Dynapac CA500 Series Instruction Manual

DYNAPAC
CA500
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
O500EN1
OPERATION

19
ILF015WO1

Vibratory Roller
CA500
Operation
O500EN1, October 2004
Diesel engine:
CA500: Cummins B5.9-VE-TAA
These instructions apply from:
CA500 PIN (S/N) *79290607*
Reservation for changes.
Printed in Sweden.
The Dynapac CA500 is available in D (smooth drum) and PD (padfoot) versions, of which the
CA500D is designed for compacting rock fill. The main range of application for the PD versions 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.
Certain accessories, such as the compaction meter, tachograph and the DCA field computer,
are described in separate instructions.
KEEP THIS MANUAL FOR
FUTURE REFERENCE

2 CA500 O500EN1
Safety instructions – Personal safety
Special caution – Machine or component damage
The safety manual, which accompanies each
machine, must be studied by each operator of
the roller. Always follow the safety rules and
do not remove the manual from the roller.
This manual contains instructions concerning operation
and use of the roller. For information regarding care and
maintenance, see the manual, “MAINTENANCE, CA500".
When starting up and driving a cold machine,
which implies cold hydraulic fluid, the braking
distance will be longer than normal until the
machine reaches normal working temperature.
CONTENTS
WARNING SYMBOLS
SAFETY MANUAL
GENERAL 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.
Page
Safety instructions (Read the Safety Manual also) ...........3
Safety when driving ..........................................................4
Safety decals, location/description ...............................5, 6
Machine and engine plates ...........................................7, 8
Instruments and controls ..................................................9
Instruments and controls, functional description ......10, 11
Controls in the cab ..........................................................12
Controls in the cab, functional description ......................13
Before starting ...........................................................14-16
Starting ...........................................................................17
Driving ............................................................................18
Vibration/Driving .............................................................19
Driving on difficult courses .............................................19
Braking ...........................................................................20
Parking ...........................................................................21
Instructions for lifting .......................................................22
Towing ............................................................................23
Instructions for towing .....................................................24
Transport ........................................................................25
Towing/Retrieval .............................................................25
Operating instructions - Summary ..................................26

3CA500 O500EN1
SAFETY INSTRUCTIONS (Read the Safety Manual also)
1. The operator must be familiar with the contents of the OPERATION MANU-
AL before starting the roller.
2. Make sure that all instructions in the MAINTENANCE MANUAL are fol-
lowed.
3. Only trained and/or experienced operators may drive the roller. Passen-
gers are not allowed on the roller. Remain seated during all operation.
4. Never use the roller if it is in need of adjustment or repairs.
5. Board and leave the roller only when it is stationary. Use the grips and
railings that are provided. Always use a ”three-point grip” - both feet and
one hand or one foot and both hands - when boarding or exiting the ma-
chine.
6. The ROPS (Roll Over Protective Structure) should always be used when
the machine is operated on risky ground.
7. Drive slowly in sharp bends.
8. Avoid driving at an angle on slopes; drive straight up or down.
9. When driving close to unsafe edges or holes, make sure that at least two
thirds of the drum width is firmly on material that has already been com-
pacted.
10. Make sure that there are no obstacles in the direction of travel, on the
ground or overhead.
11. Drive extra carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on ma-
chines fitted with ROPS.
13. Keep the roller clean. Clean dirt and grease from the operator’s platform
without delay. Keep all signs and decals clean and clearly legible.
14. Safety measures before refueling:
– Stop the engine.
– Do not smoke.
– No naked flame in the vicinity.
– Ground the nozzle of the filling device against the tank to prevent
sparks.
15. Before repairs or service:
– Place chocks against the drums/wheels and against the strike-off blade.
– Lock the articulation if required.
16. Hearing protectors are recommended if the noise level exceeds 85 dB(A).
The noise level may vary depending on what material the machine is oper-
ating on.
17. Make no changes or modifications on the roller that could affect safety.
Changes may only be made following written consent by Dynapac.
18. Do not use the roller until the hydraulic fluid has reached its normal work-
ing temperature. Braking distance can be longer than usual if the fluid is
cold. See starting instructions in the OPERATION MANUAL.

4 CA500 O500EN1
SAFETY WHEN DRIVING
Slopes
Fig. 2 Tipping angle on side slopes
Max 20°
or 36%
Driving near an edge
At least
2/3
Fig. 1 Position of drum when driving
near an edge
When you drive near an edge, at least two thirds of the
drum width must be on solid ground.
Remember that the machine’s center of
gravity is displaced outward when you
steer to one side. For example, it shifts to
the right when you steer to the left.
The ROPS (Roll Over Protective Structure)
is always recommended when driving on
slopes or insecure ground.
Where possible, avoid all driving across a
slope. Instead, drive up and down on slo-
ping ground.
The tilting angle is measured on a hard, level surface
with the machine stationary, steering angle zero, vi-
bration switched OFF and all tanks full. Remember
that loose ground, steering of the machine, vibration
switched ON, driving speed and raising the center of
gravity (for example, with accessories) may cause the
machine to topple even on a smaller slope than that
stated here.
To leave the cab in an emergency, release
the hammer located on the rear right post
and break the rear window.

5CA500 O500EN1
SAFETY DECALS, LOCATION/DESCRIPTION
3 2 16 9 7
15 6111511108
13 4, 14 2 3
1561151 1011
12
4, 14

6 CA500 O500EN1
SAFETY DECALS, LOCATION/DESCRIPTION
Crush zone, articulation/
Drum. Maintain a safe
distance from the crush
zone.
Warning - hot surfaces in
the engine compartment.
Do not touch.
Warning - rotating engine
components. Keep your
hands at a safe distance from
the danger zone.
The operator is urgently
requested to read the safety
manual, and the operation
and maintenance instructions
before using the machine.
The articulation must be in-
terlocked when lifting. Read
the instruction manual.
Lifting point
Emergency exit
Tires filled with ballast
Read the instruction manual.
Hydraulic fluid
Securing
point
Lifting plate
1.
2.
3.
5.
6.
10.
8.
14.
7.
4.
16.
9.
12.
11.
13.
15.
Mass Kg
= Optional
Diesel fuel
Tire pressure
Battery discon-
nector Handbook
compartment

7CA500 O500EN1
MACHINE AND ENGINE PLATES
Machine plate
PIN on frame
Fig. 3 Operator’s platform
1. Machine plate
Fig. 4 Front frame
1. PIN
1
The machine type plate (1) is affixed on the front
left edge of the tractor frame. The plate shows the
manufacturer's name and address, type of machine
and PIN "Part Identification Number" (serial number).
Please state the PIN (serial number) of the roller when
ordering spare parts.
The PIN (1) of the machine is punched on the front
right edge of the forward frame beam.
1

8 CA500 O500EN1
Fig. 5 Engine
1. Engine plate
Engine plate
The engine data plate (1) is affixed to the right side of
the engine under the injection pump. The plate indica-
tes the type of engine, serial number and engine data.
Please state the engine serial number when ordering
spare parts. See also the engine manual.
MACHINE AND ENGINE PLATES
Engine plate
1
Cummins Engine Company, Inc
Columbus, Indiana
47202-3005
Warning Injury may result and warranty
is voided
if fuel rate, rpm or altitude exceed
Date of MFG
Z Z Z Z
CID/L. 359/5,9 CPL 2063 Engine Serial No. FEL EPA
Family XCEXL0359ABA Cust. Spec. 376983 NOx
Engine Model PM
Valve lash Timing-TDC 0.2Inch .010 Int. .020 Exh.
MM .254 Int. .508 Exh. Fuel rate at rated HP/KW 93 mm3/stcold
e 11�97/68AA�00/000�0011�00
Firing Order 1-5-3-6-2-4
Rated HP/kW 173/129 at 2200
FR91089 Low Idle RPM 800 - 1100

9CA500 O500EN1
INSTRUMENTS AND CONTROLS
1. Horn
2. Starter switch
3. Hazard beacon
4. Working lights
5. Reserve/Parking brake knob
6. Instrument protection
7. Warning lamp, charging
8. Brake warning lamp
9. Warning lamp, engine oil pressure/
Warning lamp, engine temperature
10. Warning lamp, hydraulic filter
11. Warning lamp, air filter
Fig. 6 Instruments and control panel
12. Warning lamp, hydraulic temperature
13. Amplitude selector Low/0/High
14. Speed selector, drum
15. Speed selector, rear axle
16. Engine revs control
17. Fuel gauge
18. Fuse box
19. Vibration ON/OFF
20. Forward/Reverse lever
21. Test button for warning lamps
22. Handbook compartment
= Optional
6 10 11
5
4
21
3
2
1
22
17
16
19
20
18
12
13
14
15 7 8 9

10 CA500 O500EN1
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
1 Horn, switch
2 Starter switch
3 Hazard beacon, switch
(Optional)
4 Working lights,
switch (Optional)
5 Reserve brake/Parking brake
6 Instrument protection
7 Warning lamp, battery
charging
8 Brake warning lamp
9 Warning lamp, oil pressure
10 Warning lamp, hydraulic filter
11 Warning lamp, air filter
12 Warning lamp, hydraulic
temperature
Item in Designation Symbol Function
fig. 6
Press to sound the horn.
In mode the electric circuit is broken.
In mode all instruments and electric con-
trols are powered.
In mode the starter motor is energized.
Turn to the right to switch on the hazard
beacon.
Turn to the right to switch on the working
lights.
Push in to activate the reserve brake.
Parking brake is applied if pushed in when
machine is stationary. Both brakes are rele-
ased when knob is pulled out.
Fold down over the instruments to protect
from weather and damage.
The alternator is not charging if this lamp
lights when the engine is running.
Stop the engine and locate the fault.
This lamp will light when the parking or
reserve brake knob is pressed and the bra-
kes are applied.
This lamp lights if lubricating pressure in the
engine is too low. Stop the engine immedia-
tely and locate the fault.
If the lamp lights up when the diesel engine
is running at full speed, the hydraulic fluid
filters must be replaced.
The air filter should be cleaned or replaced if
this lamp lights when the engine is running at
full speed.
This lamp lights if the hydraulic fuel is too hot.
Stop the roller, and allow the fluid to cool
down by idling the engine. Locate and re-
medy the fault.

11CA500 O500EN1
INSTRUMENTS AND CONTROLS, FUNCTIONAL DESCRIPTION
13 Amplitude selector
14 Speed selector, drum
15 Speed selector, rear axle
16 Revs control, diesel engine
17 Fuel gauge
18 Fuse box
19 Vibration ON/OFF, switch
20 Forward/Reverse control
21 Test button for warning lamps
22 Handbook compartment
Item in Designation Symbol Function
fig. 6
Left mode gives low amplitude.
Right mode gives high amplitude.
Vibration switched OFF in O mode.
Transport speed (High)
Working speed (Low)
Transport speed (High)
Working speed (Low)
Upper mode, engine working revs.
Lower mode, idling revs.
Indicates fuel level.
Contains fuses for the electrical system.
Push and release the switch to engage
vibration, push once more to disengage
vibration. The above applies only when the
amplitude selector (13) is in position High or
Low.
The lever must be in neutral to start the
engine, it cannot be started with the for-
ward/reverse lever in any other position.
Direction of travel and speed of the roller
is regulated with the forward/reverse lever.
The roller moves forward when the lever is
moved forward, etc. Speed of the roller is
regulated in proportion to how far the lever
is moved from neutral. The further from
neutral, the higher the speed.
The lamps 10, 11, 12 are checked when the
switch is pressed.
Stowage space for safety manual and
operator’s manuals.

12 CA500 O500EN1
CONTROLS IN THE CAB
Fig. 7a Cab roof, front Fig. 7b Cab roof, rear
14
Fig. 7c Cab, right side
23
5 6
Fig. 7d Cab, rear
7
Fig. 7e Cab, left side
8

13CA500 O500EN1
CONTROLS IN THE CAB, FUNCTIONAL DESCRIPTION
Items in Designation Symbol Function
fig. 7
1 Wiper front, switch
2 Wiper rear, switch
3 Screenwash front and rear
panes, switch
4 Hammer for emergency
evacuation
6 Heater (Optional)
7 Air fan, switch
(Optional)
8 Cab lighting,
switch
9 Windshield washer fluid
Press to turn on the front wiper.
Press to turn on the rear wiper.
Press at the top to spray the windscreen.
Press at the bottom to spray the rear screen.
To evacuate the cab in an emergency, relea-
se the hammer and break the REAR window.
Left mode, maximum heating.
Right mode, heating turned off.
Left mode, fan turned off. Right mode, cab
ventilation increases in three steps.
Press to turn on the cab lights.
Fill with new fluid as needed.

14 CA500 O500EN1
BEFORE STARTING
Battery disconnecter
– Switching ON
Operator’s seat in cab and with
ROPS (Optional) – Setting
Fig. 10 Operator’s seat
1. Locking lever - length adjustment
2. Lever - weight adjustment
3. Seat belt
Fig. 8 Engine compartment
1. Battery disconnecter
2. Hourmeter
Adjust the operator’s seat to ensure a comfortable pos-
ture and so that all controls are within easy reach.
The seat can be adjusted as follows:
• Length adjustment (1)
• Cushioning to suit weight of operator (2).
Always make sure that the seat is secure
before beginning operation.
Remember to use the seat belt (3).
Operator’s seat – Setting
Fig. 9 Operator’s seat
1. Locking lever - length adjustment
Adjust the operator’s seat to ensure a comfortable pos-
ture and so that all controls are within easy reach.
The seat can be adjusted as follows:
• Length adjustment (1)
Always make sure that the seat is secure
before beginning operation.
Remember to carry out daily service. See maintenance
manual.
The battery disconnecter is located in the engine
compartment. Open the engine cover and set the key
(1) to the ON position. The entire roller will be powered.
The hourmeter (2) records the number of hours so long
as the engine is running.
The engine hood must be unlocked during
operation, so that battery power can be
disconnected quickly if necessary.
1
1
2
3
2
1

15CA500 O500EN1
BEFORE STARTING
Turn the starter switch (2) to position I. Press the button
(21) and make sure that all the control lamps light.
Check that the fuel gauge (17) gives a reading.
Check that the warning lamps for charging (7), oil pres-
sure (12) and parking brake (8) light.
Instruments and lamps
– Checking
Operator’s station
Fig. 13 Operator’s station
1. Seat belt
2. ROPS
3. Rubber element
4. Anti-slip
If the roller is equipped with a ROPS (Roll Over Pro-
tective Structure) or a cab, always use the seat belt (1)
and wear a hard hat.
Replace the seat belt (1) if it shows signs of
wear or has been subjected to severe force.
Check that the rubber elements (3) on the
platform are intact. Worn elements will impair
comfort.
Ensure that the anti-slip (4) on the platform is
in good condition; replace with new anti-slip if
friction is poor.
If the machine is fitted with a cab, make sure
that the door is closed when in motion.
1
Reserve/parking brake
– Check
Fig. 12 Controls panel
5. Reserve/parking brake knob
8. Brake lamp
Ensure that the reserve/parking brake knob
(30) is pressed down.
The roller can start to move if the engine
is started on sloping ground if the parking
brake is not applied.
2
5 8
Fig. 11 Instrument panel
2. Starter switch
7. Charging lamp
8. Brake lamp
9. Oil pressure lamp
17. Fuel gauge
21. Test button for warning lamps
3
4
7 8 9
21
2
17

16 CA500 O500EN1
BEFORE STARTING
Field of view
Fig. 14 Field of view
Before starting, make sure that the field of view is
unobstructed, both in front and behind. All cab windows
must be clean and rearview mirrors properly adjusted.

17CA500 O500EN1
STARTING
Starting the engine
Set the forward/reverse lever (20) in neutral. The engi-
ne can only be started with the lever in neutral.
Set the amplitude selector (13) for Low/High vibration
to mode O.
Set the revs control (16) to the idling mode.
Turn the starter switch (2) to mode I. Activate the star-
ter by turning the switch one position further.
Do not run the starter motor too long. If the
engine does not start immediately, wait a mi-
nute or so before making a new attempt.
Warm up the diesel engine with the engine speed
control at the idling setting for a few minutes, or for a
longer period if the ambient air temperature is below
+10°C (+50°F).
Check while warming up that the warning lamps for
oil pressure (9) and charging (7) are out. The warning
lamp (8) for the parking brake shall still light.
When starting up and driving a cold mach-
ine, ie, cold hydraulic fluid, the braking dis-
tance will be longer than normal until the
fluid reaches normal working temperature.
Ensure that ventilation (evacuation) is
adequate if the engine is run indoors. ie,
danger of carbon monoxide poisoning.
Fig. 15 Control panel
2. Starter switch
7. Charging lamp
8. Brake lamp
9. Oil pressure lamp/engine
temperature
13. Amplitude selector
16. Revs control
20. Forward/Reverse lever
7 8 9
2
13
16 20

18 CA500 O500EN1
DRIVING
Under no circumstances may the machine
be operated from the outside. The operator
must remain seated inside the machine
during all operation.
Move the revs control lever (16) upwards and latch it at
its limit, engine speed should now be about 2300 rpm.
Ensure that the steering is working properly by turning
the steering wheel once to the right and once to the left
while the roller is stationary.
Ensure that the area in front of and behind
the roller is clear.
Pull up the reserve/parking brake knob (5)
and check that the warning lamp for the
parking brake is out. When starting the
roller on a slope, be prepared that it may
begin to roll.
Driving the roller
Fig. 16 Instrument panel
5. Reserve/parking brake knob
11. Warning lamp, air filter
14. Speed selector, drum
15. Speed selector, rear axle
16. Revs control
20. Forward/Reverse lever
Check occasionally while driving that no lamps light.
If the oil pressure lamp lights, stop the roller and the
engine immediately. Check and remedy any fault; see
also the maintenance manual and the engine manual.
If the warning lamp (11) for the air cleaner
lights during operation (at full engine revs), the
main filter must be cleaned or replaced; see
Maintenance Manual.
Set the High/Low speed selectors (14) and (15) to the
desired mode, see decal on the control panel.
Max. speeds
Low drum/Low rear axle = 4 km/h (2.5 mph)
High drum/Low rear axle = 5 km/h (3 mph)
Low drum/High rear axle = 6 km/h (3.7 mph)
High drum/High rear axle = 11 km/h (6.8 mph)
The High/High mode may only be used for
transport runs on an even surface.
Carefully move the forward/reverse lever (20) in the
desired direction of travel. Speed increases as the lever
is moved farther from the neutral position.
Speed must always be regulated with the
forward/reverse lever and never by changing
speed of the engine.
Test the reserve brake by pressing the
reserve/parking brake knob (5) while the
roller is running slowly forward. Stop the
roller and identify the fault if the brake
does not work.
5 11
14
15
16 20