Dynapac CC 501 User manual

Box 504, SE-371 23 Karlskrona, Sweden
Telephone [phone]
Telefax [phone]
DYNAPAC
CC 501/501C
M501EN3
MAINTENANCE

We reserve the right to change specifications without notice.
Printed in Sweden.
Vibration and Combination roller
CC 501/501C
Maintenance
M501EN3, June 1999
Diesel engine:
Cummins 6CT 8.3
These instructions apply from
CC 501: PIN (S/N) *60910502*
CC 501C:PIN (S/N)*60010501*
CC 501 and CC 501C are two rollers in the CC 50 family in the heavier category.
The CC 501 features articulated steering and propulsion on both drums compared to the
CC 501C, which has propulsion on one drum and all of its rubber wheels.
The CC 501 and CC 501C feature high power, high capacity and high quality in major
demanding applications, such as highway and airfield construction involving compaction of
various drybound macadam compounds.
Separate information about accessories is available on request.
KEEPTHISMANUAL
AVAILABLEFOR
FUTUREUSE

2CC 501/501C M501EN3
CONTENTS
Page
Lubricants, symbols ......................................................... 3
Specifications................................................................4-5
Maintenance schedule and measures ..........................6-9
Every 10 hours of operation (daily) ........................... 10-13
Every 50 hours of operation (weekly) ....................... 14-16
Every 250 hours of operation (monthly) .................... 17-18
Every 500 hours of operation (every three months).. 19-20
Every 2000 hours of operation (yearly).....................21-22
Long-term parking .......................................................... 23
Special instructions ........................................................ 24
Electrical system, fuses................................................. 25
Safety instructions—Personal safety.
Special caution—Machine or component damage.
Read the entire manual before starting any
service work.
Ensure that ventilation (extraction) is adequate if
the engine is run indoors.
It is essential that the machine is properly cared for 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 detrimental to the environment.
This manual contains instructions for periodic activities
that should normally be performed by the operator.
For the diesel engine, the engine manufacturer’s
instructions—found in the engine manual—also
apply. This manual is included in the product binder.
WARNING SYMBOLS
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.

3
CC 501/501C M501EN3
LUBRICANTS AND SYMBOLS
Always use high-quality lubricants in the
recommended amounts. Too much grease or
oil can cause overheating and subsequent
increased wear.
ENGINE OIL,
ambient temperature -10 to +50°C
(14 to 122°F)
HYDRAULIC FLUID,
ambient temperature -10 to +40°C
(14 to 104°F)
ambient temperature higher than +40°C
(104°F)
DRUM OIL/TRANSMISSION OIL,
ambient temperature -15 to +40°C
(5 to 104°F)
ambient temperature higher than +40°C
(104°F)
GREASE
GREASE FOR ARTICULATION JOINT
FUEL
COOLANT,
50/50 mixture with water
Engine, oil level
Engine,oilfilter
Air filter
Coolant, level
Transmission/Drum, oil level
Recycling
Hydraulic reservoir, level
Hydraulic fluid, filter
Sprinkler water
Sprinkler
Lubricatingoil
Battery
Tire pressure
Fuelfilter
50/50
Grade: API Service CD/SE
SAE 15W/40
Grade:
Shell Tellus Oil TX68 or equivalent
Shell Tellus Oil T100 or equivalent
Grade: API, GL-5
SAE 80W/90 HD
Shell Spirax HD85W/140 or equivalent
Shell EP Grease 2 or equivalent
SKF LGEM2 or equivalent
Seeenginemanual
Shell Anti Freeze 402 or equivalent.
Antifreeze down to about –35°C (–31°).
Other lubricants are required for driving in
extremely high or low ambient temperatures.
See “Special instructions,” or consult Dynapac.

4CC 501/501C M501EN3
Fluid volumes Liters (gal or qts)
Drums.............................................. 26.5 l/drum (7 gal/drum)
Hydraulic reservoir ........................... 340 l (90 gal)
Fuel tank........................................... 340 l (90 gal)
Water tanks front/rear................ 670/670l (177/177 gal) CC 501, 670/318 l (177/84 gal) CC 501C
Coolant ............................................... 38 l (10 gal)
Diesel engine ......................................19 l (6 gal)
Pump drive ...........................................4 l (4.3 qts)
Drum drive............................................ 3 l/drum (3.2 qts/drum)
Electrical system
Battery ...................................... 12 V, 160 Ah
Alternator .................................. 12 V, 95 A
Fuses ....................................... 8 A
Compaction data CC 501 CC 501C
Static linear load, kg/cm (pli)
Front ......................................... 35 (196) ...................... 36 (202)
Rear.......................................... 39 (218)
Tire load, kg/tire (lbs/tire) ............................................... 3100 (6,834)
Amplitude, mm (in)
High: ......................................... 0,73 (0.029) ................ 0,73 (0.029)
Low: .......................................... 0,37 (0.015) ................ 0,37 (0.015)
Frequency, Hz (vpm) ............... 45 (2700) .................... 45 (2700)
Centrifugal force, kN (lb)
At high amplitude: ..................... 187 (42,075) ............... 187 (42,075)
At low amplitude: ...................... 94 (21,150) ................. 94 (21,150)
Propulsion CC 501 CC 501C
Speed range, km/h (mil/h) 0-13 (0-8.1) 0-10,5 (0-6.5)
Climbing capacity (theoretical) % 30 31
SPECIFICATIONS
Tires (CC 501C)
Dimension 15.0 R24 Pilote
Qty. 4
Air pressure See diagram on next page
Weight Sizes CC 501 CC 501C
Weight EN500-1,
standard equipped roller, kg (lbs) 16 500 (36,376) 20 900 (46,076)
Length, standard equipped roller, mm (in) 5 653 (12,463) 5 653 (12,463)
Width, standard equipped roller, mm (in) 2 430 (5357) 2 430 (5357)
Height, standard equipped roller, mm (in) 2 630 (5798) 2 630 (5798)
(Shippingheight)
Height, standard equipped roller with ROPS 3 330 (7341) 3 330 (7341)

5
CC 501/501C M501EN3
SPECIFICATIONS (cont’d)
Note.
The diagram applies for a wheel load of 3100 kg (6,834 lbs).
(1 bar = 100 kPa)
Tire pressure (bar)
Contact
area,
cm
2
(in
2
)
HYDRAULIC SYSTEM CC 501 CC 501C
Opening pressure, MPa (lbs/in2)
Drive system 35 (5,076) 35 (5,076)
Supply system 2,0 (290) 2,0 (290)
Vibration system 14 (2,030) 14 (2,030)
Steering system 14 (2,030) 14 (2,030)
Brake release 1,5 (217) 1,5 (217)
Hydraulic system
(Measured with vibration switched ON and on a
foam-rubbermat)
Vibration in the operator’s seat is 0.89 m/s² (2.92 ft/s²)
(CC501) and 0.19 m/s² (0.62 ft/s²)(CC501C).
Vibration in the floor at the operator’s station is 0.58 m/s²
(1.90 ft/s²)(CC501) and 0.20 m/s² (0.66 ft/s²)(CC501C).
Operator’s station - Vibration
(ISO 2631)
(Hand/arm - steering wheel and F/R
lever vibration is less than the limit
value, 2.5 m/s2 (8.2 ft/s2).)
Measured acoustic power level, LpA, on hard base
and vibration switched OFF:
LpA: 87 dB(A)
Machine with cab: LpA: 85 dB(A)
Measured acoustic power level, LwA, on hard base
and vibration switched OFF according to SS4591010:
LwA: 109 dB(A)
Machine with cab: LwA: 106 dB(A)
Noise level - Operator’s station
(ISO 6394)
Acoustic power level -
Surroundings
(SS 4591010)
(36.6) (42.7) (48.8) (54.9) (61.0) (67.1) (73.2)

6CC 501/501C M501EN3
MAINTENANCE SCHEDULE
1. Water tanks
2. Sprinklers
3. Fuel tank
4. Engine suspension
5. Fuses
6. Drumoilfilling/level
7. Scrapers
8. Rubberelement,
fastening screws
16. Drive belts
17. Coolantfilter
18. Drum drive
19. Controltable
20. Air filter
21. Engine oil level
22. Fuelfilter
9. Flywheel casing,
pump drive
10. Hydraulic filter
11. Articulationjoint,
steering cylinder
12. Hydraulic reservoir
13. Battery
14. Tires (CC 501C)
15. Radiator
6
14131211109787
15 16 17
Fig.1 Maintenancepoints
18
19
22 21 20
521
1234

7
CC 501/501C M501EN3
MAINTENANCE MEASURES
Items in Measure See page Comments
fig. 1
Before starting up
21 Check oil level in the engine Seeenginemanual
15 Check coolant level 10 Seeengine manual
15 Check for free circulation of cooling air 10 Seeengine manual
22 Drain the water trap on the fuel filters 10 Seeengine manual
Test the brakes 10
2 Inspect and clean the sprinkler system 11
7 Check the scraper setting 12
12 Check level of the hydraulic reservoir and top
off with hydraulic fluid as required 13
3 Refuel 13
Every 10 hours of operation (daily)
Items in Measure See page Comments
fig. 1
21 Change the engine oil and oil filter Seeenginemanual
20 Clean the filter element in the air cleaner 14
Check that hoses and connections are tight
14 Check tire pressure (CC 501C) 14
8 Check rubber elements and bolted joints 15
11 Grease the articulation joint and the steering
cylinder mounts 15
12 Check the hydraulic reservoir cover/breather 15
22 Drain the engine fuel pre-filter 16
13 Check the battery 16
After the first 50 hours of operation, change all the lubricating oils,
but not the hydraulic fluid.
The periodic measures must be carried out at the
stated hours of operation.
Remove all dirt before filling or draining, when
checking oils and fuel, and when lubricating with
oil or grease.
Every 50 hours of operation (weekly)

8CC 501/501C M501EN3
MAINTENANCE SCHEDULE
1. Water tanks
2. Sprinklers
3. Fuel tank
4. Engine suspension
5. Fuses
6. Drumoilfilling/level
7. Scrapers
8. Rubberelement,
fastening screws
16. Drive belts
17. Coolantfilter
18. Drum drive
19. Controltable
20. Air filter
21. Engine oil level
22. Fuelfilter
9. Flywheel casing,
pump drive
10. Hydraulic filter
11. Articulationjoint,
steering cylinder
12. Hydraulic reservoir
13. Battery
14. Tires (CC 501C)
15. Radiator
6
14131211109787
15 16 17
Fig.1 Maintenancepoints
18
19
22 21 20
521
1234

9
CC 501/501C M501EN3
Items in Measure See page Comments
fig. 1
16 Check belt tension of the radiator fan and
alternator Seeenginemanual
21 Change the engine oil and oil filter Seeenginemanual
10 Replace the hydraulic filter and clean the
outside of the hydraulic fluid cooler 17
9 Check the oil level in the pump drive 18
18 Check oil level in the drum drives
(2 on CC 501) 18
Items in Measure See page Comments
fig. 1
12 Change the hydraulic fluid 21
6 Check oil in the drums
(2x2 on CC 501) 21
18 Change oil in the drum drives (2 on CC 501) 22
9 Change oil in the pump drive 22
1 Empty and clean the water tanks
Every 2000 hours of operation (yearly)
MAINTENANCE MEASURES, cont’d
Every 250 hours of operation (monthly)
Every 500 hours of operation (every three months)
Items in Measure See page Comments
fig. 1
6 Check oil level in the drums
(2x2 on CC 501) 19
19 Lubricate controls, pivoted joints and the
control table bearings 19
4 Control tighten engine suspension and
boltedjoints 20
3 Drain condensation from the fuel tank 20
12 Drain condensation from the hydraulic
reservoir 20
22 Replace the engine fuel filters (2 off) Seeenginemanual
17 Change the engine coolant filter Seeenginemanual
Items in Measure See page Comments
fig. 1
Check/adjust engine valve clearance Seeenginemanual
16 Check the belt stretcher, engine Seeenginemanual
Every 1000 hours of operation (every six months)

10 CC 501/501C M501EN3
EVERY 10 HOURS OF OPERATION (Daily)
Open the drain tap at the bottom of the outer fuel filter
and drain off water and sediment until pure fuel flows
out. See also engine manual.
Fig.3 Water trap on the fuel filter
1. Drain cock
Brakes - Check
Check brake function:
Drive the roller slowly forward.
Press down the parking brake (11). The roller should
slow down and come to a standstill as the brake warn-
ing lamp (10) lights.
After checking the brakes, put the forward/reverse
lever (24) in neutral before resetting the parking brake.
Pull out the parking brake knob.
1
Take great care if the radiator cap must be
opened while the engine is hot.
Danger of being burned. Wear gloves and
safety goggles.
Fill with coolant comprised of 50% water and 50%
antifreeze. See page 3 in these instructions and the
enginemanual.
Change the coolant and flush the system every
other year. Ensure that air has free passage
through the radiator.
Coolant level - Checking,
filling(Circulationofcoolingair)
Fig.2 Radiator cap
Fig.4 Instrument panel
10. Brake warning lamp
11. Parking brake knob
24. Forward/Reverse lever
11
24
10
Water trap - Draining

11
CC 501/501C M501EN3
EVERY 10 HOURS OF OPERATION (Daily)
4
Use only clean water in the water tanks. Ensure that
the strainer (1) in the filler is fitted. Take out the strainer
and clean it as required.
Sprinkler system
- Checking, cleaning
1
Fig.5 Water tank
1. Strainer
Fig.6 Sprinkler system
1. Stop cock
2. Pressure filter housing
3. Water pump
Fig.7 Nozzle
1. Strainer
2. Rubber seal
3. Nozzle
4. Holder
2
31
Close the tap (1) and remove the housing of the
pressure filter (2), to clean the strainer and housing.
Check that water is sprayed evenly over the entire
surface of the drum. If any nozzle is not spraying
evenly, release the holder and take out the strainer,
rubber seal and nozzle; see figure 7 showing how the
parts are fitted.
Clean using compressed air or water.
Wear protective goggles when working with
compressed air.
1
3
2

12 CC 501/501C M501EN3
Adjust the scrapers to give a clearance of 1–2 mm
(0.04-0.08 in) along the entire width of the drum.
Unscrew the fastening screws (1).
Push the scraper (2) to the correct position, 1–2 mm
(0.04-0.08 in) from the drum (3).
Tighten the screws.
When the rubber/plastic has become so worn that the
scraper cannot be adjusted any more, lower the
scraper, unscrew the screws holding the blade, and
replace with a new one. Put the scraper back in position.
Scrapers -
Inspection and setting
2
23
Fig.8 Scraper setting
1. Fastening screw
2. Scraper
3. Drum
1
1
EVERY 10 HOURS OF OPERATION (Daily), cont’d
Tire scrapers
Checking - setting
Fig.9 Scraper setting
1. Scraper blade
2. Locking pin
3. Limit stop
Fig.10 Scraper setting
1. Scraper blade
2. Locking pin
Make sure that the scrapers (1) are against the tires
when compacting asphalt compounds. Pull out the
cotter (2) and lower the scraper blades (1) against the
tires. The screw (3) is an adjustable limit stop for the
scraper blades.
The scrapers must hang freely from the tires during
transport driving. Lift up the scraper blades (1) and
latch them in the raised position with the cotter (2).
1
3
2
1 2
1-2 mm
0.04-0.08 in
1-2 mm
0.04-0.08 in

13
CC 501/501C M501EN3
EVERY 10 HOURS OF OPERATION (Daily), cont’d
Hydraulic reservoir
- checking the fluid level
Stop the diesel engine while refueling. 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.
Refuel at the end of each working day up to the lower
edge of the filler pipe on the fuel tank.
Use diesel fuel recommended by the engine
manufacturer.
Place the roller on a level surface and check the fluid
level in the sight glass (1).
Top off with hydraulic fluid through the filler hole (2) if
the level is 20 mm (0.8 in) or more below the upper
edge of the sight glass.
Check that the strainer in the filler hole is intact.
Always secure the side covers WITH THE
SUPPORT (1) when they are opened.
Fig.12 Side covers
1. Support
Fig.13 Refueling
1. Filler pipe
1
1
1
2
Fig.11 Hydraulic reservoir
1. Sight glass
2. Filling
Fuel tank
-refueling
Securing the side covers

14 CC 501/501C M501EN3
EVERY 50 HOURS OF OPERATION (Weekly)
Tires - tire pressure
(CC501C)
Cleaning with
compressed air
Air cleaner - cleaning
thefilterelement Loosen the wing nut (1) at the center of the filter and
take off the cover (2).
Loosen the wing nut and pull out the main filter (3).
Remove the backup filter (7).
Ensure that dust has not penetrated the main filter and
wipe the filter housing (4) clean with a clean rag.
Ensure that the main filter and its rubber seals are intact.
Ensure that connections and hoses between the filter
housing and engine are intact and tight.
Clean the emptying slit of the dust trap (6).
Replace the backup filter (7) with a new one
after it has been cleaned three times and when
changing the main filter. The backup filter may
not be cleaned. The main filter may be cleaned a
maximum of 5 times before being replaced with
a new one.
7
4
3
Fig.14 Air cleaner
1. Wing nut
2. Cover
3. Main filter
4. Filter housing
5. Seal
6. Dust trap
7. Backup filter
6
1
2
5
1
Fig.15 Main filter
Check the tire pressure with a pressure gauge.
Ensure that the tires have equal pressure. Two valves
can be reached from the right side and two from the left
side.
Recommended pressure is 300–900 kPa (3–9 bar).
See also the diagram on page 5.
Use compressed air at a maximum pressure of 0.7
MPa (7 bar). Blow up and down the paper pleats on the
inside of the filter element. Hold the nozzle at least 20
mm (0.8 in) from the paper pleats so as to avoid tearing
the paper.
Wear protective goggles when working with
compressed air.
Fig.16 Wheel,right side
1. Air valves

15
CC 501/501C M501EN3
EVERY 50 HOURS OF OPERATION (Weekly), cont’d
Steering cylinder and steering
joint-lubrication Do not allow anyone near the steering joints
when the engine is running. Danger of being
crushed.
Wipe the nipples clean from grease and dirt.
Lubricate the steering cylinder mounts (1) with two
strokes of the grease gun and the horizontal and vertical
bearings of the steering joint (2) with five strokes each.
If grease does not penetrate the bearings, relieve load
on the articulation with a jack and repeat the greasing.
Ensure that grease penetrates the bearings and leave a
little grease on the nipples to prevent dirt from entering.
Ensure that the breather holes (1) in the hydraulic
reservoir cover are not clogged. Clean the cover with
diesel oil and blow dry with compressed air as required.
Wear protective goggles when working with
compressed air.
1
2
Rubber elements and fastening
screws - check
Hydraulic reservoir cover
- inspecting the breather holes
Fig.17 Drum
1. Rubber element
2. Fastening screw
Fig.18 Lubricantnipples
1. Steering cylinder mounts
2. Steering joint bearings
Fig.19 Reservoir cover
1. Breather hole
1
1
1
1
1
Max 76 mm (3 in)
2
Check all rubber elements (1), replace all of the ele-
ments if more than 25% of them on one side of the
drum are cracked deeper than 10–15 mm (0.4-0.6 in).
Use the blade of a knife or pointed object to assist
when checking.
Ensure that the fastening screws (2) are tightened.
With a caliper gauge, measure the length of the
rubber element including the mounting plates.
See separate workshop instructions if the size
is more than 76 mm (3 in).

16 CC 501/501C M501EN3
EVERY 50 HOURS OF OPERATION (Weekly), cont’d
If water and other contamination is visible in the bowl,
remove and clean it.
Unscrew the nut (1) and take the bowl (2) down.
Take out the gasket and strainer from the filter head.
Inspect and clean the parts in diesel oil. Reassemble.
Pump fuel with the hand pump and check for tightness.
Diesel engine pre-filter - draining
Fig.20 Pre-filter
1. Nut
2. Glass bowl
Fig.21 Electrolyte level in battery
1. Cell cap
2. Electrolyte level
3. Plate
2
1
Battery - check
Never use an open flame when checking the
electrolyte level. Explosive gas is generated
when the alternator is charging.
Wipe the top of the battery.
Wear safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.
Take off the cell caps and ensure that electrolyte is
about 10 mm (0.4 in) above the plates. Check the level
of all cells. Top off with distilled water to the right level if
the level is low. If the air temperature is below freezing,
the engine should be run for a while before topping up
with distilled water, there is otherwise a risk that the
battery fluid will freeze.
Ensure that the ventilation holes in the cell cover are
not clogged. Then put the cover back on.
The cable shoes should be clean and well tightened.
Clean corroded cable shoes and grease them with
acid-free Vaseline.
When disconnecting the battery, always discon-
nect the negative cable first.
When connecting the battery, always connect
the positive cable first.
Discarded used batteries properly. Batteries
contain lead, which is detrimental to the environ-
ment.
Before doing any electric welding on the
machine, disconnect the battery ground
cable and then all electrical connections to
the alternator.
1
2
3
10 mm
(0.4in)

17
CC 501/501C M501EN3
EVERY 250 HOURS OF OPERATION (Monthly)
Hydraulic system
- changing the filters Remove the filters and empty the fluid into the spill-oil
container. Discard the filters; they are disposable and
cannot be cleaned.
Ensure that the old gaskets do not remain on
the filter holders. Leakage may otherwise occur
between the new and the old sealing rings.
Thoroughly clean the sealing surfaces of the filter
holders.
Apply a thin coat of fresh hydraulic fluid to the new filter
gaskets.
Tighten the filters by hand. First, screw on until the filter
seal lies against the filter holder. Then screw a further
half-turn.
Do not tighten the filter too hard; this could
damage the seal.
Start the engine and ensure that no hydraulic fluid leaks
from the filters.
Ensure that ventilation (extraction) is ade-
quate if the engine is run indoors.
(Risk of carbon monoxide poisoning.)
Check the fluid level in the sight glass (2) and top off as
required.
When you read the filter indicator, the hydraulic fluid
should be warm and the engine running at full revs.
Ensure that the air flow through the radiator is unob-
structed. Clean a dirty radiator with water or com-
pressed air. Blow the radiator in the opposite direction
to that of the cooling air. Ensure that seals and noise
absorbers are not damaged by the cleaning operation.
Wear protective goggles when working with
compressed air.
Fig.22 Hydraulic fluid system
1. Filter
2. Sight glass
2
1

18 CC 501/501C M501EN3
1
3
Drum drive
- checking the oil level Place the roller on a level surface with the filler plug (1)
at its highest point.
Wipe clean around the plugs.
Remove the plugs and ensure that the oil level reaches
the level plug (2).
Top off with transmission oil as required, see the lubri-
cant specifications on page 3.
21
Fig.23 Pump drive
1. Filler plug
2. Level plug
Ensure that the roller is level.
Switch off the engine and apply the parking
brake/reserve brake.
Unscrew the level plug (2) on the right side of the pump
drive. The oil level should reach the lower edge of the
hole.
Top off with oil through the filler plug (1) until it starts to
run out from the level plug hole. See page 3 for the
grade of oil.
Clean and screw in the plugs tightly.
Pump drive
- checking the oil level
Fig.24 Drum drive
1. Filler plug
2. Level plug
3. Drain plug
EVERY 250 HOURS OF OPERATION (Monthly)
2