Dynapac CA 262 Series Maintenance Manual Download Page 3

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Vibratory Roller

CA 262/362/512

Maintenance

M262EN2, August 2003

Diesel engine:

CA 262/362/512: Cummins 6BTAA 5.9C

These instructions apply from:

CA 262D

PIN (S/N) *67520262*

CA 262PD

PIN (S/N) *67620262*

CA 362D

PIN (S/N) *72420362*

CA 362PD

PIN (S/N) *72520362*

CA 512D

PIN (S/N) *70420512*

CA 512PD

PIN (S/N) *70520512*

Reservation for changes.

Printed in Sweden.

Dynapac’s medium-range vibratory soil compactors are the CA 262/362 and CA 512. They are

available in D (smooth drum) and PD (padfoot) versions, of which the CA 362D and CA 512D

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 is an optional feature of the machines, but is included in this manual. Other

accessories, such as the compaction meter, compaction computer and speed recorder, are

described in separate instructions.

KEEP THIS MANUAL FOR

FUTURE REFERENCE

Summary of Contents for CA 262 Series

Page 1: ...DYNAPAC CA 262 362 512 Box 504 SE 371 23 Karlskrona Sweden Telephone 46 455 30 60 00 Telefax 46 455 30 60 30 Web www dynapac com M262EN2 MAINTENANCE ...

Page 2: ...19 ILF015WO1 ...

Page 3: ...h drum and PD padfoot versions of which the CA 362D and CA 512D 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: ...d 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 to the diesel engine for which the manufacturer s instructions are detailed in the engine manual This is found under a separate flap in the roller s product binder CALIFORNIA Pr...

Page 5: ... 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 LUBRICANTS AND SYMBOLS Other fuel and lubricants are required for operation in extremely hig...

Page 6: ...ating mass with ROPS EN500 kg lbs 12950 28 555 15600 34 398 15800 34 839 Operating mass without ROPS kg lbs 12450 27 452 15100 33 295 15300 33 736 Operating mass with cab kg lbs 12950 28 554 15600 34 398 15800 34 839 Length standard equipped roller mm in 5702 224 6000 236 6000 236 Width standard equipped roller mm in 2384 94 2350 92 2350 92 Height with ROPS mm in 2977 117 2945 116 2987 118 Height ...

Page 7: ...h amplitude kN lb 300 67 500 300 67 500 300 67 500 Centrifugal force Low amplitude kN lb 146 32 850 238 53 550 238 53 550 Vibration data CA262D CA262PD CA362D Static linear load kg cm pli 25 5 143 37 5 210 Amplitude High mm in 1 7 0 066 1 6 0 062 1 7 0 066 Amplitude Low mm in 0 8 0 031 0 8 0 031 0 8 0 031 Frequency High amplitude Hz vpm 33 1980 33 1980 33 1980 Frequency Low amplitude Hz vpm 33 198...

Page 8: ...t treated ROPS ROPS bolts must always be tightened dry 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 Air conditioner Optional The...

Page 9: ...ame directive The limit value is 5 m s2 CA 262 362 112 86 77 CA 512 112 84 77 The acoustic values are measured in conformance with EU directive 2000 14 EC on EU equipped machines on soft polymer material with vibration switched ON and the operator s seat in transport mode Acoustic values Model Guaranteed acoustic power level dB A LwA Acoustic pressure level operator s ear platform dB A LpA Acousti...

Page 10: ...r 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 Diesel engine mountings 4 pcs 28 Feed pump fuel 29 Diesel fuel filler 30 Battery 31 Radiator 32 Hydraulic fl...

Page 11: ...ace 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 ...

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 the...

Page 13: ...king Adjustment Fig 2 Scrapers 1 Scraper blade 2 Screws x4 Fig 3 Scrapers 1 Scraper blade 2 Screws Fig 4 Scrapers 1 Screws 2 Scraper beam 3 Scraper teeth CA 362 512 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 CA 262PD 362PD 512PD Loosen the screws 1 then adjust the beam 2 to 25 mm between the teeth 3 and the drum ...

Page 14: ...g vents 1 Hood lock 1 Fig 5 Scrapers 1 Scraper blade 2 Screws CA 262 362 512 Soft scrapers Loosen the screws 2 and adjust to light contact against the drum Tighten the screws Fig 7 Radiator 1 Max level 2 Min level 3 Filler cap Check that level of the coolant is between the max and min marks Danger of scalding Take great caution if the radiator cap must be opened while the engine is hot Wear protec...

Page 15: ...efuel 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 ted part of the roller before refuelling and against the filler pipe 1 while refuelling Never refuel while the engine is running do not smoke and avoid spi...

Page 16: ...e lever 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 1 2 ...

Page 17: ...up 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 Fig 14 Air filter 4 Backup filter Backup filter Replacement 4 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: ...le rear right steering cylinder mount x1 5 Lubricating nipple rear left steering cylinder mount x1 1 Fig 16 Steering joint right side 1 Lubricating nipples steering joint x3 2 Lubricating nipple steering joint 512 on the left side on 262 362 3 Lubricating nipples cylinder mount x1 Wipe all the nipples clean from dirt and grease Lubricate each nipple 4 and 5 with two strokes of a grease gun Turn th...

Page 19: ... Air valve 2 Wheel nut 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 knob The filter is located on the left side in the front of the engine compartm...

Page 20: ...n 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 Optional CA262PD EVERY 50 HOURS OF OPERATION Weekly ...

Page 21: ...vel check differential housing 1 Oil level Filler plug Rear axle planetary gears Check oil level Fig 23 Oil level check planetary gear CA 262 362 Std 1 Oil level Filler plug 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 reaches the lower edge of the plug hole Top off with oil to the right level if t...

Page 22: ... 1 Indicator pin Wipe the filling plug and level plug clean from dirt Unscrew the filling plug 1 Fig 25 Oil level check Drum gearbox 1 Oil level plug 2 Filler plug 3 Drainplug Drum gearbox 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 Us...

Page 23: ...g with compressed air or a high pressure washer Fig 30 Engine room 1 Water cooler 2 Intercooler 3 Hydraulic fluid cooler Radiator Check clean 1 2 3 Fig 29 Drum 1 Ventilated screw Drum cartridge Cleaning the ventilation screw Clean the drum ventilation hole The hole is required to eliminate excess pressure inside the drum 1 Then unscrew the level plug 3 at the bottom of the cartridge until the hole...

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: ...imental to the envi ronment Before doing any electric welding on the machine disconnect the battery ground cable and then all electrical connections to the alternator EVERY 250 HOURS OF OPERATION Monthly Battery Check electrolyte level Make sure there are no open flame in the vicinity when checking the electrolyte level An explosive gas is formed in the battery during the charging process Lift up ...

Page 26: ...mmable fluid Reinstall the strainer and the bowl Start the engine and check that the pre filter does not leak Make sure there is adequate ventilation extraction if the diesel engine is run in doors Risk of carbon monoxide poisoning 3 2 1 Fig 38 Left side of engine 1 Drain plug 2 Oil filter Diesel engine Changing the filter and oil Position the roller on a level surface Stop the engine and apply th...

Page 27: ... forward tighten the screws and check the tension of the chain Seat bearing Lubrication 4 5 6 3 2 1 Fig 40 Seat bearing 1 Lubrication nipple 2 Cogwheel 3 Steering chain 4 Adjusting screw 5 Cover 6 Slide rails 7 Slew interlock 7 Fig 39 Underneath operator s position 1 Steering chain 2 Chain tightening device 3 Adjusting nut 4 Nuts 5 Control valve mount Steering chain and Seat bearing Lubrication Op...

Page 28: ...ers 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 oil leakage between the old and new seals Clean the filter holder sealing surfaces thoroughly Apply a thin film of hydraulic fluid on the seals of the new filter Screw on...

Page 29: ...f it has not yet been cleaned five times see under 50 hours for filter replacement If a clogged filter is not replaced the exhaust fumes will be black and the engine will loose power There will also be danger of severe damage to the engine 2 3 Fig 45 Air cleaner 1 Locking braces 2 Cover 3 Main filter 4 Backup filter 5 Filter housing 1 4 5 Air filter Replacement Never work under the roller with the...

Page 30: ... and deposit it in an approved manner Rear axle planetary gears Oil change Fig 47 Planetary gear drainage position 1 Plug 1 CA 512 CA 262 362 Std 1 Fig 48 Planetarygear fillingposition 1 Plug 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 the lubrication specification 1 CA 512...

Page 31: ...tive 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 1 EVERY 1000 HOURS OF OPERATION Every six months ...

Page 32: ... litres 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 ...

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 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 screws 1 S...

Page 34: ...tive 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 unobstructed so that condensation does not accumulate inside the unit Check the drain by squeezing the valves 2 underneath the...

Page 35: ...gh the sight glass it is a sign that the level of refrigerant is too low If so stop the unit There is a risk of damage to the unit if it is run with insufficient refrigerant 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 ...

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: ...t fuses All fuses are flat pin fuses The tachograph and memory for the radio are protected at the battery master disconnect switch by a 10A fuse 6 Fig 62 Fuse box left side 1 7 5A 1 Brake valve starter relay hourmeter 7 5A 2 VBS relay 7 5A 3 Indicating panel 7 5A 4 Horn 7 5A 5 Low High speed Strike off blade 3A 6 Reversing alarm Fuse box left side 2 7 5A 1 Instrumentation 3A 2 Compaction meter 7 5...

Page 39: ...ighting 40 A Orange Preheater supply relay 125 A Orange Fuses in the cab Fig 63 Fuse box overhead in cab 20A 1 Condenser fans cab roof 10A 2 Radio 5A 3 Cab interior lighting 25A 4 Air conditioner fan 10A 5 Rear screen wiper screen wash 10A 6 Front screen wiper screen wash 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...

Page 40: ...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 The control box 1 automatically regulates preheating of the diesel engine ie the box receives its activating signal from a temperature sensor on the engine intake pipe ...

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