Dynapac CA500 Series Maintenance Manual
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Dynapac CA500 Series Maintenance Manual

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DYNAPAC
CA500
MAINTENANCE
M500EN1
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00, Fax: +46 455 30 60 30
www.dynapac.com

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  • Page 1 DYNAPAC CA500 MAINTENANCE M500EN1 Box 504, SE-371 23 Karlskrona, Sweden Phone: +46 455 30 60 00, Fax: +46 455 30 60 30 www.dynapac.com...
  • Page 2 ILF015WO1...
  • Page 3 CA500 PIN (S/N) *79290607* 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.

  • Page 4: Table Of Contents

    CONTENTS 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)..

  • Page 5: Lubricants And Symbols

    Shell Anti Freeze 402 or equivalent. 50/50 mixture with water Anti-freeze down to about -35°C (-31°F). Other lubricants are required for driving in extremely high or low ambient temperatures. See the “Special instructions” chapter, or consult Dynapac. Engine, oil level Air filter Engine, oil filter...

  • Page 6: Technical Specifications

    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)
  • Page 7 TECHNICAL SPECIFICATIONS Tightening torque Tightening torque in Nm (lbf.ft) for oiled, bright galvani- zed bolts tightened with a torque wrench. STRENGTH CLASS thread 10.9 12.9 8,4 (6.2) 12 (8.9) 14,6 (10.8) 21 (15.5) 28 (20.7) 34 (21.1) 40 (15.5) 56 (41.3) 68 (25.1) 70 (51.6) 98 (72.3)
  • Page 8 TECHNICAL SPECIFICATIONS Vibrations – Drivers seat The vibration values are measured in conformance (ISO 2631) 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/s Operator’s station, vibration, entire body (operator’s seat):...

  • Page 9: Maintenance Schedule

    MAINTENANCE SCHEDULE Fig. 1 Service points 1. Radiator grille 13. Scrapers 25. Draining, fuel tank 2. Oil level, diesel engine 14. Drum cartridge oil, level plug, x2 26. Engine suspension, x4 3. Fuel filter, fuel pre-filter 15. Rubber elements and fastening screws 27.

  • Page 10: Maintenance Measures

    MAINTENANCE MEASURES 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.

  • Page 11: Every 250 Hours Of Operation (Monthly)

    MAINTENANCE MEASURES Every 250 hours of operation (monthly) Items in Measure See page Comments fig. 1 Check the oil level in the rear axle/planetary gearing Change engine oil and oil filter See engine instruction manual Check oil level in the gearbox Accessory D/PD Check oil level in the drum cartridge 18, 19...
  • Page 12 EVERY 10 HOURS OF OPERATION (Daily) Scrapers – Checking/Adjusting 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).
  • Page 13 EVERY 10 HOURS OF OPERATION (Daily) Air circulation – Check 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.
  • Page 14 EVERY 10 HOURS OF OPERATION (Daily) Engine – 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. Observe caution.
  • Page 15 EVERY 10 HOURS OF OPERATION (Daily) Brakes – Check 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.
  • Page 16 EVERY 50 HOURS OF OPERATION (Weekly) Air cleaner – Checking/cleaning 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.
  • Page 17 EVERY 50 HOURS OF OPERATION (Weekly) Steering joint/Steering cylinders – Lubrication 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.
  • Page 18 EVERY 50 HOURS OF OPERATION (Weekly) 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.
  • Page 19 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.
  • Page 20 EVERY 250 HOURS OF OPERATION (Monthly) Drum gearbox – Checking the oil level Position 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.
  • Page 21 EVERY 250 HOURS OF OPERATION (Monthly) Drum cartridge Unscrew the level plug (3) at the bottom of the cart- ridge until the hole in the middle of the plug becomes visible. Top off with oil through the filling plug (1), until oil begins to run out from the level-plug hole.
  • Page 22 EVERY 250 HOURS OF OPERATION (Monthly) Coolers – Checking/cleaning Open the engine cover to gain access to the water and hydraulic coolers. Ensure that the flow of air through the coolers (1) and (2) is unobstructed. Clean a dirty radiator using compressed air or a high- pressure water jet.
  • Page 23 EVERY 250 HOURS OF OPERATION (Monthly) Battery – Checking the electrolyte level Never use an open flame when checking the electrolyte level. Explosive gas is gene- rated when the alternator is charging. Open the cover and release the quick-screws (1). Lift the battery cover (2).
  • Page 24 EVERY 500 HOURS OF OPERATION (Every three months) Fuel pre-filter – Cleaning 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. When water or sediment is visible in the plastic bowl (3) drain the bowl by opening the drain valve (2).
  • Page 25 EVERY 1000 HOURS OF OPERATION (Every six months) Hydraulic filter – Replacement 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. Loosen the cap/breather filter (2) on top of the reser- voir to relieve any excess pressure inside.
  • Page 26 EVERY 1000 HOURS OF OPERATION (Every six months) Hydraulic reservoir – Draining Condensation in the hydraulic reservoir is drained via the drain plug (1). Drain only after the roller has stood still during a long period, for example, overnight. Drain as follows: Remove the plug (2).
  • Page 27 EVERY 1000 HOURS OF OPERATION (Every six months) Rear axle differential – Oil change Never work under the roller with the engine running. Park on a level surface and block the wheels securely. Wipe clean and remove the level/filler plug (1) and all five drain plugs (2) and drain the oil into a suitable re- ceptacle.
  • Page 28 EVERY 1000 HOURS OF OPERATION (Every six months) Rear axle planetary gearing – Oil change Position the roller with the plug (1) at its lowest position. Wipe clean, unscrew the plug (1) and drain the oil into a suitable receptacle. The volume is about 2 litres (2.1 qts).
  • Page 29 EVERY 2000 HOURS OF OPERATION (Yearly) Hydraulic reservoir – Changing the fluid Place the roller on a level surface. Switch the engine off and push in the reserve/parking brake knob for all checking and adjust- ments on the roller, unless otherwise speci- fied.
  • Page 30 EVERY 2000 HOURS OF OPERATION (Yearly) Drum gearbox – Oil change Place the roller on a level surface with the plugs (1) and (2) as illustrated. Wipe clean, unscrew the plugs (1, 2 and 3) and drain the oil into a suitable receptacle, capacity about 3 liters (3.2 qts).

  • Page 31: Long-Term Storage

    LONG-TERM STORAGE Follow these instructions for storage longer than one month: The measures apply for a period of up to 6 months. The items marked * must be restored before using the roller. Fig. 46 Roller protected against the weather Diesel engine * See manufacturer’s instructions in the engine ma- nual that accompanies the roller.

  • Page 32: Special Instructions

    SPECIAL INSTRUCTIONS Standard oils and other recom- Upon delivery from the factory, the various systems mended fluids and components are filled with the oils specified see lubricant specification and they can be used at ambient temperatures from -10°C to +40°C (14°F - 104°F). A maximum temperature of +35°C (95°F) app- lies for biological hydraulic fluid.

  • Page 33: Electrical System, Fuses

    ELECTRICAL SYSTEM, FUSES Fuses and relays The electrical regulating and control system is protec- ted by fuses and relays. The number depends on how much additional equipment the machine is prepared for. The two fuse boxes (3, 4) and the relays (5, 6, 7, 8) are located behind the lower instrument plate, which is removed by unscrewing the screws (1 and 2).
  • Page 34 ELECTRICAL SYSTEM, FUSES Fuse boxes in steering column Fig. shows the rating and function of the different fuses. All fuses are flat pin fuses. Fig. 49 Fuse box, left side Fuse box, right side 7.5A 1. Hourmeter 7.5A 1. High/Low gear 7.5A 2.

This manual is also suitable for:

Ca500dCa500pd

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