Dynapac CA612 User manual
Instructions manualInstructions manual
ICA612-4EN2.pdfICA612-4EN2.pdf
Driving & MaintenanceDriving & Maintenance
Vibratory rollerVibratory roller
CA612CA612
EngineEngine
Cummins QSB 6.7CCummins QSB 6.7C
Serial numberSerial number
*715X0658* -*715X0658* -
10000124x0A000001 -10000124x0A000001 -
Translation of original instructionTranslation of original instruction
Reservation for changesReservation for changes
Printed in SwedenPrinted in Sweden
2000h-Maintenance
ICA612-4EN2.pdf2012-04-12
Table of Contents
Introduction .............................................................................................................................. 1
The machine ............................................................................................... 1
Intended use ............................................................................................... 1
Warning symbols......................................................................................... 1
Safety information ....................................................................................... 1
General ....................................................................................................... 2
CE marking and Declaration of conformity.................................................. 3
Safety - General instructions.................................................................................................... 5
Safety - when operating ........................................................................................................... 7
Driving near edges ...................................................................................... 7
Slopes ......................................................................................................... 7
Safety (Optional) ...................................................................................................................... 9
Air conditioning............................................................................................ 9
Special instructions ................................................................................................................ 11
Standard lubricants and other recommended oils and fluids .................... 11
Higher ambient temperatures, above +40°C (104°F)................................ 11
Temperatures............................................................................................ 11
High pressure cleaning ............................................................................. 11
Fire fighting ............................................................................................... 12
Roll Over Protective Structure (ROPS), ROPS approved cab .................. 12
Battery handling ........................................................................................ 12
Jump starting............................................................................................. 13
Technical specifications ......................................................................................................... 15
Vibrations - Operator station ..................................................................... 15
Noise level................................................................................................. 15
Electrical system ....................................................................................... 15
Dimensions, side view............................................................................... 16
Dimensions, top view ................................................................................ 17
Weights and volumes................................................................................ 17
Working capacity....................................................................................... 18
2000h-Maintenance
ICA612-4EN2.pdf 2012-04-12
General ..................................................................................................... 18
Tightening torque ...................................................................................... 20
ROPS - bolts ............................................................................................. 21
Hydraulic system....................................................................................... 21
Automatic Climate Control (ACC) (Optional)............................................. 21
Machine description ............................................................................................................... 23
Identification ............................................................................................................ 23
Product identification number on the frame .............................................. 23
Machine plate............................................................................................ 23
Explanation of 17PIN serial number.......................................................... 24
Engine plates ............................................................................................ 24
Decals...................................................................................................................... 25
Location - decals ....................................................................................... 25
Safety decals............................................................................................. 26
Info decals................................................................................................. 28
Instruments/Controls ............................................................................................... 29
Locations - Instruments and controls ........................................................ 29
Locations - Control panel and controls...................................................... 30
Function descriptions ................................................................................ 30
Controls in the cab .................................................................................... 34
Function description of instruments and controls in the cab ..................... 35
Electrical system...................................................................................................... 36
Fuses ........................................................................................................ 36
Fuses in cab.............................................................................................. 38
Main fuses................................................................................................. 38
Fuses at battery master disconnect switch ............................................... 39
Relays ....................................................................................................... 39
Relays in cab............................................................................................. 40
Operation ............................................................................................................................... 41
Before starting ......................................................................................................... 41
2000h-Maintenance
ICA612-4EN2.pdf2012-04-12
Master switch - Switching on..................................................................... 41
Operator’s seat - Adjusting....................................................................... 41
Control unit - Setting ................................................................................. 42
Operator’s seat in cab - Adjusting ............................................................. 42
Instruments and lamps - Checking........................................................... 43
Parking brake - Check............................................................................... 43
Interlock..................................................................................................... 44
Operator position....................................................................................... 44
View .......................................................................................................... 45
Starting .................................................................................................................... 46
Starting the engine .................................................................................... 46
Operating................................................................................................................. 47
Operating the roller ................................................................................... 47
Operating on difficult surfaces................................................................... 49
Vibration .................................................................................................................. 50
Amplitude/frequency - Changeover........................................................... 50
Manual vibration - Switching on ................................................................ 50
Braking .................................................................................................................... 51
Emergency braking ................................................................................... 51
Normal braking.......................................................................................... 51
Switching off.............................................................................................. 52
Parking .................................................................................................................... 52
Chocking the drums .................................................................................. 52
Master switch ............................................................................................ 52
Long-term parking.................................................................................................................. 53
Engine ....................................................................................................... 53
Battery....................................................................................................... 53
Air cleaner, exhaust pipe........................................................................... 53
Fuel tank ................................................................................................... 53
Hydraulic reservoir .................................................................................... 53
2000h-Maintenance
ICA612-4EN2.pdf 2012-04-12
Tires (All-weather)..................................................................................... 53
Steering cylinder, hinges, etc. ................................................................... 54
Hoods, tarpaulin ........................................................................................ 54
Miscellaneous ........................................................................................................................ 55
Lifting ....................................................................................................................... 55
Locking the articulation ............................................................................. 55
Lifting the roller.......................................................................................... 55
Unlocking the articulation .......................................................................... 56
Towing/Recovering.................................................................................................. 56
Alternative 1 .............................................................................................. 56
Short distance towing with the engine running.......................................... 56
Alternative 2 .............................................................................................. 57
Towing short distances where the engine is inoperative........................... 57
Rear axle brake......................................................................................... 57
Drum gearbox brake ................................................................................. 58
Towing the roller........................................................................................ 59
Roller prepared for transport ..................................................................... 59
Operating instructions - Summary ......................................................................................... 61
Preventive maintenance ........................................................................................................ 63
Acceptance and delivery inspection.......................................................... 63
Warranty.................................................................................................... 63
Maintenance - Lubricants and symbols ................................................................................. 65
Maintenance symbols ............................................................................... 67
Maintenance - Maintenance schedule ................................................................................... 69
Service and maintenance points ............................................................... 69
General ..................................................................................................... 70
Every 10 hours of operation (Daily)........................................................... 70
After the FIRST 50 hours of operation ...................................................... 70
Every 50 hours of operation (Weekly)....................................................... 71
Every 250 hours of operation (Monthly) .................................................... 71
2000h-Maintenance
ICA612-4EN2.pdf2012-04-12
Every 500 hours of operation (Every three months) ................................. 72
Every 1000 hours of operation (Every six months) ................................... 72
Every 2000 hours of operation (Yearly) .................................................... 73
Maintenance, 10h .................................................................................................................. 75
Scrapers - Check, adjustment................................................................... 75
Scrapers, Pad-drum .................................................................................. 76
Flexible scrapers (Optional) ...................................................................... 76
Air circulation - Check ............................................................................... 77
Coolant level - Check ................................................................................ 77
Diesel engine Check oil level ................................................................... 78
Hydraulic reservoir - Check fluid level....................................................... 78
Fuel tank - Filling....................................................................................... 79
Brakes - Check.......................................................................................... 80
Maintenance - 50h ................................................................................................................. 81
Air cleaner
Checking - Change the main air filter........................................................ 81
Backup filter - Change............................................................................... 82
Air cleaner
- Cleaning.................................................................................................. 82
Articulation - Lubrication............................................................................ 83
Steering joint - Lubrication ........................................................................ 83
Tires - Air pressure - Wheel nuts - Tightening .......................................... 84
Automatic Climate Control (Optional) - Inspection .................................... 84
Maintenance - 250h ............................................................................................................... 87
Rear axle differential - Check oil level....................................................... 87
Rear axle planetary gears - Check oil level............................................... 87
Drum gearbox - Checking the oil level ...................................................... 88
Drum cartridge - Checking the oil level ..................................................... 88
Drum cartridge - Cleaning the ventilation screw ....................................... 89
Radiator - Check/Cleaning ........................................................................ 89
2000h-Maintenance
ICA612-4EN2.pdf 2012-04-12
Bolted joints - Checking tightening torque................................................. 90
Rubber elements and fastening screws - Check....................................... 90
Battery - Check electrolyte level................................................................ 90
Battery cell ................................................................................................ 91
Air conditioning (Optional)
- Inspection................................................................................................ 91
Maintenance - 500h ............................................................................................................... 93
Controls and moving joints - Lubrication ................................................... 93
Fuel pre-filter - Cleaning............................................................................ 94
Diesel engine - Oil and Filter change ........................................................ 94
Steering chain and seat bearing - Lubrication........................................... 95
Seat bearing - Lubrication ......................................................................... 96
Maintenance - 1000h ............................................................................................................. 97
Hydraulic filter - Replacement ................................................................... 97
Hydraulic reservoir - Draining.................................................................... 98
Fuel tank - Drainage.................................................................................. 99
Rear axle differential - Oil change............................................................. 99
Rear axle planetary gear - Oil change .................................................... 100
Air conditioning (Optional)
Fresh air filter - Change .......................................................................... 100
Maintenance - 2000h ........................................................................................................... 101
Hydraulic reservoir - Oil change.............................................................. 101
Drum cartridge - Oil change .................................................................... 102
Drum gearbox - Oil change ..................................................................... 103
Forward/Reverse lever
- Lubrication ........................................................................................... 103
Steering hitch - Check............................................................................. 104
Automatic Climate Control (Optional)
- Overhaul ............................................................................................... 104
Compressor - Check (Optional) .............................................................. 105
Drying filter - Check................................................................................. 105
Introduction
ICA612-4EN2.pdf2012-04-12
Introduction
The machine
CA612 is one of Dynapac's heavy soil compaction
rollers. It is available in D (smooth drum) and PD
(padfoot drum) versions.
Intended use
The D version is intended for the compaction of
rockfill. The main area of application for the PD
version is on cohesive material and weathered stone
material.
All types of base courses and subbase courses can be
compacted deeper and the interchangeable drums, D
to PD, and vice versa, facilitate even greater variety in
the range of application.
The cab and safety-related accessories are described
in this manual. Other accessories, such as compaction
meter, tachograph and field computer, are described
in separate instructions.
Warning symbols
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
WARNING ! Marks a danger or a hazardous
procedure that can result in life threatening or
serious injury if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
CAUTION ! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
Safety information
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
It is recommended to at least train operators in
handling and daily maintenance of the machine
in accordance with the instruction manual.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
Passengers are not allowed on the machine, and
you must sit in the seat when operating the
machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
1
Introduction
ICA612-4EN2.pdf 2012-04-12
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Read the entire manual before starting the
machine and before carrying out any
maintenance.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
Ensure good ventilation (extraction of air by fan)
where the engine is run indoors.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
General
This manual contains instructions for machine
operation and maintenance.
The machine must be correctly maintained for
maximal performance.
The machine should be kept clean so that any
leakages, loose bolts and loose connections are
discovered at as early a point in time as possible.
Inspect the machine every day, before starting.
Inspect the entire machine so that any leakages or
other faults are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
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 normally carried out by the operator.
2
Table of contents
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