Dynapac Vibratory roller CA 250. Operation & Maintenance (2003)

Vibratory roller

CA 250

Maintenance

M250EN3, April 2003

Diesel engine:

CA 250: Cummins 4BTAA 3.9C

These instructions apply from:

CA 250

PIN (S/N) *65720251*

CA 250D

PIN (S/N) *65820251*

CA 250PD PIN (S/N) *65920251*

CA 250P PIN (S/N) *66020251*

Dynapac's medium heavy vibratory soil compactor is the CA 250.

This compactor is available in (smooth drum), P (padfoot) and PD versions respectively.

Both the P and PD versions are used mainly on cohesive material and disintegrated rock.

All types of base courses and subbase courses can be compacted deeper and the interchangeable

drums, ie, std to P, D to PD and vice versa, facilitate even greater variety in the range of

application.

The cab and safety-related accessories are described in this manual. Other accessories,

such as compaction meter, speed recorder and CCS/RA field computer,

are described in separate instructions.

Reservation for changes.

Printed in Sweden.

CONTENTS

Page

Lubricants and symbols

Technical specifications

4-6

Maintenance schedule

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)

Every 1000 hours of operation (Every six months) .. 23-26

Every 2000 hours of operation (Yearly)

27, 28

Long-term Storage

Special instructions

Electrical system, fuses

31, 32

WARNING SYMBOLS

Safety instructions—Personal safety

Special caution—Machine or component damage

GENERAL

Read the entire manual before starting any

service work.

Ensure that ventilation (extraction) is adequa-

te if the engine is run indoors.

It is essential that the machine is cared for in a proper

manner to ensure satisfactory operation. Keep the

machine clean to facilitate quick and timely detection of

any leakage, loose bolts and loose connections.

Make a habit each day, before starting up, of checking the

roller to detect any leakage or damage. Also check the

ground underneath the roller, where it is most often easier

to detect any leakage.

TAKE CARE OF THE ENVIRONMENT

Do not leave behind any oil, fuel or other

CALIFORNIA

substances that are detrimental to the

environment.

Proposition 65 Warning

This manual contains instructions for periodic measures

Diesel engine exhaust and some of its

that should normally be performed by the operator.

constituents are known to the State of

California to cause cancer, birth defects,

The manufacturer’s instructions noted in the

and other reproductive harm.

engine manual also apply. This is placed under a

separate flap in the roller’s product folder.

CA 250 M250EN3

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

Shell Rimula Super 15W/40 or equivalent

API Service CH-4 (CG-4)

HYDRAULIC FLUID

ambient temperature

-10° C - +40° C (14°F - 104°F)

Shell Tellus TX68 or equivalent

ambient temperature higher than +40° C

Shell Tellus T100 or equivalent

TRANSMISSION OIL

lambient temperature

Shell Spirax SAE 80W/90, HD API, GL-5

-15°C - +40°C (5°F - 104°F)

ambient temperature

Shell Spirax HD85W/140 or equivalent

higher than +40°C (above 104°F)

DRUM-CARTRIDGE OIL

Synthetic oil, MOBIL SHC 629.

GREASE

Shell LGHB2 (NLGI-class 2) or equivalent for

the articulation.

Shell Retinax LX2 or equivalent for other

grease points.

FUEL

See engine manual

COOLANT

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

Battery

Hydraulic reservoir, level

Tire pressure

Hydraulic fluid filter

Drum, oil level

Transmission, oil level

Coolant, level

Lubricating oil

Recycling

Fuel filter

CA 250 M250EN3

TECHNICAL SPECIFICATIONS

Weight and sizes

CA250

CA250D

CA250PD CA250P

Operating mass with ROPS,

EN500, kg (lbs)

10600 (23,400)10800 (23,800)12200 (26,900)12000 (26,500)

Operating mass without ROPS, kg (lbs) . 10235 (22,600) 10435 (23,000) 11835 (26,100)

11635 (25,700)

Operating mass with cab, kg (lbs)

10735 (23,700) 10935 (24,100) 12335 (27,200)

12135 (26,800)

Length, standard-equipped

roller, mm (in)

5 550 (219)

Width, standard-equipped roller, mm (in) 2 384 (94)

2 384 (94)

Height, with ROPS, mm (in)

2 922 (115)

2 977 (117)

Height, with ROPS/silencer, mm (in)

2 190 (86)

2 210 (87)

Height, with cab, mm (in)

2 952 (116)

2 965 (117)

Fluid volumes (Liters)

(gal or qts)

Rear axle:

• Differential

(12.7 qts)

• Planetary gearing

1,7/side

(1.8 qts) /each side

Drum gearing

3,0

(3.2 qts)

Cartridge, vibration generator

2,2/side

(2.8 qts) /each side

Hydraulic reservoir

(13.7 gal)

Fluid in hydraulic system

(6 gal)

Lubricating oil, Diesel engine

(10.6 qts)

Coolant, Diesel engine

(6.3 gal)

Fuel tank

250

(66 gal)

Electrical system

Battery

12 V, 170 Ah

Alternator

14 V, 63A

Fuses

See under main heading: Electrical system

Tires

Tire size

23.1 x 26.0 8 Ply, 600/60-30,5

Air pressure

110 kPa (1,1 kp/cm²)

As extra equipment, the tires can be filled with liquid (extra weight up to 700 kg/tire)

(1543 lbs/tire). Remember this extra weight when you perform service.

Compaction data

CA250

CA250D

CA250PD/P

Static linear load

kg/cm (pli)

28,1 (157.4)

29,1 (163)

Amplitude (High)

mm (in)

1,7 (0.067)

1,6 (0.063)

Amplitude (Low)

mm (in)

0,8 (0.031)

Frequency (High amplitude)

Hz (vpm)

33 (1980)

Frequency (Low amplitude)

Hz (vpm)

33 (1980)

Centrifugal force (High amplitude)

kN (lb)

246 (55,350)

246(55,350)

300 (67,500)

Centrifugal force (Low amplitude)

kN (lb)

113 (25,425)

146 (36,500)

CA 250 M250EN3

TECHNICAL SPECIFICATIONS

Tightening torque

Tightening torque in Nm (lbf.ft) for oiled, bright

galvanized bolts tightened with a torque wrench.

STRENGTH CLASS

thread

8.8

10.9

12.9

8,4 (6.2)

12 (8.9)

14,6 (10.8)

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)

ROPS

ROPS bolts must always be tightened dry.

Bolt size:

M24 (P/N 90 39 64)

Strength class:

10.9

Tightening torque:

800 Nm (for Dacromet treated)

Hydraulic system

Opening pressure, MPa (psi)

Drive system

38,0 (5,500)

Charge system

2,0 (290)

Vibration system

42,5 (6,150)

Steering system

18,0 (2,600)

Brake release

1,4 (200)

CA 250 M250EN3

TECHNICAL SPECIFICATIONS

Vibrations - Drivers seat

The vibration values are measured in conformance

(ISO 2631)

with the operation cycle described in EU directive

2003/14/EC on EU-equipped machines, on soft

polymer material with vibration switched ON and

operator’s seat in the transport mode.

Operator’s station, vibration, hand/arm

(steering wheel/lever):

Below limit value.

Limit value: <2.5 m/s2.

Operator’s station, vibration, entire body

(operator’s seat):

Below limit value.

Limit value: <0.5 m/s2.

Vibration levels may vary when driving on

different courses and with different seat

positions.

Acoustic values

The acoustic values are measured in conformance with the operation

cycle described in EU directive 2003/14/EC on EU-equipped

machines, on soft polymer material with vibration switched ON and

operator’s seat in the transport mode.

Model

Guaranteed

Acoustic

acoustic

pressure level,

power level

operator’s ear

dB(A) LwA

(platform)

(cab) dB(A)

dB(A) LpA

LpA

CA 250

109

Noise level can vary when driving on different

courses and with different seat positions.

CA 250 M250EN3

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. Feed pump, fuel

4. Air filter

16. Steering joint

28. Diesel fuel, filling

5. Hydraulic reservoir, sight glass

17. Steering cylinder, x2

29. Battery

6. Breather filter

18. Flywheel casing, hydraulic pumps

30. Radiator

7. Hydraulic filter, x1

19. Wheel nuts

31. Hydraulic fluid cooler

8. Drain hydraulic reservoir

20. Tire pressure

32. Drive belts, cooling, alternator

9. Hydraulic fluid, filling

21. Rear axle, differential

33. Forward/Reverse lever

10..Fuse box

22. Rear axle, planetary gearing, x2

11. Drum cartridge oil filler, x2

23. Rear axle suspension, two sides

12. Drum gearbox

24. Oil filter, diesel engine

CA 250 M250EN3

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.

Every 10 hours of operation (daily)

Items in

Measure

See page

Comments

fig. 1

Before starting up

Check the scraper setting

10, 11

Check for free circulation of cooling air

Check coolant level

See engine instruction manual

Check oil level in the engine

See engine instruction manual

Refuel

Check the hydraulic reservoir level

Test the brakes

Every 50 hours of operation (weekly)

Items in

Measure

See page

Comments

fig. 1

Check that hoses and connections are tight

Control/clean the filter element in the air cleaner

Replace as required

Grease the steering joints

Grease the steering cylinder brackets

Check tightness of the wheel nuts

Check the tire pressure

After the first 50 hours of operation change only the drum oil and all the oil filters.

CA 250 M250EN3

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 17

Check oil level in the gearbox

Accessory D/PD

Check oil level in the drum cartridge

18, 19

Clean the coolers

19, 23

Inspect tightening of bolted joints

Applies only to new or

renovated component.

Check rubber elements and bolted joints

Check the battery

Every 500 hours of operation (every three months)

Items in

Measure

See page

Comments

fig. 1

Change engine oil and oil filter

See engine instruction manual

Replace fuel filter

See engine instruction manual

Clean the initial fuel filter

Inspect breather filter on the hydraulic reservoir 23

Every 1000 hours of operation (every six months)

Items in

Measure

See page

Comments

fig. 1

Change the hydraulic filter

Drain condensation from the hydraulic reservoir 24

Drain condensation from the fuel tank

Replace main filter in the air cleaner

Change oil in the rear axle differential

Change oil in the rear axle planetary gearing

Check engine valve clearance

See engine instruction manual

Check belt tension of drive system

See engine instruction manual

Every 2000 hours of operation (yearly)

Items in

Measure

See page

Comments

fig. 1

8, 9

Change the hydraulic fluid

Change oil in the drum cartridge

Change oil in the drum gearbox

Accessory D/PD

Lubricate the Forward/Reverse controls

CA 250 M250EN3

EVERY 10 HOURS OF OPERATION (Daily)

Scrapers

- Checking/Adjusting

Remember that the drum tends to move as the

machine turns. Consequently, if adjustments

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).

Tighten the screws.

Fig. 2

Scrapers

1. Scraper blade

2. Screws (x4)

CA 250 Double steel scrapers (Optional)

Loosen the screws (2) and adjust the scraper blade to

20 mm (0.8 in). Tighten the screws.

Repeat the procedure on the other scraper.

Fig. 3

Scrapers

1. Scraper blade

2. Screws

CA 250 P/PD

Loosen the screws (1), then adjust the beam (2) to 25

mm (1.0 in) between the teeth (3) and the drum.

Tighten the screws (1).

Fig. 4

Scrapers

1. Screws

2. Scraper beam

3. Scraper tooth

CA 250 M250EN3

EVERY 10 HOURS OF OPERATION (Daily)

CA 250 Soft scrapers (Optional)

Loosen the screws (2) and adjust to give light contact

with the drum. Tighten the screws.

Fig. 5

Scrapers

1. Scraper blade

2. Screws

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. The engine must be switched off. Wear

gloves and safety goggles.

Fig. 6

Cooling air grille

1. Filler cap (coolant)

Ensure that coolant level is between the max/min

marks.

The coolant tank is located above the engine cooling

fan and is best visible from the left side of the roller.

The filler cap (3) is accessible from the top of the

engine hood, see figure above.

Fill with coolant consisting of 50% water and 50%

antifreeze. See page 3 in these instructions and the

engine manual.

Change the coolant and flush the system

every other year. Ensure that air has free

Fig. 7

Radiator

1. Max. level

passage through the radiator. To bleed the

2. Min. level

system, run the engine warm and increase

3. Filler cap

speed to maximum revs, then switch off the

engine and top up to the correct level.

CA 250 M250EN3

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. Beware of hot parts of

the engine and hot radiator when taking

out the oil dipstick. Wear gloves and safety

goggles.

The dipstick is on the right-hand side of the engine.

Pull the dipstick (1) up and check that the oil level is

between the upper and lower marks. See the engine

Fig. 8

Engine compartment

manual for further details.

1. Oil dipstick

Fuel tank - Refueling

Refuel every day. Top off to the lower edge of the filler

pipe. Use diesel fuel in accordance with the engine

manufacturer’s specifications.

Stop the diesel engine. 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.

The fuel tank holds 250 litres (66 gal).

Check that there is no sediment or water in the

fuel pre-filter (2).

Fig. 9

Fuel tank

Clean the pre-filter if required, see under "500

1. Filler pipe

hours of operation".

2. Fuel pre-filter

Hydraulic reservoir

– Checking the fluid level

Place the roller on level ground and check that the fluid

level is between the max. and min. marks in the sight

glass (1). Top off with hydraulic fluid according to the

lubricant specification if the level is too low.

Fig. 10

Hydraulic reservoir

1. Sight glass

2. Filler pipe

CA 250 M250EN3

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.

Pull out the reserve/parking brake knob.

The roller is now ready for operation.

Fig. 11

Control panel

1. Reserve/parking brake knob

2. Forward/reverse lever

3. Brake warning lamp

CA 250 M250EN3

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/

parking brake knob for all checking and

adjustments on the roller, unless otherwise

specified.

Replace or clean the main filter of the air

cleaner when the warning lamp on the instru-

ment panel lights at full engine revs.

Release the three locking braces (1) and pull off the

Fig. 12

Air cleaner

cover (2) and take out the main filter (3).

1. Locking braces

2. Cover

Do not remove the backup filter (4).

3. Main filter

4. Backup filter

5. Filter housing

Main filter - Cleaning with

compressed air

To clean the main filter, blow up and down along the

paper pleats with compressed air at maximum 5 bar

(72 psi) pressure.

Hold the nozzle at least 2-3 cm (0.8-1.2 in) from the

paper pleats to avoid tearing the paper.

Wear protective goggles when working

with compressed air.

Wipe the inside of the cover (2) and filter housing (5).

Check that the hose clamps between the filter

Fig. 13

Main filter

housing and suction hose are tight and that the

hoses are intact. Inspect all hoses all the way

to the engine.

Change the main filter at the latest after 5

cleanings.

Backup filter

- Replacement

Replace the backup filter with a new one after every

fifth replacement or cleaning of the main filter. The

secondary filter cannot be cleaned.

To change the backup filter (4), pull the old filter out of

its holder, insert a new one and reassemble the air

cleaner in the reverse order in relation to the

instructions in the figure above.

Fig. 14

Air filter

4. Backup filter

CA 250 M250EN3

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. Danger of

being crushed when steering is operated.

Push the reserve/parking brake knob be-

fore lubricating.

Turn the steering wheel fully to the left to gain access to

all six nipples on the right side of the steering system.

Fig. 15

Steering joint, right side

Use grease according to the lubricant

specification.

Steering joint

- Lubrication

Wipe the nipples clean from grease and dirt.

Grease each nipple (1 and 2) with five strokes of the

grease gun. Ensure that grease penetrates the

bearings.

If grease does not penetrate the bearings, it

may be necessary to relieve the articulation

joint with a jack while repeating the greasing

process.

Fig. 16

Steering joint, right side

1. Grease nipples, steering joint (x4)

2. Grease nipple, cylinder mount (x1)

Steering cylinders

– Lubrication

Wipe the nipples clean from grease and dirt.

Grease the nipples (3 and 4) with five strokes of the

grease gun.

Turn the steering wheel fully to the right to gain access

to the forward grease nipple on the left steering cylinder

and the nipple on the bearing cover. Allow a little grease

to remain on the nipples after greasing. This will prevent

contamination from entering the nipples.

Fig. 17

Steering cylinder, right side

3. Lubricant nipple right rear

steering cylinder mount (x1)

4. Lubricant nipple left rear steering

cylinder mount (x1)

CA 250 M250EN3

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.

Tire pressure is noted under the heading Specifica-

tions.

Check both tires.

When you change the tires, it is important that

both tires have the same rolling radius, to

ensure proper operation of the anti-slip device

in the rear axle.

Fig. 18

Wheels

1. Air valve

Check tightening torque of the wheel nuts (2) at 470

2. Wheel nut

Nm (350 lbf.ft).

Check both wheels and all nuts.

(Applies only on new machine or newly fitted wheels.)

When pumping the tires, see the safety

manual that accompanies the roller.

The wheel is heavier than normal when the

tyres are filled with liquid.

CA 250 M250EN3

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 engi-

ne running. Park on a level surface. Block

the wheels securely.

Wipe clean, remove the level plug (1) and check that

the oil level reaches the lower edge of the plug hole.

Top off to the right level if the level is low. Use trans-

mission oil. See lubricant specification.

Fig. 19

Level check—differential housing

1. Level/Filler plug

Rear axle planetary gearing

- Checking the oil level

Position the roller with the plug (1) in the planetary

gearing at 9 o'clock.

Wipe clean, remove the level plug and check that the oil

level reaches the lower edge of the plug hole. Top off to

the right level if the level is low. Use transmission oil.

See lubricant specification.

Check the oil level in the same way in the other plan-

etary gearing of the rear axle.

Fig. 20

Level check

- planetary gearing, std

1. Level/Filler plug

Fig. 21

Level check

- planetary gearing, accessory

1. Level/Filler plug

CA 250 M250EN3

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.

Top off to the right level if the level is low. Use trans-

mission oil according to the lubricant specification.

Clean and screw in the plugs tight.

Fig. 22

Level check - drum gearbox

1. Level plug

2. Filler plug

3. Drain plug

Drum cartridge

- Checking the oil level

Position the machine level so that the indicator pin (1)

on the inside of the drum is aligned with the top of the

drum frame.

Fig. 23

Left side of drum

1. Indicator pin

Drum cartridge

- Checking the oil level

Wipe the filling plug and level plug clean from dirt.

Unscrew the filling plug (1).

Fig. 24

Roller, right-hand side

1. Filler plug

2. Drain plug

3. Level plug

CA 250 M250EN3

EVERY 250 HOURS OF OPERATION (Monthly)

Drum cartridge

Unscrew the level plug (3) at the bottom of the cartridge

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. The level is correct

when it stops running.

Ensure that only MOBIL SHC 629 is used in

the cartridges.

Clean and refit the plugs. Repeat the procedure on the

opposite side.

Fig. 25

Drum cartridge

2. Drain plug

Do not overfill with oil - risk for overheating.

3. Level plug

Drum cartridge

- Cleaning the ventilation screw

Clean the drum ventilation hole. The hole is required to

eliminate excess pressure inside the drum.

Fig. 26

Drum

1. Ventilated screw

CA 250 M250EN3

EVERY 250 HOURS OF OPERATION (Monthly)

Coolers

- Checking/cleaning

Open the engine cover to gain access to the water and

hydraulic coolers, and the intercooler.

Ensure that the flow of air through the coolers (1), (2)

and (3) is unobstructed.

Clean a dirty radiator using compressed air or a high-

pressure water jet. Blow or wash the radiator in the

opposite direction to that of the cooling air.

Take care when using a high-pressure water

jet; do not hold the nozzle too near the cooler.

The cooler may otherwise be damaged.

Fig. 27

Hydraulic cooler

1. Water cooler

Wear protective goggles when working

2. Hydraulic fluid cooler

3. Intercooler

with compressed air or high-pressure

water jet.

Bolted joints

- Tightening check

Steering pump against diesel engine (1) 38 Nm

(28 ft.lbs).

Rear axle suspension (2) 330 Nm (243 ft.lbs) oiled.

Engine suspension (3). Check that all M12 bolts (x20),

are tightened (20 off), 78 Nm (57 ft.lbs).

Wheel nuts (4). Check that all nuts are tightened, 470

Nm (347 ft.lbs), oiled.

(The above applies only to new or replaced

Fig. 28

Right side of machine

components.)

1. Steering pump

2. Rear axle

3. Engine suspension

4. Wheel nuts

Rubber elements and fastening

screws - Check

Check all rubber elements (1), replace all of the

elements 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.

Fig. 29

Drum, vibration side

1. Rubber element

2. Fastening screws

CA 250 M250EN3

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).

Wipe the top of the battery dry.

Wear safety goggles. The battery contains

acid. Rinse with water if electrolyte comes

Fig. 30

Battery box

into contact with the body.

1. Quick-screws

2. Battery cover

3. Battery

Battery cell

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. Let the engine run for a while before

topping up with distilled water if the ambient tempera-

ture is below freezing. Otherwise, the electrolyte might

freeze.

10 mm

(0.4 in)

Ensure that 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

Fig. 31

Electrolyte level in battery

1. Cell cap

acid-free Vaseline.

2. Electrolyte level

3. Plate

When disconnecting the battery, always

disconnect the negative cable first. When

connecting the battery, always connect the

positive cable first.

Discard used batteries in a proper way.

Batteries contains lead, which is detrimental to

the environment.

Before doing any electric welding on the

machine, disconnect the battery ground

cable and then all electrical connections to

the alternator.

CA 250 M250EN3

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.

Loosen the screw (1) and remove the bowl (2).

Take out the strainer (3) and clean in a non-flammable

fluid. Replace the filter as required. Fit the strainer and

bowl.

Start the engine and check that the pre-filter does not

leak.

Fig. 32

Engine

Make sure there is adequate ventilation

1. Screw

(extraction) if the diesel engine is run in-

2. Glass bowl

doors. Risk of carbon monoxide poisoning.

3. Strainer

Diesel engine

- Oil and filter change

Place the roller on a level surface. Switch

off the engine and apply the parking brake/

Reserve brake.

The oil drain plug (1) is most easily accessible from

underneath the engine. Drain off the oil while the engine

is warm. Place a receptacle that holds at least 15

liters(16 qts) under the drain plug.

Observe caution when draining hot oil.

Protect your hands.

Fill oil according to the engine manual. Replace the

engine oil filter (2) at the same time. See also engine

Fig. 33

Left side of engine

instruction manual.

1. Drain plug

2. Oil filter

Dispose of the drained oil and filter in an

approved manner.

CA 250 M250EN3

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 reservoir

to relieve any excess pressure inside.

Ensure that the breather filter (2) is not clogged, air

must have unobstructed passage through the cap in

both directions.

If clogged in either direction, clean with a little diesel oil

Fig. 34

Hydraulic reservoir

and blow with compressed air until free passage is

2. Filler cap/Breather filter

assured, or replace the cap with a new one.

3. Sight glass

Wear protective goggles when working

with compressed air.

Clean thoroughly round the hydraulic filter. Remove the

hydraulic filter (1) and scrap it. They are of the

expendable type and cannot be cleaned.

Ensure that the old sealing ring is not left on

the filter holder. Leakage may otherwise occur

between the new and the old seals.

Thoroughly clean the sealing surface of the filter holder.

Fig. 35

Engine compartment

Apply a thin coat of fresh hydraulic fluid on the new

1. Hydraulic filter (x1)

filter seal. Screw on the filter 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, which could

damage the gasket.

Start the engine and ensure that there is no leakage of

hydraulic fluid from the filter. Check the fluid level in the

sight glass (3) and top off as required.

Ensure that ventilation (extraction) is

adequate if the engine is run indoors.

Risk of carbon monoxide poisoning.

CA 250 M250EN3

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).

Hold a suitable receptacle under the tap.

Open the tap (1) and drain off any condensation.

Close the drain tap.

Fig. 36

Hydraulic reservoir, underneath

1. Drain cock

Refit the plug.

2. Plug

Fuel tank - Draining

Water and sediment in the fuel tank are drained via the

drain plug in the bottom of the fuel tank.

Take great care when draining. Do not drop

the plug so that all the fuel runs out.

Drain only after the roller has stood still during a long

period, for example, overnight. The fuel level should be

as low as possible.

The roller should preferably have stood sloping so that

water and sediment are concentrated over the drain

plug (1). Drain as follows:

Fig. 37

Fuel tank

Hold a suitable receptacle under the plug (1).

1. Drain plug

Loosen the plug and drain off the water and sediment

until only pure fuel flows from the plug. Tighten the plug

again.

Air filter - Changing

Replace the main filter of the air cleaner, even if it has

not yet been cleaned five times, see every 50 hours of

operation for changing the filter.

Fig. 38

Air cleaner

1. Locking flaps

2. Cover

3. Main filter

4. Backup filter

5. Filter housing

CA 250 M250EN3

EVERY 1000 HOURS OF OPERATION (Every six months)

Rear axle differential

- Oil change

Never work under the roller with the engi-

ne 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

receptacle. The volume is almost 12 litres (12.7 qts).

Save the oil and deposit it in an approved

manner.

Refit the drainage plugs and top up with fresh oil until

the correct level is reached.

Note: It takes a while for the oil to flow into the axle. Do

not fill the entire volume all at once.

Fig. 39

Rear axle

Refit the oil-level/filler plug. Use transmission oil, see

1. Level/Filler plug

the lubrication specification.

2. Drain plugs

CA 250 M250EN3

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).

Save the oil and deposit it in an approved

manner.

Std.

Accessory

Fig. 40

Planetary gearing / draining position

1. Plug

Position the roller with the plug at 9 o'clock.

Fill with oil to lower edge of level hole.

Clean and screw the plug back into place and repeat

the procedure on the other side. Use transmission oil.

See lubricant specification.

Std.

Accessory

Fig. 41

Planetary gearing / filling position

1. Plug

CA 250 M250EN3

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 adjustments

on the roller, unless otherwise specified.

Observe caution when draining hot oil.

Protect your hands.

Obtain a container for collecting the used fluid. The con-

tainer should have a volume of at least 60 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,

Fig. 42

Hydraulic reservoir, underneath

after the plug (2) has been removed and the tap opened.

1. Stop cock

2. Plug

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

Drum cartridge

level”.

- Oil change

Replace the hydraulic fluid filters at the same time.

Start the diesel engine and operate the various hydraulic

functions.

Make sure there is adequate ventilation

(extraction) if the diesel engine is run in-

doors. Risk of carbon monoxide poisoning.

Check the fluid level and top up if necessary.

Position the machine level so that the indicator pin (1)

on the inside of the drum is aligned with the top of the

drum frame.

Fig. 43

Left side of drum

1. Indicator pin

Drum cartridge

- Oil change

Place a receptacle for about 5 litres (5.3 qts)

underneath the level/drain plug (2).

Save the oil and deposit it in an approved

manner.

Clean and unscrew the filler plug (1) and the

drain plug (2).

Allow all of the oil to drain off. Fit the drain plug, and fill

with fresh synthetic oil according to instructions under

the heading “Drum cartridge - Checking the oil level”.

Fig. 44

Drum, right side

Repeat the procedure on the opposite side.

1. Filler plug

2. Drain plug

Ensure that only MOBIL SHC 629 is used in

3. Level plug

the cartridges.

CA 250 M250EN3

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).

Refit the plug (1) and fill with 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).

Fig. 45

Drum gearbox

1. Drain plug

2. Filler plug

3. Level plug

Steering joint - Check

Inspect the steering joint to detect any damage or

cracks.

Check and correct any loose bolts.

Check also for any stiffness and play.

Fig. 46

Steering joint

Controls and pivoted joints

- Lubrication

Lubricate the forward/reverse control mechanism.

Unscrew the two screws (2) and take off the protective

cover (1). Oil the mechanism.

Refit the cover and screws.

Fig. 47

Operator’s station

1. Forward/Reverse lever

2. Screws

CA 250 M250EN3

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. 48

Roller protected against the

weather

Diesel engine

See manufacturer’s instructions in the engine ma-

nual that accompanies the roller.

Battery

Remove the battery from the roller, clean it, check

that the electrolyte level is correct and trickle charge

the battery once a month.

Air cleaner, exhaust pipe

Cover the air cleaner or its opening with plastic or

tape. Cover the exhaust opening. This is necessary

to prevent moisture from entering the engine.

Fuel tank

Fill the fuel tank completely to prevent condensation.

Hydraulic reservoir

Drain off any condensation water and fill the hydrau-

lic reservoir to the upper mark.

Steering cylinder, hinges, etc.

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 rails, the engine-speed control

and the forward/reverse control mechanism.

Tires (All weather)

Ensure that tire pressure is 110 kPa (1.1 kp/ cm²).

Hoods, tarpaulin

Place the instrument cover on the steering column.

Cover the entire machine with a tarpaulin, which

should hand some way off the ground. If possible,

store the roller indoors, preferably in a building with a

uniform temperature.

CA 250 M250EN3

SPECIAL INSTRUCTIONS

Standard oils and other

Upon delivery from the factory, the various systems

recommended 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)

applies for biological hydraulic fluid.

When operating in hotter ambient temperatures, but up

Higher ambient temperature

to max. +50°C (122°F), the following instructions apply:

max. +50°C (122°F)

The diesel engine can handle this temperature with the

standard oil, but the following oils must be used in the

other components:

Hydraulic system with mineral fluid: Shell Tellus TX100

or corresponding.

Other components using transmission oil:

Shell Spirax HD 85W/140 or corresponding.

Temperature

The temperature limits apply to standard versions of

the roller.

Rollers that are fitted with additional equipment, such

as noise suppression, etc., may require extra observa-

tion in the higher temperature ranges.

High-pressure washing

When washing the machine, do not direct the

jet of water directly at the fuel or hydraulic fluid

tank 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.

In the event of fire in the machine, use an ABE-powder

Fire fighting

fire extinguisher if possible. A BE type carbon dioxide

fire extinguisher may also be used.

Protective structure (ROPS)

If the roller is equipped with a protective structure

(ROPS, Roll Over Protective Structure), or protective

cab, never subject the structure or cab to welding or

drilling. Never attempt to repair a damaged structure or

cab; they must be replaced with new ones.

Starting aid

When using an auxiliary battery to assist starting,

always connect the positive terminal of the auxiliary

battery to the positive terminal of the roller battery, and

negative to negative.

CA 250 M250EN3

ELECTRICAL SYSTEM, FUSES

Fuses and relays

The electrical regulating and control system is

protected 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).

The machine is equipped with a 12 V electrical system

and an alternator.

Connect the battery to the correct polarity

(- to ground). The cable between battery

and alternator must not be disconnected

when the engine is running.

Fig. 49 Instrument panel

1. Screws

2. Screws

Fig. 50

Instrument panel

3,4. Fuse box

5. VBS relay

6. Main relay

7. Hourmeter relay

8. Lights relay

= Optional

CA 250 M250EN3

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. 51

Fuse box, left side

Fuse box, right side

7.5A

1. Hourmeter

7.5A

1. High/Low gear

7.5A

2. VBS relay

2. Compaction meter

7.5A

3. Warning lamp

7.5A

3. Hazard beacon

7.5A

4. Horn, Fuel gauge

4. Reversing alarm

7.5A

5. -

20A

5. Working lights

10A

6. Front wiper, cab

20A

6. Working lights

= Optional

Main fuses

There is one main fuse (4), located behind the battery

disconnector. Unscrew the screws (1) to release the

plastic cover.

The fuses are of the flat pin type.

The preheater relays (2) and the start relay (3) are also

fitted here. The control box for the engine preheater (5)

is mounted underneath the battery disconnecter.

Main fuse 30 A (Green)

Fig. 52

Cooler location

1. Screws

5. Control box for engine preheater

Fig. 53

Relay box viewed from the rear

2. Preheating relays

3. Start relay

4. Main fuse

5. Control box for engine preheater

CA 250 M250EN3