Dynapac CA 252 Maintenance Manual Download Page 1

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DYNAPAC

CA 252/302/402

Box 504, SE-371 23 Karlskrona, Sweden

Telephone +46 455 30 60 00

Telefax +46 455 30 60 30

Web www.dynapac.com

M252EN6

MAINTENANCE

Summary of Contents for CA 252

Page 1: ...DYNAPAC CA 252 302 402 Box 504 SE 371 23 Karlskrona Sweden Telephone 46 455 30 60 00 Telefax 46 455 30 60 30 Web www dynapac com M252EN6 MAINTENANCE ...

Page 2: ...19 ILF015WO1 ...

Page 3: ...h drum and PD padfoot versions of which the CA 302D and CA 402D are designed for the compaction of rock fill The PD versions have their major range of application on cohesive material and disintegrated rock All types of base courses and subbase courses can be compacted deeper and the interchange able drums D to PD and vice versa facilitate even greater variety in the range of application The cab i...

Page 4: ...day before start ing up by checking all round and underneath the machine to detect any sign of leakage or other faults SPARE A THOUGHT FOR THE ENVIRONMENT Do not let oil fuel and other environmentally hazardous substances contami nate the environment This manual contains instructions for periodic measures that should normally be performed by the operator There are additional instructions relating ...

Page 5: ...140 or equivalent above 40 C above 104 F DRUM CARTRIDGE OIL Mobil SHC 629 GREASE SKF LGHB2 NLGI Class 2 or equivalent for the articulated joint Shell Retinax LX2 or equivalent for other grease points FUEL See the engine manual COOLANT GlycoShell or equivalent mixed 50 50 with water Anti freeze protection down to about 41 C 106 F Other fuel and lubricants are required for operation in extremely hig...

Page 6: ...3800 30 429 Length standard equipped roller mm in 5550 218 5550 218 5550 218 Width standard equipped roller mm in 2384 94 2384 94 2424 95 Height with ROPS mm in 2924 115 2977 117 2924 115 Height without ROPS mm in 2190 86 2210 87 2190 86 Height with cab mm in 2952 116 2965 117 2952 116 Fluid volumes litres gal or qts CA 252 302 402 Rear axle Differential 12 12 7 qts Planetary gears 2 0 2 1 qts sid...

Page 7: ...e High amplitude kN lb 300 67 500 300 67 500 300 67 500 Centrifugal force Low amplitude kN lb 146 32 850 146 32 850 146 32 850 Vibration data CA252 CA252D CA252PD Static linear load kg cm pli 24 2 136 25 1 141 Amplitude High mm in 1 7 0 066 1 7 0 066 1 6 0 062 Amplitude Low mm in 0 8 0 031 0 8 0 031 0 8 0 031 Frequency High amplitude Hz vpm 33 33 1980 33 33 1980 33 33 1980 Centrifugal force High a...

Page 8: ... 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 galvanized bolts tightened with a torque wrench Hydraulic system Bolt size M24 P N 90 39 64 Strength class 10 9 Tighteningtorque 800 Nm 590 lbf ft for Dacromet treated ROPS The system described in this manual is of the ACC type Automatic Climate Control ie a system that m...

Page 9: ...tive The limit value is 5 m s2 TECHNICAL SPECIFICATIONS CA 252 302 402 108 79 75 The acoustic values are measured in conformance with the operation cycle described in EU directive 2000 14 EC on EU equipped machines on soft polymer material with vibration switched ON and operator s seat in the transport mode Acoustic values Model Guaranteed acoustic power level dB A LwA Acoustic pressure level oper...

Page 10: ...rum cartridge filling 2 fillers 13 Drum gearbox 14 Scrapers 15 Drum cartridge oil level plugs 2 pcs 16 Rubber elements and attachment screws 17 Steering joint 18 Steering cylinders 2 pcs 19 Flywheel casing hydraulic pumps 20 Wheel nuts 21 Tires pressure 22 Rear axle differential 23 Rear axle planetary gears 2 pcs 24 Rear axle suspension 2 sides 25 Oil filter diesel engine 26 Drainage fuel tank 27 ...

Page 11: ...e as required 17 Lubricate steering joint 16 18 Lubricate steering cylinders attachments 16 20 Check the wheel nuts are tightened 17 New machine only 21 Check tire pressure 17 38 Inspect the air conditioning 17 Optional Lubricate the strike off blade bearings 18 Optional After the first 50 hours of operation change only the drum oil and all the oil filters Every 50 hours of operation Weekly The pe...

Page 12: ... of operation Monthly Item in Measure See page Comments fig 1 7 Check bleeder filter on hydraulic reservoir 26 8 Change hydraulic fluid filter 26 9 Drain condensate from hydraulic reservoir 26 26 Drain condensate from fuel tank 27 4 Replace air cleaner main filter 27 22 Change oil in rear axle differential 27 23 Change oil in the rear axle planetary gearing 28 39 Replace the fresh air filter in th...

Page 13: ...he values stated If necessary adjust distance to the drum as follows CA 252 5Loosen the screws 2 and adjust the scraper 1 to 20 mm from the drum Tighten the screws Fig 3 Scrapers 1 Scraper blade 2 Screws CA 302 402 Loosen the screws 2 and adjust the scraper 1 to 20 mm from the drum Tighten the screws Repeat the procedure on the other scraper Fig 4 Scrapers 1 Screws 2 Scraper beam 3 Scraper teeth C...

Page 14: ...h the radiator 1 3 2 Coolant level Check EVERY 10 HOURS OF OPERATION Daily CA 252 402 Soft scrapers Optional Loosen the screws 2 and adjust to light contact against the drum Tighten the screws 2 1 1 2 Fig 5 Scrapers 1 Scraper blade 2 Screws Ensure that the engine has free circulation of cooling air through the vents in the hood To open the engine hood turn the locking arms upward 1 and raise the h...

Page 15: ...de of the engine Pull up the dipstick 1 and check that the oil level is between the upper and lower marks For further details refer to the engine manual Refuel daily with diesel fuel up to the lower edge of the filler pipe 1 Follow the engine manufacturer s specification with regard to the quality of diesel fuel Switch off the diesel engine Short circuit press the filler gun against a non insula t...

Page 16: ...e lever 1 2 Check operation of the brakes as follows Drive the roller slowly forward Push the reserve parking brake knob 1 the warning lamp on the instrument panel should light and the roller should stop After testing the brakes set the forward reverse lever 2 in neutral Pull up the reserve parking brake knob The roller is now ready for operation ...

Page 17: ...er The backup filter cannot be cleaned When replacing the backup filter 4 pull out the old fil ter from its holder insert a new one and refit the air cleaner in the reverse order to the instructions given in the figure above If the main filter is to be cleaned compressed air at max 5 bar 72 psi pressure should be used Blow up and down along the paper creases on the inside of the filter Hold the no...

Page 18: ...ering is operated Push the reserve parking brake knob before lubricating Turn the steering wheel fully to the left to gain access to all lubricating nipples of the steering system on the right hand side of the machine x6 Use grease as per the lubricant specification Wipe all the nipples clean from dirt and grease Lubricate each nipple 4 and 5 with two strokes of a grease gun Turn the steering whee...

Page 19: ...fitted wheels Check the safety manual that accompanies the roller before filling the tires with air Never work under the roller with the engi ne running Park on a level surface chock the wheels and press the parking brake control Open the engine hood while the unit is running and look at the sight glass 1 to make sure that no bubbles are visible on the dryer filter Always push the parking brake kn...

Page 20: ...when operating the blade Lower the blade Wipe the nipples clean from grease and dirt three on each side of the machine Grease each nipple 1 with four strokes of the grease gun Ensure that grease penetrates the bearings Fig 21 Strike off blade 1 Lubricant nipples 1 Strike off blade Lubrication OptionalPD EVERY 50 HOURS OF OPERATION Weekly ...

Page 21: ... Block the wheels securely Wipe clean and remove the level plug 1 and check that the oil level reaches the lower edge of the plug hole Top off with oil to the right level if the level is low Use transmission oil according to the lubricant specification Position the roller with the level plug 1 in the planetary gears at 9 o clock Wipe clean and remove the level plug 1 and check that the oil level r...

Page 22: ... Check oil level 1 2 Wipe clean the area around the plug 1 and then undo the plug Ensure that the oil level reaches up to the lower edge of the plug hole Top off with oil to the right level if the level is low Use transmission oil according to the lubricant specification Position the roller with the filler plugs 2 straight up Clean and screw in the plugs tightly 3 Fig 27 Roller right hand side 1 F...

Page 23: ...natively cleaned with a high pressure washer Blow or wash the cooler in the opposite direction to that of the cooling air Be careful when using a high pressure washer do not place the nozzle too close to the radiator Use protective goggles when working with compressed air or a high pressure washer Clean the drum ventilation hole The hole is required to eliminate excess pressure inside the drum The...

Page 24: ...htened 78 Nm 57 lbf ft Wheel nuts 4 Check that all nuts are tightened 470 Nm 347 lbf ft oiled The above applies to new or replaced components only Check all the rubber elements 1 and replace them all if more than 25 of the elements on the same side of the roller have cracks deeper than 10 15 mm 0 4 0 6 in Use a knife blade or other pointed tool when carrying out this check Check also that the scre...

Page 25: ...ers The cable terminals must be properly tightened and clean Corroded cable connections should be cleaned and greased with alkaline Vaseline When disconnecting the battery always disconnect the negative cable first When connecting the battery always connect the positive cable first Discard used batteries properly Batteries contain lead which is detrimental to the envi ronment Before doing any elec...

Page 26: ...oil Position the roller on a level surface Stop the engine and apply the parking brake reserve brake The oil drain plug 1 is most easily accessible from underneath the engine Drain the oil when the engine is warm Place a receptacle for at least 15 litres 16 qts underneath the drain plug Observe caution when draining hot oil Protect your hands Change the engine oil filter 2 at the same time See als...

Page 27: ...e gun Lubricate the seat locking latch 7 accessible from below Also grease the slide rails of the seat 6 If the seat begins to bind when resetting it needs to be lubricated more often Clean and grease the chain 3 between the seat and the steering column If the chain becomes slack on the cogwheel 2 loosen the screws 4 and move the steering column forward tighten the screws and check the tension of ...

Page 28: ...r until the blockage disappears or replace the cover with a new one Always use protective goggles when work ing with compressed air Clean thoroughly around the oil filters Remove the oil filters 1 and dispose of them in an approved manner They are single use filters and cannot be cleaned Check that the old sealing rings do not remain stuck on the filter holders otherwise this might give rise to oi...

Page 29: ... will gather near the drainage plug 1 Drain as follows Place a container under the plug 1 Undo the plug and drain off the water and sediment until only clean diesel fuel appears through the plug opening Refit the plug Replace the main filter 3 of the air cleaner even if it has not yet been cleaned five times see under 50 hours for filter replacement If a clogged filter is not replaced the exhaust ...

Page 30: ...ptional 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 Save the oil and deposit it in an approved manner Position the roller with the plug at 9 o clock Fill with oil to lower edge of level hole Refit the plug and repeat the process on the other side Use transmission oil See t...

Page 31: ...Use a stepladder to reach the filter 1 As an alternative the filter can be reached via the cab window on the right side Loosen the two screws 2 at the rear of the cab roof Take down the whole holder and remove the filter insert Replace with a new filter It may be necessary to replace the filter more often if the machine is used in a dusty environment ...

Page 32: ...res 16 gal A suitable container may be an empty oil drum or similar item which is placed beside the roller The fluid then runs in a hose from the drainage plug 1 to the oil drum after the plug 2 has been removed and the tap opened Save the oil and deposit it in an approved manner Fill up with fresh hydraulic fluid as per the instructions under the heading Hydraulic reservoir Check fluid level Repl...

Page 33: ...h oil up to the level plug 3 according to Drum gearbox Checking the oil level Use transmission oil see Lubricant Specification Clean and refit the level plug 3 and filler plug 2 2 1 3 Forward Reverse lever Lubrication Fig 54 Forward Reverse lever 1 Screw 2 Plate 3 Cam disk 1 2 3 Unscrew the screws 1 and remove the plate 2 Grease the contact surface of the cam disc 3 Refit the plate 2 with the scre...

Page 34: ...he aid of compressed air Blow from above The air jet could damage the flanges of the elements if it is too powerful Wear protective goggles when working with compressed air Inspect the fastening of the condenser element Clean the cooler unit and the cooling elements 1 free from dust with the aid of compressed air Inspect the system hoses for chafing Make sure that drainage from the cooling unit is...

Page 35: ... Check the moisture indicator 2 The color should be blue if it is beige the dryer cartridge must be replaced by an authorized service company The compressor will be damaged if the unit is run with too little refrigerant Do not disconnect the hose coupling The cooling system is pressurized Incorrect handling can result in serious personal injuries The system contains pressurized refriger ant Releas...

Page 36: ...ture from penetrating into the engine Fill the fuel tank completely to prevent condensation Drain off any condensation water and fill the hydrau lic reservoir to the upper mark Lubricate the steering joint bearings and the steering cylinder s two bearings with grease Grease the steering cylinder s piston with conservation grease Grease also the engine compartment cover s hin ges the seat slide rai...

Page 37: ...nk covers This is particularly important when using a high pressure washing unit Do not spray water directly on electric components or the instrument panel Put a plastic bag over the filler cap of the fuel tank and secure with a rubber band This will prevent water from entering the venting hole in the filler cap This could otherwise cause operational disturbance for example a clogged filter If the...

Page 38: ...in fuse 7 5A 3 Position light left front and rear 5A 4 Position light right front and rear 5A 5 Direction indicator left front rear and side 5A 6 Direction indicator right front rear and side When driving lights are fitted Optional The electrical regulating and control system is protected against overload by 27 fuses and 12 relays The number depends on how much extra equipment is fitted on the mac...

Page 39: ...ere Fuses in the cab The electric system in the cab is equipped with its own fuse box located overhead at the front right part of the cab The figure shows the ampere rating and function of the different fuses All fuses are of the flat pin type Relays Fig 65 Instrument panel 1 2 3 Fig 63 Fuse box overhead in cab 20A 1 Condenser fans cab roof 10A 2 Radio 5A 3 Cab interior lighting 25A 4 Air conditio...

Page 40: ...Fig 66 Cab roof front 1 Instrument plate 2 K30 Relay for air conditioner fan 3 K31 Relay for condenser fans radio 4 Fuse box Unscrew the instrument plate 1 to replace the relays for air conditioner fan and condenser fan on the cab roof and radio Relays in cab ...

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