) (www.panolin.com) FLUID, PANOLIN FLUID, PANOLIN When it leaves the factory, the When it leaves the factory, the machine may be filled with machine may be filled with...
Page 99: Maintenance - Maintenance Schedule
Maintenance - Maintenance schedule Maintenance - Maintenance schedule Service and maintenance points 33,34 31,32 6,7,10 2, 3 22,23 17,18 Fig. Service and maintenance points Diesel fuel, filling Diesel fuel, filling 14. Scrapers 14. Scrapers 27. Seat bearing * 27. Seat bearing * Oil level, diesel engine Oil level, diesel engine 15.
Page 100: Periodic Service (Service Message) - Optional
Maintenance - Maintenance schedule Remove all dirt before filling, when checking Remove all dirt before filling, when checking oils and fuel and when lubricating using oil or oils and fuel and when lubricating using oil or grease. grease. The manufacturer’s instructions found in the The manufacturer’s instructions found in the engine manual also apply.
Page 101: Every 10 Hours Of Operation (Daily)
Maintenance - Maintenance schedule Every 10 hours of operation (Daily) Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Before starting up for the first time on that day Before starting up for the first time on that day Check the scraper setting Check the scraper setting...
Page 102: Every 250 / 750 / 1250 / 1750 Hours Of Operation
Maintenance - Maintenance schedule Every 250 / 750 / 1250 / 1750 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Check the oil level in drum cartridges Check the oil level in drum cartridges 23,22...
Page 103: Every 1000 Hours Of Operation
Maintenance - Maintenance schedule Every 1000 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Change the hydraulic fluid filter Change the hydraulic fluid filter Check the oil level in drum cartridges Check the oil level in drum cartridges Inspect the filter element in the air cleaner...
Page 104: Every 2000 Hours Of Operation
Maintenance - Maintenance schedule Every 2000 hours of operation Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment 6,10 6,10 Change the hydraulic fluid Change the hydraulic fluid Change the hydraulic fluid filter Change the hydraulic fluid filter...
Page 105: Every Other Year
Maintenance - Maintenance schedule Every other year Refer to the contents to find the page number of the sections referred to ! Pos. in fig Pos. in fig Action Action Comment Comment Change the coolant (glycol) Change the coolant (glycol) Change the oil in the hydraulic tank Change the oil in the hydraulic tank Change the oil in drum cartridges...
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Page 107: Maintenance, 10H
Maintenance, 10h Maintenance, 10h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.
Page 108: Flexible Scrapers (Optional)
Maintenance, 10h Flexible scrapers (Optional) Loosen the screws (2). Then, adjust the scraper blade (1) so that it lightly touches the drum. Tighten the screws (2). Fig. Scrapers 1. Scraper blade 2. Screws Air circulation - Check Ensure that the engine has free circulation of cooling air through the protective grille in the hood.
Page 109: Coolant Level - Check
Maintenance, 10h Coolant level - Check Place the roller on a flat surface and check the level of the coolant in the sight glass (2). Top up with coolant if the level is too low. Take great caution if the radiator cap must be Take great caution if the radiator cap must be opened while the engine is hot.
Page 110: Fuel Tank - Filling
Maintenance, 10h Fuel tank - Filling Top up the fuel tank every day. Follow the engine manufacturer's specifications for diesel fuel. The new Tier 4i/Stage IIIB Cummins engines The new Tier 4i/Stage IIIB Cummins engines require the use of Ultra Low Sulphur Diesel require the use of Ultra Low Sulphur Diesel (ULSD) fuel, which has a sulphur content of 15 (ULSD) fuel, which has a sulphur content of 15...
Page 111: Maintenance, First 50H
Maintenance, first 50h Maintenance, first 50h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.
Page 112: Drum Cartridge - Oil Change
Maintenance, first 50h Clean thoroughly around the oil filter. Remove the oil filter (1) and hand in to an Remove the oil filter (1) and hand in to an environment-friendly waste disposal station. This environment-friendly waste disposal station. This is a single-use filter and cannot be cleaned. is a single-use filter and cannot be cleaned.
Page 113: Tires - Air Pressure - Wheel Nuts - Tightening
Maintenance, first 50h Place a receptacle for about 5 liters (1.32 gal) underneath the drain plug (2). Observe care when draining drum oil/hot drum oil. Observe care when draining drum oil/hot drum oil. Wear protective gloves and goggles. Wear protective gloves and goggles. Save the oil and hand in to an Save the oil and hand in to an environment-friendly waste disposal station.
Page 114: Drum Gearbox - Oil Change
Maintenance, first 50h Drum gearbox - Oil change Wipe clean, unscrew the plugs (1, 2 and 3) and drain the oil into a suitable receptacle, capacity about 5.0 liters (5,3 qts.). Refit the drain plug (1) and fill with oil up to the level plug (3), according to "Drum gearbox - Checking the oil level".
Page 115: Maintenance - 50H
Maintenance - 50h Maintenance - 50h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.
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Page 117: Maintenance - 250 / 750 / 1250 / 1750H
Maintenance - 250 / 750 / 1250 / 1750h Maintenance - 250 / 750 / 1250 / 1750h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or...
Page 118: Rear Axle Differential (No Spin) - Check Oil Level
Maintenance - 250 / 750 / 1250 / 1750h Rear axle differential (No Spin) - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running.
Page 119: Drum Gearbox - Checking The Oil Level
Maintenance - 250 / 750 / 1250 / 1750h Drum gearbox - Checking the oil level Wipe clean the area around the level plug (1) and then undo the plug. Ensure that the oil level reaches up to the lower edge of the plug hole.
Page 120: Rubber Elements And Fastening Screws - Check
Maintenance - 250 / 750 / 1250 / 1750h Rubber elements and fastening screws - Check Check all rubber elements (1), replace all of the elements if more than 25% of them on one side of the drum are cracked deeper than 10-15 mm (0.4-0.6 in). Check using a knife blade or pointed object.
Page 121: Air Conditioning (Optional) - Inspection
Maintenance - 250 / 750 / 1250 / 1750h Air conditioning (Optional) - Inspection Inspect refrigerant hoses and connections and make sure that there are no signs of an oil film that can indicate a refrigerant leakage. The refrigerant contains tracing liquid, which makes it possible to detect leaks with the aid of a UV lamp.
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Page 123: Maintenance - 500 / 1500H
Maintenance - 500 / 1500h Maintenance - 500 / 1500h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.
Page 124: Backup Filter - Change
Maintenance - 500 / 1500h Backup filter - Change Change the backup filter with a new filter after every second replacement of the main filter. To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.
Page 125: Radiator - Check/Cleaning
Maintenance - 500 / 1500h Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1), (2) and (3). Clean a dirty radiator using compressed air or a high-pressure water jet. Undo the two screws (5) and tilt the condenser element upwards.
Page 126: Rear Axle Differential (No Spin) - Check Oil Level
Maintenance - 500 / 1500h drum. Rear axle differential (No Spin) - Check oil level Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running.
Page 127: Drum Gearbox - Checking The Oil Level
Maintenance - 500 / 1500h Drum gearbox - Checking the oil level Wipe clean the area around the level plug (1) and then undo the plug. Ensure that the oil level reaches up to the lower edge of the plug hole. Top off with oil to the right level if the level is low.
Page 128: Diesel Engine - Oil And Filter Change
Maintenance - 500 / 1500h Diesel engine - Oil and Filter change The oil drain plug (1) can be accessed most easily from the right rear underside of the tractor frame, and is installed with a hose in the engine. Drain the oil when the engine is warm.
Page 129: Replacing The Fuel Filter
Maintenance - 500 / 1500h Replacing the fuel filter Place a container underneath to collect fuel that runs out when the filter is released. Screw off the fuel filter (1). The filter is of the disposable type and cannot be cleaned. Han in to environment-friendly station.
Page 130: Seat Bearing - Lubrication
Maintenance - 500 / 1500h Seat bearing - Lubrication Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism. Remove the cover (5) to access the lubrication nipple (1).
Page 131: Maintenance - 1000H
Maintenance - 1000h Maintenance - 1000h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.
Page 132: Drum Cartridge - Checking The Oil Level
Maintenance - 1000h Clean thoroughly around the oil filter. Remove the oil filter (1) and hand in to an Remove the oil filter (1) and hand in to an environment-friendly waste disposal station. This environment-friendly waste disposal station. This is a single-use filter and cannot be cleaned. is a single-use filter and cannot be cleaned.
Page 133: Air Cleaner
Maintenance - 1000h The oil should now come up to the sight glass (3). If necessary, release the filler plug (1) and fill to half the sight glass (3). Clean the magnetic filler plug (1) of any metallic residue, before refitting the plug. Ensure that only AtlasCopco Drum Oil 1000 is Ensure that only AtlasCopco Drum Oil 1000 is used in the cartridges.
Page 134: Backup Filter - Change
Maintenance - 1000h Backup filter - Change Change the backup filter with a new filter after every second replacement of the main filter. To change the backup filter (1), pull the old filter out of its holder, insert a new filter and reassemble the air cleaner in the reverse order.
Page 135: Rear Axle Differential (No Spin) - Oil Change
Maintenance - 1000h Rear axle differential (No Spin) - Oil change Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.
Page 136: Radiator - Check/Cleaning
Maintenance - 1000h Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1), (2) and (3). Clean a dirty radiator using compressed air or a high-pressure water jet. Undo the two screws (5) and tilt the condenser element upwards.
Page 137: Fuel Pre-Filter - Replacement
Maintenance - 1000h Fuel pre-filter - Replacement Ensure good ventilation (air extraction) if the Ensure good ventilation (air extraction) if the diesel engine is run indoors. Risk of carbon diesel engine is run indoors. Risk of carbon monoxide poisoning. monoxide poisoning. See the engine's instruction manual for filter replacement, in the Fuel system chapter.
Page 138: Diesel Engine - Oil And Filter Change
Maintenance - 1000h Diesel engine - Oil and Filter change The oil drain plug (1) can be accessed most easily from the right rear underside of the tractor frame, and is installed with a hose in the engine. Drain the oil when the engine is warm. Place a receptacle that holds 19 liters (5 gal) under the drain plug.
Page 139: Seat Bearing - Lubrication
Maintenance - 1000h Seat bearing - Lubrication Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism. Remove the cover (5) to access the lubrication nipple (1).
Page 140: Fuel Tank - Draining (Optional)
Maintenance - 1000h Fuel tank - Draining (Optional) Water and sediment in the fuel tank are removed via the drainage plug in the bottom of the fuel tank. Be very careful during draining. Do not drop the Be very careful during draining. Do not drop the plug or else all the fuel will flow out.
Page 141: Steering Hitch - Tightening
Maintenance - 1000h Steering hitch - Tightening Nobody must be allowed near the steering joint Nobody must be allowed near the steering joint when the engine is running. Risk of being when the engine is running. Risk of being crushed when the steering is operated. Switch crushed when the steering is operated.
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Page 143: Maintenance - 2000H
Maintenance - 2000h Maintenance - 2000h Park the roller on a level surface. Park the roller on a level surface. The engine must be switched off and the The engine must be switched off and the parking brake activated when checking or parking brake activated when checking or adjusting the roller, unless otherwise specified.
Page 144: Hydraulic Filter - Replacement
Maintenance - 2000h Hydraulic filter - Replacement Undo the filler cap/bleeder filter (2) on top of the reservoir so that over-pressure inside the reservoir can be eliminated. Make sure that the bleeding filter (2) is not clogged, air must have unobstructed passage through the cap in both directions.
Page 145: Drum Cartridge - Checking The Oil Level
Maintenance - 2000h Drum cartridge - Checking the oil level Position the roller on a flat surface with the groove (1) on the inside of the drum aligned with the top of the drum frame. Fig. Left drum side 1. Groove The oil should now come up to the sight glass (3).
Page 146: Backup Filter - Change
Maintenance - 2000h Release the clips (1), pull off the cover (2), and pull out the main filter (3). Do not remove the backup filter (4). Clean the air cleaner if necessary, see section Air cleaner - Cleaning. When replacing the main filter (3), insert a new filter and refit the air cleaner in the reverse order.
Page 147: Air Cleaner - Cleaning
Maintenance - 2000h Air cleaner - Cleaning Wipe clean on both sides of the outlet Wipe clean the inside of the cover (2) and the filter pipe. housing (5). See the previous illustration. Wipe also both surfaces for the outlet pipe; see adjacent figure.
Page 148: Rear Axle Differential (No Spin) - Oil Change
Maintenance - 2000h Rear axle differential (No Spin) - Oil change Never work under the roller when the engine is Never work under the roller when the engine is running. Park on a level surface. Block the wheels running. Park on a level surface. Block the wheels securely.
Page 149: Radiator - Check/Cleaning
Maintenance - 2000h Radiator - Check/Cleaning Check that air can pass unobstructed through the radiators (1), (2) and (3). Clean a dirty radiator using compressed air or a high-pressure water jet. Undo the two screws (5) and tilt the condenser element upwards.
Page 150: Fuel Pre-Filter - Replacement
Maintenance - 2000h Fuel pre-filter - Replacement Ensure good ventilation (air extraction) if the Ensure good ventilation (air extraction) if the diesel engine is run indoors. Risk of carbon diesel engine is run indoors. Risk of carbon monoxide poisoning. monoxide poisoning. See the engine's instruction manual for filter replacement, in the Fuel system chapter.
Page 151: Diesel Engine - Oil And Filter Change
Maintenance - 2000h Diesel engine - Oil and Filter change The oil drain plug (1) can be accessed most easily from the right rear underside of the tractor frame, and is installed with a hose in the engine. Drain the oil when the engine is warm. Place a receptacle that holds 19 liters (5 gal) under the drain plug.
Page 152: Seat Bearing - Lubrication
Maintenance - 2000h Seat bearing - Lubrication Keep in mind that the chain is a vital part of the Keep in mind that the chain is a vital part of the steering mechanism. steering mechanism. Remove the cover (5) to access the lubrication nipple (1).
Page 153: Fuel Tank - Draining (Optional)
Maintenance - 2000h Fuel tank - Draining (Optional) Water and sediment in the fuel tank are removed via the drainage plug in the bottom of the fuel tank. Be very careful during draining. Do not drop the Be very careful during draining. Do not drop the plug or else all the fuel will flow out.
Page 154: Automatic Climate Control (Optional) - Overhaul
Maintenance - 2000h Automatic Climate Control (Optional) - Overhaul Regular inspection and maintenance are necessary to ensure satisfactory long-term operation. Clean all dust from the condenser element (1) using compressed air. Blow from underneath. The air jet can damage the element flanges if it is The air jet can damage the element flanges if it is too powerful.
Page 155 Maintenance - 2000h Steering hitch - Tightening Nobody must be allowed near the steering joint Nobody must be allowed near the steering joint when the engine is running. Risk of being when the engine is running. Risk of being crushed when the steering is operated. Switch crushed when the steering is operated.
Page 156 Dynapac Compaction Equipment AB Atlas Copco Road Construction Equipment AB Box 504, SE 371 23 Karlskrona, Sweden Phone.+46 (0) 455 30 60 00 Fax. +46 (0)455 30 60 30 www.atlascopco.com...

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