Dynapac CA 152, CA 150 Workshop Manual

DYNAPAC

CA 150/152

WORKSHOP MANUAL

W1080EN1

CONVERTING DRUM

STD/D TO 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

CA 150/152

Workshop Manual,

Converting drum Std/D to P/PD

W1080EN1, January 2002

These instructions apply from:

CA 150 PIN (S/N) *64X20152*

2

CA 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
detrimental to the environment.

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

- Drilling machine

- 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 Fitting the pad half

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 Drilling through holes

2

4

CA 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 Fitting the pad half

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.

6

CA 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 pre­tensioned; 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 the teeth

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 dam­aged 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

8

CA 150/152 W1080EN1

DRAWING 38 53 45

9CA 150/152 W1080EN1

TOOLS, HEXAGONAL SOCKET WRENCH 38 55 04