Dynapac CA500 Series User manual

DYNAPAC
CA500
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
M500EN1
MAINTENANCE

19
ILF015WO1

Vibratory Roller
CA500
Maintenance
M500EN1, 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 M500EN1
CONTENTS
Read the entire manual before starting any
service work.
Ensure that ventilation (extraction) is adequa-
te if the engine is run indoors.
It is essential that the machine is cared for in a proper
manner to ensure satisfactory operation. Keep the mach-
ine clean to facilitate quick and timely detection of any
leakage, loose bolts and loose connections.
Make a habit each day, before starting up, of checking the
roller to detect any leakage or damage. Also check the
ground underneath the roller, where it is most often easier
to detect any leakage.
TAKE CARE OF THE ENVIRONMENT
Do not leave behind any oil, fuel or other sub-
stances that are detrimental to the environment.
This manual contains instructions for periodic measures
that should normally be performed by the operator.
The manufacturer’s instructions noted in the
engine manual also apply. This is placed under a
separate flap in the roller’s product folder.
GENERAL
Safety instructions—Personal safety
Special caution—Machine or component damage
WARNING SYMBOLS
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
Lubricants and symbols .................................................... 3
Technical specifications ................................................. 4-6
Maintenance schedule ...................................................... 7
Maintenance measures ................................................ 8, 9
Every 10 hours of operation (Daily) ........................... 10-13
Every 50 hours of operation (Weekly) ....................... 14-16
Every 250 hours of operation (Monthly) .................... 17-21
Every 500 hours of operation (Every three months) ....... 22
Every 1000 hours of operation (Every six months) .... 23-26
Every 2000 hours of operation (Yearly) .................... 27, 28
Long-term Storage ......................................................... 29
Special instructions ........................................................ 30
Electrical system, fuses ............................................ 31, 32

3CA500 M500EN1
LUBRICANTS AND SYMBOLS
ENGINE OIL Shell Rimula Super 15W/40 or equivalent
API Service CH-4 (CG-4)
HYDRAULIC FLUID
ambient temperature
-10° C - +40° C (14°F - 104°F) Shell Tellus TX68 or equivalent
ambient temperature higher than +40° C Shell Tellus T100 or equivalent
TRANSMISSION OIL
lambient temperature Shell Spirax SAE 80W/90, HD API, GL-5
-15°C - +40°C (5°F - 104°F)
ambient temperature Shell Spirax HD85W/140 or equivalent
higher than +40°C (above 104°F)
DRUM-CARTRIDGE OIL Synthetic oil, MOBIL SHC 629.
GREASE Shell LGHB2 (NLGI-class 2) or equivalent for
the articulation.
Shell Retinax LX2 or equivalent for other
grease points.
FUEL See engine manual
COOLANT Shell Anti Freeze 402 or equivalent.
50/50 mixture with water Anti-freeze down to about -35°C (-31°F).
Engine, oil level Air filter
Engine, oil filter Battery
Hydraulic reservoir, level Tire pressure
Hydraulic fluid filter Drum, oil level
Transmission, oil level Coolant, level
Lubricating oil Recycling
Fuel filter
Always use high-quality lubricants in the recommended amounts. Too much
grease or oil can cause overheating and subsequent increased wear.
Other lubricants are required for driving in extremely high or low ambient
temperatures. See the “Special instructions” chapter, or consult Dynapac.

4 CA500 M500EN1
TECHNICAL SPECIFICATIONS
Weight and sizes CA500D CA500PD
Operating mass with ROPS,
EN500, kg (lbs) .................................................15400 (34,000) ............15600 (34,400)
Operating mass without ROPS, kg (lbs) ..........14900 (32,900) ............15100 (33,300)
Operating mass with cab, kg (lbs) ...................15400 (34,000) ............15600 (34,400)
Length, standard-equipped
roller, mm (in) ....................................................5999 (236) ...................5999 (236)
Width, standard-equipped roller, mm (in) .........2350 (93) .....................2350 (93)
Height, with ROPS, mm (in) .............................2929 (115) ...................2987 (117)
Height, with ROPS/silencer, mm (in) ................2190 (86) ......................2208 (87)
Height, with cab, mm (in) ..................................2952 (116) ....................2987 (117)
Fluid volumes (Liters) (gal or qts)
Rear axle:
• Differential .................................................12,5 (12.7 qts)
• Planetary gearing .....................................1,85/side (1.8 qts) /each side
Drum gearing ...............................................3,5 (3.2 qts)
Cartridge, vibration generator ......................2,2/side (2.8 qts) /each side
Hydraulic reservoir .......................................52 (13.7 gal)
Fluid in hydraulic system .............................38 (10 gal)
Lubricating oil, Diesel engine ......................14 (10.6 qts)
Coolant, Diesel engine ................................34 (9 gal)
Fuel tank ......................................................320 (84.5 gal)
Electrical system
Battery .........................................................12 V, 170 Ah
Alternator .....................................................14 V, 105A
Fuses ...........................................................See under main heading: Electrical system
Tires
Tire size .......................................................23.1 x 26.0 8 Ply, 600/60-30,5
Air pressure ................................................110 kPa (1,1 kp/cm2)
As extra equipment, the tires can be filled with liquid (extra weight up to 700 kg/tire)
(1543 lbs/tire). Remember this extra weight when you perform service.
Compaction data CA500D CA500PD
Static linear load ........................ kg/cm (pli) 49,3 (276) -
Amplitude (High) .............................mm (in) 1,8 (0.070) 1,7 (0.066)
Amplitude (Low) ..............................mm (in) 1,1 (0.043) 1,0 (0.039)
Frequency (High/Low amplitude) . Hz (vpm) 29/33 (1740/1980) 29/33 (1740/1980)
Centrifugal force (High amplitude) ... kN (lb) 300 (67,442) 300 (67,442)
Centrifugal force (Low amplitude) .... kN (lb) 238 (53,504) 238 (53,504)

5CA500 M500EN1
Opening pressure, MPa (psi)
Drive system 38,0 (5,500)
Charge system 2,0 (290)
Vibration system 42,5 (6,150)
Steering system 18,0 (2,600)
Brake release 1,4 (200)
Tightening torque
Hydraulic system
ROPS
M STRENGTH CLASS
thread 8.8 10.9 12.9
M6 8,4 (6.2) 12 (8.9) 14,6 (10.8)
M8 21 (15.5) 28 (20.7) 34 (21.1)
M10 40 (15.5) 56 (41.3) 68 (25.1)
M12 70 (51.6) 98 (72.3) 117 (86.3)
M16 169 (124.7) 240 (177) 290 (213.9)
M20 330 (243.4) 470 (346.7) 560 (413.1)
M24 570 (420.4) 800 (590.1) 960 (708.1)
M30 1130 (833.5) 1580 (1165.4) 1900 (1401.4)
M36 1960 (1445.7) 2800 (2065.3) –
Tightening torque in Nm (lbf.ft) for oiled, bright galvani-
zed bolts tightened with a torque wrench.
Bolt size: M24 (P/N 90 39 64)
Strength class: 10.9
Tightening torque: 800 Nm (for Dacromet treated)
ROPS bolts must always be tightened dry.
TECHNICAL SPECIFICATIONS

6 CA500 M500EN1
CA500 111 88 87
The acoustic values are measured in conformance with the operation
cycle described in EU directive 2000/14/EC, on soft polymer material
with vibration switched ON.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A) LwA
Acoustic pres-
sure level,
operator’s
ear (platform)
dB(A) LpA
Acoustic pres-
sure level,
operator’s ear
(cab) dB(A)
LpA
Noise level can vary when driving on different
courses and with different seat positions.
The vibration values are measured in conformance
with the operation cycle described in EU directive
2000/14/EC, on soft polymer material with vibration
switched ON.
Operator’s station, vibration, hand/arm
(steering wheel/lever):
Below limit value.
Limit value: <2.5 m/s2.
Operator’s station, vibration, entire body
(operator’s seat):
Below limit value.
Limit value: <0.5 m/s2.
Vibrations – Drivers seat
(ISO 2631)
Vibration levels may vary when driving on dif-
ferent courses.
TECHNICAL SPECIFICATIONS

7CA500 M500EN1
MAINTENANCE SCHEDULE
1 2 3 4 5 6 7 8 9 33 10 11 12
26 25 24 23 22 21 20 19 18 17 16 15 14
13
32
31
30
29
28
27
Fig. 1 Service points
1. Radiator grille
2. Oil level, diesel engine
3. Fuel filter, fuel pre-filter
4. Air filter
5. Hydraulic reservoir, sight glass
6. Breather filter
7. Hydraulic filter, x1
8. Drain hydraulic reservoir
9. Hydraulic fluid, filling
10.. Fuse box
11. Drum cartridge oil filler, x2
12. Drum gearbox
13. Scrapers
14. Drum cartridge oil, level plug, x2
15. Rubber elements and fastening screws
16. Steering joint
17. Steering cylinder, x2
18. Flywheel casing, hydraulic pumps
19. Wheel nuts
20. Tire pressure
21. Rear axle, differential
22. Rear axle, planetary gearing, x2
23. Rear axle suspension, two sides
24. Oil filter, diesel engine
25. Draining, fuel tank
26. Engine suspension, x4
27. Feed pump, fuel
28. Diesel fuel, filling
29. Battery
30. Radiator
31. Hydraulic fluid cooler
32. Drive belts, cooling, alternator
33. Forward/Reverse lever

8 CA500 M500EN1
Perform periodic maintenance measures daily, weekly,
etc. whichever comes first, or after the stipulated hours
of operation.
Remove all dirt before filling, when checking
oils and fuel, and when lubricating with oil or
grease.
The manufacturer’s instructions noted in the
engine manual also apply.
MAINTENANCE MEASURES
Every 10 hours of operation (daily)
Items in Measure See page Comments
fig. 1
4 Check that hoses and connections are tight 14
6 Control/clean the filter element in the air cleaner 14 Replace as required
16 Grease the steering joints 15
17 Grease the steering cylinder brackets 15
19 Check tightness of the wheel nuts 16
20 Check the tire pressure 16
After the first 50 hours of operation change only the drum oil and all the oil filters.
Every 50 hours of operation (weekly)
Items in Measure See page Comments
fig. 1
Before starting up
13 Check the scraper setting 10, 11
1 Check for free circulation of cooling air 11
30 Check coolant level 11 See engine instruction manual
2 Check oil level in the engine 12 See engine instruction manual
28 Refuel 12
5 Check the hydraulic reservoir level 12
Test the brakes 13

9CA500 M500EN1
MAINTENANCE MEASURES
Items in Measure See page Comments
fig. 1
22 Check the oil level in the rear axle/planetary
gearing 17
24 Change engine oil and oil filter 17 See engine instruction manual
12 Check oil level in the gearbox 18 Accessory D/PD
14 Check oil level in the drum cartridge 18, 19
31 Clean the coolers 20
19, 23 Inspect tightening of bolted joints 20 Applies only to new or
renovated component.
15 Check rubber elements and bolted joints 21
29 Check the battery 21
Every 250 hours of operation (monthly)
Items in Measure See page Comments
fig. 1
7 Change the hydraulic filter 23
8 Drain condensation from the hydraulic reservoir 24
25 Drain condensation from the fuel tank 24
4 Replace main filter in the air cleaner 24
21 Change oil in the rear axle differential 25
22 Change oil in the rear axle planetary gearing 26
Check engine valve clearance See engine instruction manual
32 Check belt tension of drive system See engine instruction manual
Every 1000 hours of operation (every six months)
Items in Measure See page Comments
fig. 1
8, 9 Change the hydraulic fluid 27
12 Change oil in the drum cartridge 27
12 Change oil in the drum gearbox 28 Accessory D/PD
33 Lubricate the Forward/Reverse controls 28
Every 2000 hours of operation (yearly)
Items in Measure See page Comments
fig. 1
3 Replace fuel filter See engine instruction manual
3 Clean/Replace the initial fuel filter 22
6 Inspect breather filter on the hydraulic reservoir 23
Every 500 hours of operation (every three months)

10 CA500 M500EN1
EVERY 10 HOURS OF OPERATION (Daily)
Remember that the drum tends to move as
the machine turns. Consequently, if adjust-
ments are made closer than the values noted
below, the scrapers may be damaged or the
drum may wear more than usual.v
If required, adjust distance to the drum as follows:
Loosen the screws (2) and adjust to 20 mm (0.8 in).
Tighten the screws.
Scrapers
– Checking/Adjusting
Fig. 2 Scrapers
1. Scraper blade
2. Screws
Fig. 3 Scrapers
1. Screws
2. Scraper tooth
CA500PD
Loosen the screws (1) and adjust each scraper tooth
(2) to 20 mm (1.0 in) between the teeth and the drum.
Tighten the screws (1).
2 1
Soft scrapers (Optional)
Loosen the screws (2) and adjust the scraper blade (1)
to give light contact with the drum. Tighten the screws.
2 1 1 2
Fig. 4 Scrapers
1. Scraper blade
2. Screws
1 2

11CA500 M500EN1
Ensure that the engine has unimpeded circulation of
cooling air through the protective grille to the engine.
Observe caution if the filler cap must be
opened while the engine is hot.
NB. The engine must be switched off. Wear
gloves and safety goggles.
Air circulation – Check
Fig. 5 Cooling air grille
EVERY 10 HOURS OF OPERATION (Daily)
3
1 2
Fig. 6 Radiator
1. Max. level
2. Min. level
3. Filler cap
Check that level of the coolant is between the max. and
min. marks.
Observe caution. Take great caution if the
radiator cap must be opened while the
engine is hot. Wear protective gloves and
goggles.
Fill with a mixture of 50% water and 50% anti freeze.
See page 3 in these instructions and in the engine ma-
nual.
Flush the system every other year and change
the coolant. Ensure also that air can flow un-
restricted through the radiator.
Coolant level – Check

12 CA500 M500EN1
Hydraulic reservoir
– Checking the fluid level
Refuel every day. Top off to the lower edge of the filler
pipe. Use diesel fuel in accordance with the engine
manufacturer’s specifications.
Stop the diesel engine. Short (press) the
filler gun against a non-insulated part of
the roller before refueling, and against the
filler pipe (1) while refueling is in progress.
The fuel tank holds 320 litres (85 gal).
EVERY 10 HOURS OF OPERATION (Daily)
Engine
– Checking the oil level
Fig. 7 Engine compartment
1. Oil dipstick
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Observe caution. Beware of hot parts of
the engine and hot radiator when taking
out the oil dipstick. Wear gloves and safety
goggles.
The dipstick is on the right-hand side of the engine.
Pull the dipstick (1) up and check that the oil level is
between the upper and lower marks. See the engine
manual for further details.
1
Fig. 8 Fuel tank
1. Filler pipe
2. Fuel pre-filter
Fuel tank – Refueling
1
Fig. 9 Hydraulic reservoir
1. Sight glass
2. Filler pipe
Place the roller on level ground and check that the fluid
level is between the max. and min. marks in the sight
glass (1). Top off with hydraulic fluid according to the
lubricant specification if the level is too low.
2
1

13CA500 M500EN1
EVERY 10 HOURS OF OPERATION (Daily)
Brakes – Check
Fig. 10 Control panel
1. Reserve/parking brake knob
2. Forward/reverse lever
3. Brake warning lamp
Check brake operation as follows:
Drive the roller slowly forward.
Press down the reserve/parking brake knob (1). The
brake warning lamp (3) on the instrument panel should
light and the roller should stop.
After testing the brakes, set the forward/reverse lever
(2) in neutral.
Pull out the reserve/parking brake knob.
The roller is now ready for operation.
1
3
2

14 CA500 M500EN1
EVERY 50 HOURS OF OPERATION (Weekly)
Air cleaner
– Checking/cleaning
Main filter – Cleaning with
compressed air
Fig. 12 Main filter
2 3
Fig. 11 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
Place the roller on a level surface. Switch
the engine off and push in the reserve/par-
king brake knob for all checking and ad-
justments on the roller, unless otherwise
specified.
Replace or clean the main filter of the air clea-
ner when the warning lamp on the instrument
panel lights at full engine revs.
Release the three locking braces (1) and pull off the
cover (2) and take out the main filter (3).
Do not remove the backup filter (4).
1 4 5
Replace the backup filter with a new one after every
fifth replacement or cleaning of the main filter. The se-
condary filter cannot be cleaned.
To change the backup filter (4), pull the old filter out
of its holder, insert a new one and reassemble the air
cleaner in the reverse order in relation to the instruc-
tions in the figure above.
Fig. 13 Air filter
4. Backup filter
Backup filter
– Replacement
4
To clean the main filter, blow up and down along the
paper pleats with compressed air at maximum 5 bar
(72 psi) pressure.
Hold the nozzle at least 2–3 cm (0.8-1.2 in) from the
paper pleats to avoid tearing the paper.
Wear protective goggles when working with
compressed air.
Wipe the inside of the cover (2) and filter housing (5).
Check that the hose clamps between the filter
housing and suction hose are tight and that
the hoses are intact. Inspect all hoses all the
way to the engine.
Change the main filter at the latest after 5
cleanings.

15CA500 M500EN1
Steering cylinders
– Lubrication
Steering joint
– Lubrication
Steering joint/Steering
cylinders – Lubrication
Fig. 14 Steering joint, right side
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Allow no one to get near the steering joint
when the engine is running. Danger of
being crushed when steering is operated.
Push the reserve/parking brake knob be-
fore lubricating.
Turn the steering wheel fully to the left to gain access to
all six nipples on the right side of the steering system.
Use grease according to the lubricant specifi-
cation.
Fig. 16 Steering cylinder, right side
3. Lubricant nipple right rear
steering cylinder mount (x1)
4. Lubricant nipple left rear steering
cylinder mount (x1)
1
Fig. 15 Steering joint, right side
1. Grease nipples, steering joint (x4)
2. Grease nipple, cylinder mount (x1)
EVERY 50 HOURS OF OPERATION (Weekly)
Wipe the nipples clean from grease and dirt.
Grease the nipples (3 and 4) with five strokes of the
grease gun.
Turn the steering wheel fully to the right to gain access
to the forward grease nipple on the left steering cylin-
der and the nipple on the bearing cover. Allow a little
grease to remain on the nipples after greasing. This will
prevent contamination from entering the nipples.
1
2
3 4
Wipe the nipples clean from grease and dirt.
Grease each nipple (1 and 2) with five strokes of the
grease gun. Ensure that grease penetrates the bea-
rings.
If grease does not penetrate the bearings, it
may be necessary to relieve the articulation
joint with a jack while repeating the greasing
process.
1

16 CA500 M500EN1
EVERY 50 HOURS OF OPERATION (Weekly)
1
2
Tire pressure
Wheel nuts – Tightening
Check the tire pressure with a pressure gauge.
When the tires are filled with liquid the air pressure
valve (1) must be set at "12 o'clock" when checking or
pumping.
Tire pressure is noted under the heading Specifica-
tions.
Check both tires.
When you change the tires, it is important
that both tires have the same rolling radius, to
ensure proper operation of the anti-slip device
in the rear axle.
Check tightening torque of the wheel nuts (2) at 470
Nm (350 lbf.ft).
Check both wheels and all nuts.
(Applies only on new machine or newly fitted wheels.)
When pumping the tires, see the safety
manual that accompanies the roller.
Note: The tires are filled with liquid.
This makes the wheels heavier than
normal.
Fig. 17 Wheels
1. Air valve
2. Wheel nut

17CA500 M500EN1
Rear axle planetary gearing
– Checking the oil level
EVERY 250 HOURS OF OPERATION (Monthly)
Rear axle differential
– Checking the oil level
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Never work under the roller with the engine
running. Park on a level surface. Block the
wheels securely.
Wipe clean, remove the level plug (1) and check that
the oil level reaches the lower edge of the plug hole.
Top off to the right level if the level is low. Use transmis-
sion oil. See lubricant specification.
1
Fig. 18 Level check—differential housing
1. Level/Filler plug
1
1 2
Fig. 19 Level check
- planetary gearing, std
1. Level/Filler plug
Position the roller with the plug (1) in the planetary
gearing at 9 o'clock.
Wipe clean, remove the level plug and check that the
oil level reaches the lower edge of the plug hole. Top off
to the right level if the level is low. Use transmission oil.
See lubricant specification.
Check the oil level in the same way in the other plan-
etary gearing of the rear axle.
Fig. 20 Left side of engine
1. Drain plug
2. Oil filter
Diesel engine
– Oil and filter change
Place the roller on a level surface. Switch
off the engine and apply the parking brake/
Reserve brake.
The oil drain plug (1) is most easily accessible from
underneath the engine. Drain off the oil while the
engine is warm. Place a receptacle that holds at least
15 liters(16 qts) under the drain plug.
Observe caution when draining hot oil.
Protect your hands.
Fill oil according to the engine manual. Replace the
engine oil filter (2) at the same time. See also engine
instruction manual.
Dispose of the drained oil and filter in an
approved manner.

18 CA500 M500EN1
EVERY 250 HOURS OF OPERATION (Monthly)
1
Drum cartridge
– Checking the oil level
Position the machine level so that the indicator pin (1)
on the inside of the drum is aligned with the top of the
drum frame.
Fig. 22 Left side of drum
1. Indicator pin
Fig. 23 Roller, right-hand side
1. Filler plug
2. Drain plug
3. Level plug
Drum cartridge
– Checking the oil level
Wipe the filling plug and level plug clean from dirt.
Unscrew the filling plug (1).
1
2
3
Fig. 21 Level check - drum gearbox
1. Level plug
2. Filler plug
3. Drain plug
Drum gearbox
– Checking the oil level
1
2Position the roller with the filler plugs (2) straight up.
Wipe clean round the level plug (1) and unscrew it.
Ensure that the oil level reaches up to the lower edge
of the plug hole.
Top off to the right level if the level is low. Use transmis-
sion oil according to the lubricant specification.
Clean and screw in the plugs tight.
3