Dynapac CA 152 Instruction manual

DYNAPAC
CA 150/152
WORKSHOP MANUAL
W1080EN1
CONVERTING DRUM
STD/DTO P/PD
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com

19
ILF015WO1

We reserve the right to change specifications without notice.
Printed in Sweden
Vibratory roller
CA150/152
Workshop Manual,
Converting drum Std/D to P/PD
W1080EN1, January 2002
These instructions apply from:
CA 150 PIN (S/N) *64X20152*

2CA 150/152 W1080EN1
Ensure that ventilation (extraction) is
adequate if the engine is run indoors.
The machine must be cared for properly to ensure
satisfactory operation. Keep the machine clean to facilitate
quick and timely detection of any leakage, loose bolts and
loose connections.
TAKE CARE OF THE ENVIRONMENT!
Do not leave behind any oil, fuel or other substances that are
detrimentaltotheenvironment.
CONTENTS
Safety instructions — Personal safety
Special caution — Machine or component
damage
WARNING SYMBOLS
- Make yourself familiar with the equipment of the
machine.
- Only operate the machine if your are completely
familiar with the operating and control elements as well
as the functioning of the machine.
- Use your safety equipment like helmet, safety shoes
and hearing protection.
- Make yourself familiar with your working field.
- Only operate the machine for its intended purpose.
Please observe the guidelines of the
machine manufacturer and safety manual.
GENERAL
Page
Fitting.............................................................................3-7
Dismantling ...................................................................... 7
Drawing (38 53 45)........................................................... 8
Tools, hexagonal socket wrench (38 55 04) .................... 9

3CA 150/152 W1080EN1
FITTING
Fitting must be done in a workshop environment, on a
clean, level base and with lifting capabilities for at least
500 kg (1,100 lbs). Ensure at least 3 meters (120") of
free space in front of the machine (see overleaf).
Make sure the drum is well cleaned.
Estimated time for this retrofitting is about 6 hours.
The following tools are required:
- Lift, at least 500 kg (1,100 lbs)
- Screw clamps
- Drillingmachine
- Drill, 18 mm (3/4")
- Hexagonal socket wrench 38 55 04
- Torque wrench
- Socket wrenches
Before modifying
Dismantle the front transverse beam (1).
Lift the first pad half (2) and place it on top of the drum.
Align the pad half with the outer edges of the drum. Fix
the pad half with screw clamps against the drum shell.
Keep well clear of the hoisted object.
Ensure that hoisting hooks are securely
anchored.
1
Fig.1 Fittingthepadhalf
1. Transverse beam
2. Pad half
Drill two 18 mm (3/4") holes through the pad shell and
the drum shell. Use the two 8 mm pre-drilled holes as
position guides.
Fig.2 Drillingthroughholes
2

4CA 150/152 W1080EN1
Fig.5 Fitting the second pad half
Lift the second pad half in place and align it against the
outer edges of the drum.
Keep well clear of the hoisted object.
Ensure that hoisting hooks are securely
anchored.
FITTING
Fig.3 Fitted M16 bolts
Fig.4 Drum
Fit the two M16 bolts
(items 4, 5 and 6 in drawing 38 53 45).
Run the roller slowly forward until the drum is located
with the first fitted drum shell at the bottom.
Two wooden joists 50x70 mm (2x3") with bevelled
ends.
The space required for this operation is 3 meters
(120"). The pad half nearest to the platform/cab must
be about 100 mm (4") to the upper edge of the drum
frame.
Make sure that no one is inside the
working range of the machine when you
drive it forward.

5CA 150/152 W1080EN1
FITTING
Fig.6 Clearance between pad halves
Fig.7 Pad halves
13. Fitting bolts x4
Distribute the clearance between the pad shells. This is
to ensure that the bolts fit properly.
13
Fig.8 Fittingthepadhalf
3. Bolts
3
3
Lubricate the four fitting bolts (13) and fit them with the
head upward in the outer positioned pads on both
sides.
Tighten the two pad halves together. Ensure that the
clearance is evenly distributed, about 25 mm (1"),
between the halves when you tighten the bolts (use tool
38 55 04 as a counter-support).
Drill two 18 mm (3/4") holes through the pad shell and
the drum shell. Fit the two M16 bolts.
Fit the two middle bolts (3) with the head upwards and
torque-tighten them (item 3 in drawing 38 53 45). Then
unscrew the outer fitting bolts and replace them with
M16x90.
When all four bolts are torque-tightened according to
drawing 38 53 45, reverse the machine half a turn of
the drum to gain access to the second joint. Repeat
according to the above.
Ensure that clearance is equal between the
pad shells. Use tool 38 55 04.
Save the tool and the four tightening bolts for future
use.

6CA 150/152 W1080EN1
Fig. 11 Fitted shims
1. Shims
Place shims (1) so that the scraper teeth are positioned
symmetrically between the pads.
Remember that the rubber elements are pre-
tensioned; use only enough shims to leave an
air gap of about 5 mm (3/16") between the
scraper and the drum frame, before the
scraper bolts are tightened.
FITTING
Fig.9 Fitting theteeth
Fig.10 Fitting the PD scraper
Fit the PD scraper 34 39 60 (item 2 in drawing
38 53 45). Weight about 220 kg (490 lbs).
Keep well clear of the hoisted object.
Ensure that hoisting hooks are securely
anchored.
Fit the teeth on the PD scraper.
1
5 mm
(1/5")

7CA 150/152 W1080EN1
FITTING
Fig.12 Scrapers
1. Scraper blade
2. Screws
Fig.13 Modifying CA 250 to PD
Adjust the scraper between scraper tooth and drum
shell to a distance of about 25 mm (1").
It is important to remember that the drum tends
to move as the machine turns. Consequently,
if adjustments are made closer than the values
specified above, the scrapers might be dam-
aged or drum wear may increase.
Torque-tighten the four bolts according to drawing
38 53 45.
The pad shell is now fitted and the roller is ready for
operation.
After a short test-run of about 1/2–1 hour,
retighten all of the bolts that have been fitted,
and again after another 4 hours of operation.
This is necessary to compensate certain
settling of the drum shell. If retightening is
neglected, the shell may rotate on the drum
and result in serious damage to the pad shell.
DISMANTLING
Before dismantling the pad shell, mark the halves in
some permanent way to show how they are positioned
in relation to each other.
The hole pattern and any wear to the shell necessitate
refitting the shell to its initial position.
1
2
Fig.14 Marking the pad halves

8CA 150/152 W1080EN1
DRAWING 38 53 45

9CA 150/152 W1080EN1
TOOLS, HEXAGONAL SOCKET WRENCH 38 55 04