Dynapac CA 262/362/512 Maintenance
Dynapac CA 262/362/512 Maintenance
Dynapac CA 262/362/512 Maintenance
CA 262/362/512
MAINTENANCE
M262EN2
Maintenance
M262EN2, August 2003
Diesel engine:
CA 262/362/512: Cummins 6BTAA 5.9C
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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.
WARNING SYMBOLS
GENERAL
HYDRAULIC FLUID
ambient air temperature
-10°C - +40°C (14°F - 104°F) Shell Tellus TX68 or equivalent
ambient air temperature Shell Tellus TX100 or equivalent
above +40°C (above 104°F)
Other fuel and lubricants are required for operation in extremely high or extremely low
ambient temperature. See the “Special instructions” chapter, or consult Dynapac.
CA 262/362/512 M262EN2 3
TECHNICAL SPECIFICATIONS
Operating mass with ROPS, EN500 kg (lbs) 10500 (23,153) 11900 (26,240) 13050 (28,775)
Operating mass without ROPS, kg (lbs) 10000 (22,050) 11400 (25,137) 12550 (27,672)
Operating mass with cab, kg (lbs) 10500 (23,152) 11900 (26,239) 13050 (28,775)
Length, standard-equipped roller, mm (in) 5618 (221) 5702 (224) 5673 (223)
Width, standard-equipped roller, mm (in) 2344 (92) 2344 (92) 2384 (94)
Height, with ROPS, mm (in) 2945 (116) 2977 (117) 2945 (116)
Height, without ROPS, mm (in) 2188 (86) 2212 (87) 2190 (86)
Height, with cab, mm (in) 2954 (116) 2976 (117) 2960 (116)
Height, with AC and hazard beacon, mm (in) 3254 (128) 3254 (128) 3254 (128)
Operating 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, without ROPS, mm (in) 2212 (87) 2134 (84) 2208 (87)
Height, with cab, mm (in) 2976 (117) 2952 (116) 2987 (118)
Height, with AC and hazard beacon, mm (in) 3254 (128) 3254 (128) 3254 (128)
Rear axle:
• Differential 12,0 (12.7 qts) 12,5 (13.2 qts)
• Planetary gears 2,0 (2.1 qts)/each side 1,85 (2.0 qts)/each side
Drum gearbox 3,0 (3.2 qts) 3,5 (3.7 qts)
Drum cartridge 2,3 (2.4 qts) / each side 2,3 (2.4 qts) / each side
Hydraulic reservoir 52 (13.7 gal) 52 (13.7 gal)
Oil in hydraulic system 23 (6 gal) 23 (6 gal)
Lubrication oil, diesel engine 14 (14.8 qts) 14 (14.8 qts)
Coolant, diesel engine 29 (7.7 gal) 30 (7.9 gal)
Fuel tank 320 (84.5 gal) 320 (84.5 gal)
Electrical system
Tires
Tire dimensions ............................. 23.1 x 26.0 8 Ply (std), 600/60-30,5, 14ply (Tractor)
Tire pressure ................................. 110 kPa (1,1 kp/cm2)
The tires can be optionally filled with fluid, (extra weight up to 700 kg/tire)
(1,544 lbs/tire). When servicing, bear this extra weight in mind.
4 CA 262/362/512 M262EN2
TECHNICAL SPECIFICATIONS
CA 262/362/512 M262EN2 5
TECHNICAL SPECIFICATIONS
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) –
Hydraulic system
Opening pressure,
MPa (psi) CA262/362 CA512
Air conditioner (Optional) The system described in this manual is of the ACC
type (Automatic Climate Control), ie, a system that
maintains the set temperature in the cab, on condition
that windows and doors are kept closed.
6 CA 262/362/512 M262EN2
TECHNICAL SPECIFICATIONS
Acoustic values 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.
Model Guaranteed Acoustic Acoustic
acoustic pressure level, pressure level,
power level operator’s ear operator’s ear
dB(A) LwA (platform) (cab)dB(A)
dB(A) LpA LpA
CA 262/362 112 86 77
CA 512 112 84 77
CA 262/362/512 M262EN2 7
MAINTENANCE SCHEDULE
1 2 3 4 5 6 7 8 9 10 38 39 37 11 12 13
33
32
31
30
29
14
28
27
26 25 24 23 22 21 20 19 36 35 34 18 17 16 15
8 CA 262/362/512 M262EN2
MAINTENANCE MEASURES
After the first 50 hours of operation change only the drum oil and all the oil filters.
CA 262/362/512 M262EN2 9
MAINTENANCE MEASURES
10 CA 262/362/512 M262EN2
EVERY 10 HOURS OF OPERATION (Daily)
Scrapers
– Checking / Adjustment
It is important to consider movement of the
drum when the machine turns, ie, the scrapers
can be damaged or wear of the drum may
increase if adjustment is made closer than the
values stated.
CA 262
Loosen the screws (2) and adjust the scraper (1) to 20
1 mm from the drum.
Tighten the screws.
Fig. 2 Scrapers
1. Scraper blade
2. Screws (x4)
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.
1 2
Fig. 3 Scrapers
1. Scraper blade
2. Screws
CA 262PD/362PD/512PD
Loosen the screws (1), then adjust the beam (2) to 25
mm between the teeth (3) and the drum.
Tighten the screws (1).
3 1 2
Fig. 4 Scrapers
1. Screws
2. Scraper beam
3. Scraper teeth
CA 262/362/512 M262EN2 11
EVERY 10 HOURS OF OPERATION (Daily)
2 1 1 2
Fig. 5 Scrapers
1. Scraper blade
2. Screws
12 CA 262/362/512 M262EN2
EVERY 10 HOURS OF OPERATION (Daily)
Diesel engine
– Check oil level
Place the roller on a level surface. Switch
the engine off and push in the reserve/
parking brake knob for all checking and
1
adjustments on the roller, unless otherwise
specified.
Pull up the dipstick (1) and check that the oil level is
Fig. 8 Engine compartment
between the upper and lower marks. For further details,
1. Oil dipstick refer to the engine manual.
Hydraulic reservoir
– Check fluid level
Position the roller on a level surface and check that the
2 sight glass reading (1) is between the max. – min.
marks. Top off with hydraulic fluid according to the lu-
bricant specification if the level is too low.
CA 262/362/512 M262EN2 13
EVERY 10 HOURS OF OPERATION (Daily)
14 CA 262/362/512 M262EN2
EVERY 50 HOURS OF OPERATION (Weekly)
Air cleaner
– Check/clean
Replace or clean the air cleaner’s main filter if
2 3 the warning lamp on the instrument panel lights
up when the diesel engine is operating at full
speed.
Undo the three locking braces (1). Then pull off the
cover (2) and pull out the main filter (3).
Fig. 13 Main filter Wipe the inside of the cover (2) and filter housing (5).
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.
CA 262/362/512 M262EN2 15
EVERY 50 HOURS OF OPERATION (Weekly)
16 CA 262/362/512 M262EN2
EVERY 50 HOURS OF OPERATION (Weekly)
If the tires are filled with fluid, the air valve (1) must be
in the “12 o’clock” position during pumping.
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.
Fig. 20 Cab
1. Condenser element
CA 262/362/512 M262EN2 17
EVERY 50 HOURS OF OPERATION (Weekly)
18 CA 262/362/512 M262EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Wipe clean and remove the level plug (1) and check
that the oil level reaches the lower edge of the plug
1 hole. Top off with oil to the right level if the level is low.
Use transmission oil according to the lubricant
specification.
1 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 trans-
mission oil according to the lubricant specification.
Check the oil level in the same way in the rear axle’s
other planetary gear.
CA 262/362/512 M262EN2 19
EVERY 250 HOURS OF OPERATION (Monthly)
Drum gearbox
– Check oil level
Wipe clean the area around the plug (1) and then undo
2
the plug.
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.
1
Drum cartridge
– Checking the oil level
Position the machine level so that the indicator pin (1)
1 on the inside of the drum is aligned with the top of the
drum frame.
2
Fig. 27 Roller, right-hand side
1. Filler plug
2. Drain plug
3. Level plug
20 CA 262/362/512 M262EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Drum cartridge
Then 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.
Drum cartridge
– Cleaning the ventilation screw
Clean the drum ventilation hole. The hole is required to
eliminate excess pressure inside the drum.
Fig. 29 Drum
1. Ventilated screw
Radiator
– Check/clean Place the roller on a level surface. Switch
1 2 the engine off and push in the reserve/
parking brake knob for all checking and
adjustments on the roller, unless otherwise
specified.
3
Check that air can flow freely through the radiators (1),
(2) and (3).
A dirty radiator should be blown clean with compressed
air, or alternatively 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
Fig. 30 Engine room – do not place the nozzle too close to the
1. Water cooler radiator.
2. Intercooler
3. Hydraulic fluid cooler Use protective goggles when working with
compressed air or a high-pressure washer.
CA 262/362/512 M262EN2 21
EVERY 250 HOURS OF OPERATION (Monthly)
Bolted joints
– Checking tightening torque
1
Rear axle suspension (2) 330 Nm (243 lbf.ft), oiled.
Wheel nuts (4). Check that all nuts are tightened, 470
Nm (347 lbf.ft), oiled.
3 (The above applies to new or replaced components
2 4
only.)
Fig. 31 Right side of machine
1. Steering pump
2. Rear axle
3. Engine suspension
4. Wheel nuts
22 CA 262/362/512 M262EN2
EVERY 250 HOURS OF OPERATION (Monthly)
Battery
– Check electrolyte level
Make sure there are no open flame in the
1 2 3 1 vicinity when checking the electrolyte level.
An explosive gas is formed in the battery
during the charging process.
Battery cell
Remove the cell covers and check that the fluid level is
about 10 mm (0.4 in) above the plates. Check the level
1 in all the cells. If the level is lower, top up to the correct
2 level with distilled water. If the ambient air temperature
is below freezing point, the engine should be run for a
while after the distilled water is added, otherwise there
is a risk that the water might freeze.
10 mm
Check that the ventilation holes in the cell covers are
3 not blocked, then refit the covers.
CA 262/362/512 M262EN2 23
EVERY 500 HOURS OF OPERATION (Every three months)
Prefilter – 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.
3
Loosen the screw (1) and remove the glass bowl (2).
2
Take out the strainer (3) and clean using a non-
1 flammable fluid. Reinstall the strainer and the bowl.
Start the engine and check that the pre-filter does not leak.
Fig. 37 Engine
1. Screw Make sure there is adequate ventilation
2. Glass bowl (extraction) if the diesel engine is run in-
3. Strainer doors. Risk of carbon monoxide poisoning.
Diesel engine
– Changing the filter and oil
Position the roller on a level surface. Stop
the engine and apply the parking brake/
reserve brake.
3 Clean and grease the chain (3) between the seat and
the steering column.
2 If the chain becomes slack on the cogwheel (2), loosen
1 the screws (4) and move the steering column forward,
tighten the screws and check the tension of the chain.
Fig. 40 Seat bearing
1. Lubrication nipple
2. Cogwheel
3. Steering chain
4. Adjusting screw
5. Cover
6. Slide rails
7. Slew interlock
CA 262/362/512 M262EN2 25
EVERY 1000 HOURS OF OPERATION (Every six months)
Hydraulic fluid filter Place the roller on a level surface. Switch
– Change the engine off and push in the reserve/
parking brake knob for all checking and
2 adjustments on the roller, unless otherwise
specified.
Undo the cover/bleeder filter (2) on top of the reservoir
so that over-pressure inside the reservoir can be elimi-
nated.
Check that the bleeder filter (2) is not blocked – air
should flow freely through the cover in both directions.
If there is a blockage in either direction, clean the filter
with a little diesel oil and blow through with compressed
air until the blockage disappears, or replace the cover
3 with a new one.
Fig. 41 Hydraulic fluid reservoir Always use protective goggles when work-
2. Filler cover/bleeder filter ing with compressed air.
3. Sight glass
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 oil leakage between the old and
new seals.
Clean the filter holder sealing surfaces thoroughly.
1
Apply a thin film of hydraulic fluid on the seals of the
new filter. Screw on the filter by hand.
Fig. 42 Engine compartment
1. Hydraulic fluid filters (x2) First tighten the filter until its seal is in contact
with the filter attachment. Then turn an addi-
tional half revolution. Do not over-tighten the
filter as this might damage the seal.
Start the engine and ensure that there is no leakage of
hydraulic fluid from the filters. Check level of fluid in the
sight glass (3) and top up as required.
Hydraulic reservoir Make sure there is adequate ventilation
– Drainage (extraction) if the diesel engine is run in-
doors. Risk of carbon monoxide poisoning
1
Condensate in the hydraulic reservoir is removed via
the drainage tap (1).
Drainage should be performed when the roller has been
standing for a long period of time, for example over-
night. Drain as follows:
Remove the plug (2).
Place a container under the tap.
Open the tap (1) and let any trapped condensate run out.
2
Fig. 43 Hydraulic reservoir, underside Shut the drainage tap.
1. Drainage tap Refit the plug.
2. Plug
26 CA 262/362/512 M262EN2
EVERY 1000 HOURS OF OPERATION (Every six months)
Air filter – Replacement Undo the plug and drain off the water and sediment until
only clean diesel fuel appears through the plug opening.
2 3 Refit the plug.
Wipe clean and remove the level/filler plug (1) and all
three drain plugs (2) and drain the oil into a suitable
receptacle. The volume is almost 12 litres (12.7 qts).
1
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
2 not fill the entire volume all at once.
Fig. 46 Rear axle Refit the oil-level/filler plug. Use transmission oil, see
1. Oil level/Filler plug the lubrication specification.
2. Drainage plugs
CA 262/362/512 M262EN2 27
EVERY 1000 HOURS OF OPERATION (Every six months)
Wipe clean, unscrew the plug (1) and drain the oil into a
suitable receptacle. The volume is about 2 litres (2.1 qts).
1
CA 262-362 Std.
1
CA 512
(CA 262/362 Optional)
Fig. 47 Planetary gear/drainage position
1. Plug
Refit the plug and repeat the process on the other side.
1
Use transmission oil. See the lubrication specification.
CA 262-362 Std.
CA 512
(CA 262/362 Optional)
Fig. 48 Planetary gear/filling position
1. Plug
28 CA 262/362/512 M262EN2
EVERY 1000 HOURS OF OPERATION (Every six months)
Loosen the two screws (2) at the rear of the cab roof.
Take down the whole holder and remove the filter
insert.
Fig. 49 Cab
1. Fresh air filter
2. Screw (x2)
CA 262/362/512 M262EN2 29
EVERY 2000 HOURS OF OPERATION (Yearly)
Hydraulic reservoir
Place the roller on a level surface. Switch the
– Fluid change engine off and push in the reserve/parking
1 brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Danger of being burned 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,
2
after the plug (2) has been removed and the tap opened.
Fig. 50 Hydraulic reservoir, underside
1. Drainage tap Save the oil and deposit it in an approved
2. Plug manner.
30 CA 262/362/512 M262EN2
EVERY 2000 HOURS OF OPERATION (Yearly)
Drum gearbox
– Changing the oil
2 Place the roller on a level surface with the plugs (1) and
(2) as illustrated.
Refit the plug (1) and fill with oil up to the level plug (3),
according to “Drum gearbox – Checking the oil level”.
Forward/Reverse lever
– Lubrication
Unscrew the screws (1) and remove the plate (2).
1 2 3
Fig. 54 Forward/Reverse lever
1. Screw
2. Plate
3. Cam disk
CA 262/362/512 M262EN2 31
EVERY 2000 OPERATING HOURS (Yearly)
Clean the cooler unit and the cooling elements (1) free
from dust with the aid of compressed air.
Fig. 57 Aircondition
1. Cooling element
2. Drain valve (x2)
32 CA 262/362/512 M262EN2
EVERY 2000 OPERATING HOURS (Yearly)
Compressor – Inspection
(Optional)
Inspect the compressor and hydraulic motor
fastenings.
Fig. 58 Compressor
Air cleaner, exhaust pipe * Cover the air cleaner or its opening with plastic or
tape, and cover also the exhaust pipe’s opening.
This is done so as to prevent moisture from
penetrating into the engine.
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) Check that tire pressure is 110 kPa (1,1 kp/cm2),
(16 psi).
34 CA 262/362/512 M262EN2
SPECIAL INSTRUCTIONS
Standard lubricants and other Upon delivery from the factory, the various systems
recommended oils 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).
Higher ambient temperature The diesel engine can handle this temperature with the
max. +50°C (122°F) 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.
CA 262/362/512 M262EN2 35
ELECTRICAL SYSTEM, FUSES, RELAYS
Fig. 62 Fuse box, left side (1) Fuse box, right side (3)
7.5A 1. Brake valve, starter relay, hourmeter 20A 1. Working lights, left
7.5A 2. VBS relay 20A 2. Working lights, right, instrument illumination
7.5A 3. Indicating panel 7.5A 3. Headlight, left
7.5A 4. Horn 7.5A 4. Headlight, right, instrument illumination*
7.5A 5. Low/High speed/Strike-off blade 5. –
3A 6. Reversing alarm 6. –
Fuse box, left side (2) Fuse box, right side (4)
7.5A 1. Instrumentation 10A 1. Hazard beacon
3A 2. Compaction meter 10A 2. Direction indicators, main fuse
7.5A 3. Hazard beacon 7.5A 3. Position light, left, front and rear
7.5A 4. Anti-spin 5A 4. Position light, right, front and rear
15A 5. Windscreen wiper, utility cab 5A 5. Direction indicator, left, front, rear and side
5A 6. Interior lighting, utility cab 5A 6. Direction indicator, right, front, rear and side
36 CA 262/362/512 M262EN2
ELECTRICAL SYSTEM, FUSES, RELAYS
Main fuses
There are three main fuses (2). These are located
1 behind the battery master disconnect switch. The three
screws need to be unscrewed to remove the plastic
2 cover.
3
The fuses are of the flat pin type.
The starter relay (1), preheater relay (3) and fuses for
the preheater relays (4) are also fitted here.
Relays
K2 VBS relay
K3 Main relay
K4 Horn relay
K5 Hourmeter relay
K6 Fuel level relay
K7 Reverse alarm relay
K8 Lights relay
K9 Direction indicator relay
K10 Brakes relay
= Optional
CA 262/362/512 M262EN2 37
ELECTRICAL SYSTEM, FUSES, RELAYS
Control box
1 2
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.
Relays in cab
Unscrew the instrument plate (1) to replace the relays
2, 3 for air conditioner fan and condenser fan on the cab
roof, and radio.
4 1
38 CA 262/362/512 M262EN2