DYNAPAC CA 250 OPERATION O250EN2VIMAR EC Vibratory roller CA 250 : Operation O250EN2, June 2001 Diesel engine: CA 250: Cummins 4BTA 3.9 These instructions apply from: CA 250 PIN (S/N) *65X20597* Pynapac's medium heavy vibratory soil compactor is the CA 250. It is available in versions D (Smooth drum) and PD (padfoot). The PD version ts used mainly on cohesive material and disintegrated rock, All types of base courses and subbase courses can be compacted deeper, and the interchange able drums ~ D and PD ~ 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, tachograph ancl CCS/RA field computer are described in separate instructions | We reserve the right to change specications without nets, Proted in SseedenSefety instructions (Read the Safety Manual also Safety when driving... ee Safety decals, locatior Machine and engine plates instruments and controls Instruments and controls, functional descript Controls in the cab ... Before starting Starting Operation Vibration/Driving Driving on difficult courses .. Braking : Parking Lifting Towing... Towing/Retrieval .. Transport. : Operating instructions - Summary .. ion .. A Safety instructions—Personal safety. aun | Special caution—Machine or component damage. wens Each operator of the roller must study the safety manual, which accompanies each mach ine. Always follow the safety rules and do not remove the manual from the roller. ‘This manual contains instructions for operating and using the roller. For information on care and maintenance, see the manual, ‘MAINTENANCE, CA 250." weno When you start up and drive a cold machine, the hydraulic fluid is cold, and the braking distance will be longer than normal until the machine reaches normal working temperature. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. » DYMWAPAE (A250 0250EN21. 2 3, a 2 10. "1 12, 13, 14, 15, 16. 47. 18. YMAPAC CA 250 O250EN2 The operator must be familiar with the contents of the OPERATION MAN- UAL before starting the roller. Make sure that all instructions in the MAINTENANCE MANUAL are fol- lowed. Only trained and/or experienced operators may drive the roller. Passen- Gers are not allowed on the roller. Remain seated during all operation. |. Never use the roller if it is in need of adjustment or repairs. Board and leave the roller only when it is stationary. Use the grips and railings that are provided. Always use a "three-point grip” - both feet and ‘one hand or one foot and both hands - when boarding or exiting the machine. The ROPS (Roll Over Protective Structure) should always be used when the machine is operated on risky ground. - Drive slowly in sharp bends. . Avoid driving at an angle on slopes; drive straight up or down. . When driving close to unsafe edges or holes, make sure that at least two thirds of the drum width is firmly on material that has already been com. pacted. Make sure that there are no obstacles in the direction of travel, on the ground or overhead. Drive extra carefully on uneven ground. Use the safety equipment provided. The seat belt must be worn on ma- chines fitted with ROPS, Keep the roller clean. Clean dirt and grease from the operator's platform without delay, Keep all signs and decals clean and clearly legible. Safety measures before refueling: ~ Stop the engin ~ Do not smoke. —No naked flame in the vicinity. — Ground the nozzle of the Before repairs or service: ~ Place chocks against the drums/wheels and against the strike-off blade. ~ Lock the articulation if required. Hearing protectors are recommended if the noise level exceeds 85 dB(A). The noise level may vary depending on what material the machine is oper- ating on, Make no changes or modifications on the roller that could affect safety. Changes may only be made following written consent by Dynapac. Do not use the roller until the hydraulic fluid has reached its normal work- ing temperature. Braking distance can be longer than usual if the fluid is cold. See starting instructions in the OPERATION MANUAL,Fig.1 Position of drum when driving near anedge Fig.2 Tipping angle on side slopes B| When you drive near an edge, at least two thirds of the drum width must be on solid ground, Remember that the machine's center of gravity is displaced outward when you steer to one side. For example, it shi the right when you steer to the left. to The ROPS (Roll Over Protective is always recommended when dri slopes or insecure ground. Where possible, avoid all driving across a slope. Instead, drive up and down on slop- ing ground, The tilting angle is measured on a hard, level surface with the machine stationary, steering angle zero, vibra- tion switched OFF and all tanks full. Remember that ioose ground, steering of the machine, vibration switched ON, driving speed and raising the center of gravity (for example, with accessories) may cause the machine to topple even on a smaller slope than that stated here. To leave the cab in an emergency, release the hammer located on the rear right post and break the rear window. DDVIMAPAE CA 250 O250EN2DVMAPAE CA 250 0250EN2 =TAWARNING] 110 KPa Crush zone, articulation! The operator is urgently Drum. Maintain a safe dis- requested to read the safety tance from the crush zone. manual, and the operation and maintenance instruc- tions before using the machine. Warning - rotating engine ‘components. Keep your hands at a safe distance from the danger zone. Warning - hot surfaces in the engine compartment. Do not touch. Hydraulic Battery Lift fluid disconnector Lifting plate no Securing Handbook point compartment Tires filled with ballast. ACTIVATE THE PARKING BRAKE BEFORE Read the instruction manual. LEAVING THE OPERATOR'S PLATFORM (Optional) IBYIWVAPAC CA250 0250EN2 | | | |Fig.3 Operator's platform 1. Machine plate PIN on frame Fig.4 Front frame 1.PIN Engine plate Fig. 5 Engine 1. Engine plate 2. EPA sign (USA) VMAPRAE CA 250 0250EN2 ‘The machine plate (1) is affixed on the front left edge of the tractor frame. The plate shows the manufacturer's, name and address, type of machine and PIN “Part Identification Number” (serial number). Please state the PIN (serial number) of the roller when ordering spares. DBYNAPAC «& Metso Dynapac AB Box 504, SE-371 23 Kerlskrona Sweden The PIN (1) of the machine is Punched on the front right edge of the forward frame beam. The engine plate (1) is affixed to the right side of the engine under the injection pump. The plate indicates the type of engine, serial number and engine data. Please state the engine serial number when ordering spares. See also the Engine Manual. IMPORTANT ENGINE INFORMATION This engine conforms to YYYY U.S. EPA ‘and California regulations for luty non-road compression Ignition diesel cycle engines as applicable. THIS ENGINE IS CERTIFIED TO OPERATE ‘ON DIESEL FUEL. 3935108Fig.6 Instruments and contro! panel 4. Horn 12, Waming lamp, hydraulic temperature 2, Starter switch 19, Amplitude selector Low0lHigh 3. Hazard beacon 14, Speed selector, drum @ 4, Working lights 0 15, Speed selector, rear axle 5, Reserverparking brake knob 16. Engine revs control 6. instrument protection 17. Fuel gauge 7. Warming 'amp, charging 18. Fuse box 8. Brake waming lamp 19. Vibration ONOFF 98, Waming lamp, engine oi 20, Fonward’Reverse lever prossure/Engine temperature 21. Tast button for waming iamos 10. Waming lamp, hydraulie fiter 22, Handbook compartment 11. Warning lamp, alr filter B= Optional 8 DYNIAPAT CA250 " O250EN2charging tems.in] Designation ‘Symbol | Function fig. 6 1 | Horn, switch ¥ET | Press to sound the horn. 2 | Starter switch © _ | Inposition O the electric circuit is broken. In position | all instruments and electric || controts are powered 8 In position @ the start motor is activated, 3 | Hazard beacon, switch Tum right to switch on the hazard beacon, (Optional) 4 | Working lights, switch Qa | Tum right to switch on the working lights, (Optional) TAN, 5 | Reserve brake/Parking brake Press to activate the reserve brake. Press Ay when the machine is stationary to activate the| ‘stor _ | Parking brake, Pull out to release both brakes, 6 | Instrument protection — | Fold down over the instruments to protect from weather and damage. 7 | Waring lamp, battery Kf this lamp lights while the. engine is running, the altemator is not charging Stop the engine and remedy the fault. temperature 8 | Brake warning lamp The lamp lights when the parking or reserve oO brake knob is pushed in and the brakes are applied. 9 | Warning lamp, oil pressure The lamp lights if engine oil pressure is too low. Stop the engine immediately and locate the fault. 10 | Warning lamp, hydraulic filter L {f this lamp lights while the engine is running a lol full rev, the hydraulic filters must be changed. 11 | Warning lamp, air filter {f this lamp lights while the engine is running al C) | llev, the air cleaner must be cleaned or eq | replaced, 12 | Waming lamp, hydraulic If this lamp lights, the hydraulic fluid is too hot. Do not drive the roller; cool the fluid by allowing the engine to idle and locate the fault. DVMAPAE CA 250 O250EN2ems in] Designation Function Amplitude selector The left mode gives low amplitude. The right mode gives high amplitude. Vibration is OFF in the O mode. 14 ‘Speed selector, drum (Optional) Transportation speed (High) Working speed (Low) 15 Speed selector, rear axle (Optional) Transportation speed (High) Working speed (Low) 16 Revs control, diesel engine Working revs in the upper position. Idling in the lower position, 7 Fuel gauge Indicates fuel tank level. 18 Fuse box Contains fuses for the electrical system. 19 Vibration ON/OFF, switch Press once and release to switch vibration ON, press again to switch vibration OFF. The above applies only when the amplitude selector (13) is in the High or Low mode. Forward/Reverse lever The lever must be in neutral for the engine to start; the engine will not start if the forward/ reverse lever is in any other position. The forwardireverse lever controls the driving direction and speed of the roller, Move the lever forward to drive the roller forward, etc. Roller speed is proportional to the movement of the lever from the neutral position. The further from neutral, the higher the speed. 24 “Test button for warning lamps The lamps 10, 11, 12 are checked when the switch is pressed. 22 Handbook compartment ‘Stowage space for safety manual and operator's manuals. 40 DBYMIABAE CA250 O250EN2Fig. Ta Cab root, front Fig. 7b Cab root, rear Hammer for emergency evacuation Items in] Designation Symbo! | Function fig. 7 1 | Wiper, switch Y Press to operate the wiper. 2 To evacuate the cab in an emergency, telease the hammer and break the REAR window. DYMAPAE CA 250 0250EN2Battery disconnector Switching on Lee Fig. 8 Engine compartment 1. Battery disconnector 2, Hourmeier Operator's seat - Setting 7 Fig.9 Operator's station 1. Locking lever — length adjustment Operator's seat in cab (Optional) Setting 10 Operator's seat 1. Locking lever ~ length adjustment 2, Lever ~ weight adjustment 12 Remember to carry out daily service. See the operation manual. The battery disconnecter is located in ‘the engine compartment. Open the engine hood and set the key (1) to the ON position. The entire roller is now powered. The hourmeter (2) records the number of hours so long as the engine is running. ""° The engine hood must be unlocked during operation, so that battery power can be disconnected quickly if necessary. Set the operator's seat in a comfortable position and so that the controls are easily accessible. The seat has the following adjustment facilities: Length adjustment (1). Always make sure that the seat is secure before beginning operation. Set the operator's seat in a comfortable position and so that the controls are easily accessible. The seat has the following adjustment facilities: Length adjustment (1). + Weight adjusiment (2) ”° always make sure that the seat is secure before beginning operation. IBYWAPAC CA 250 0250EN2Instruments and lamps — Check Fig. 11 Instrument panel 2. Starter switch 7 Charging lamp 8. Brake lamp 12, Oil pressure lamp 17. Fuel gauge 21, Test button for waming lamps Reservelparking brake Fig. 12 Comtrolpanet 5. Reserveiparking brake knob 8. Brake lamp Seat belt PN Ne AN Fig. 13. Operator's station 1. Seat belt 2 ROPS 3. Rubber element 4 Antisip L DYMAPAC CA 250 O250EN2 ‘Tum the starter switch (2) to position |. Press the button (21) and make sure that all the control lamps light. Check that the fuel gauge (17) gives a reading, Check that the warning lamps for charging (7), oil Pressure (12), and parking brake (8) light. wows Ensure that the reserve/parking brake knob (8) is pressed down, If the parking brake is not applied, the roller may start to roll when you start the engine on sloping ground. Always fasten the seat belt (1) that is provided it ROPS (2) (Roll Over Protective Structure) or a cab is fitted on the roller, and wear a protective helmet, wavs Always replace the seat belt (1) with a new one if it is worn or has been subjected to a heavy load. Check that the rubber elements (3) on the YP | platform are intact. Worn elements will impair = 1 comfort. Ensure that the anti-slip (4) on the platform is 1] in good condition; replace with new anti-slip if friction is poor. If the machine is fitted with a cab, make sure that the door is closed when in motion.Field of view { Fig. 14 Field of view Before starting, make sure that the field of view is unobstructed, both in front and behind. All cab windows must be clean and rearview mirrors properly adjusted. 14 IBYNWAPACE CA 250 0250EN2 |2 Starter switch 2 Charging lamp 8 Brake lamp 9. Oil pressure lampitemperature lamp 13, Amplitude selector 16. Revs contro! 20. Forward/Reverse lever DYVMAPAE CA 250 0250EN2 ee Set the forward/reverse lever (20) in neutral. The engine cannot be started if the lever is in any other Position. Set the amplitude selector (13) for Low/High vibration to O mode. Set the revs control (16) to idling mode. Turn the starter switch (2) to the right to the starting mode and release the knob immediately when the engine starts. cao Do not run the starter motor too long. if the 1} engine does not start immediately, wait a = minute or so before making a new attempt. Warm up the engine for a few minutes with the rev control in the idling mode, longer if the ambient temperature is below +10°C (+50°F), ‘Check while warming up that the warming lamps for oll pressure (9) and charging (7) are out. The warning lamp (8) for the parking brake should stil ight. wx" When you start up and drive a cold machi- ne, the hydraulic fluid is cold, and the braking distance will be longer than normal until the machine reaches normal working temperature. “X"° Ensure that ventilation (extraction) is adequate if the engine is run indoors. Risk of carbon monoxide poisoning. 15Fig.16 Instrument pane! 5. Reserve/parking brake knob 11. Waming lamp, air fiter 14, Speed selector, drum 15. Speed selector, rear axle 16. Rev contro! 20, Forward/Reverse lever 16 wise Under no circumstances may the machine be operated from the outside. The operator must remain seated inside the machine during all operation. Turn the rev control (16) upward and latch it atits limit. The engine speed should be about 2300 r/min. Check that the steering is working by tuning the Steering wheel once to the right and once to the left, while the roller is stationary. wx" Ensure that the area in front of and behind AX terolieris clear wisnine Pull up the reservelparking brake knob (5) and check that the warning lamp for the parking brake is out. When starting the Toller on a slope, be prepared that it may begin to roll. Set the High/Low speed selector (14) and (15) to the desired mode (optional feature), see decal on the instrument panel, Max. speeds Low drurvLow rear axle = 5 krrvh. (3 mph) High drur/Low rear axle = 6 km/h. (3.7 mph) (with optional accessory only) Low drumHigh rear axle = 9 knv/h. (6.5 mph) (with optional accessory only) High crum/High rear axle = 16 km’h. (10 mph) {with optional accessory only) The high/high mode may only be used for transport runs on an even surface. Carefully move the forward/reverse lever (20) in the desired direction of travel. Speed increases as the lever is moved farther from the neutral position. cure Always regulate speed with the forward/ reverse lever and never by changing the engine speed. anus Check operation of the reserveparking brake by pressing the reserve/t arking brake knob (5) while the roller is running slowly forward. Check occasionally while driving that no lamps light. If the oil pressure lamp lights, stop the roller ang the ‘engine immediately. Check and remedy any fault; see also the maintenance manual and the engine manual. unex if the warning lamp a) for the air cleaner 1] lights during operation (at full engine revs), the =| main filter must be cleaned or replaced; see Maintenance Manual. DYARIAPAE CA 250 O250EN2— Setting Drum vibration can be set in two modes, selected using the switch (13). Turn the knob to the left mode for low ‘amplitude, to the right mode for high amplitude F=5 Never alter the amplitude setting while the vibration is running. Switch vibration off first and wait until it has ceased before altering the amplitude. Engagement and disengagement of vibration is made | __With the switch (19) on top of the forwardireverse lever. | Always switch off vibration before the roller comes to a | Complete standsti. 25" Never allow vibration to be on when the roller is stationary; this may damage the surface and the machine, Fig. 17 Instrument pane! 13, Ampitude selector 19, Vibration ON/OFF if the machine is equipped with a 2-speed drum drive and becomes bogged down, tum the knobs for driving as follows. If the drum spins, set the drum drive high and the rear axle low. I the rear tires spin, set the drum drive low and the rear axle high Set the knobs to their initial positions when grip is restored to the machine. 18 Controlpanel i 14. Speed selector, drum 15. Spood solector, rear axle DYNWAPAE CA 250 0250EN2 aaUsing the reserve brake Braking is normally done with the forward/reverse lever (20). ‘The hydrostatic transmission brakes the roller when the ever is moved toward neutral. In addition, mult-dise brakes in the rear axle act as a parking brake and are activated when the reserve brake knob (6) is pressed in. waeqs® . To brake in an emergency, press the reser- velparking brake knob (5), hold the stee- ring wheel firmly and be prepared for a sudden stop. After braking, restore the forwardireverse lever to | neutral and pull up the reserve/parking brake knob. Normal braking Press the switch (19) to disengage vibration. Move the forward/reverse lever (20) to neutral to stop the roller. we" always press the parking brake knob (5), even for brief stops on sloping ground. Tum the speed control back to idling, allow the engine to idle a few minutes to coo! down. Fig.19 Controlpanel 5. Reserve brake knob werwwo When starting up and driving a cold 19. Vibration switch ONOFF machine, which implies cold hydraulic 20. Forward/Reverse lever fluid, the braking distance will be longer than normal until the machine reaches working temperature. Check instruments and warning lamps to see if any faults are indicated, Switch off all lights and other electrical functions, Turn the starter switch (2) to mode O. Lower the instru- ment cover (on rollers without cab) and lock it, Fig.20 Instrument panel 2, Starter switch 18 ; DYMWARAE CA 250 0250EN2Fig.21 Arrangement 1. Chock e Battery disconnector Fig.22 Battory compartmen 1. Battery disconnactor DVMAPAC CA 250 O250EN2 warns Never leave the roller with the engine running unless the reservelparking brake knob is pressed in. ““X"* Ensure that the roller is parked in a safe place for traffic. Chock the drums if the roller is parked on sloping ground. (ze" Remember the risk of freezing during the 1] _ winter. Fill the cooling system of the engine with antifreeze mixture. See also maintenance instructions. ‘Switch the battery disconnector (1) into disconnected mode and remove the key before leaving the roller. This will prevent discharging of the battery and will also make it difficult for any unauthorized person to start and drive the machine. Also lock the engine compartment cover.1, Locking arm 2. Locking cotter 3. Locking stud 44. Locking lug Lifting the roller Weight: See iting plate on the roller. Fig.24 Roller prepared for lifting 1. Liting plate Releasing the articulated joint interlocked mode “"* articulation must be locked to prevent inadvertent turning before lifting the roller. Tum the steering wheel so that the machine is set to drive straight forward, Push in the reserve/parking brake knob. Pull out the lowermost locking cotter (2) fitted with a wire, pull up locking stud (3) fitted with a wire. Fold out the locking arm (1) and secure it to the upper locking lug (4) on rear machine frame. Fit the locking stud (3) in the holes through the locking ‘arm (1) and locking lug (4) and secure the stud in position with the locking cotter (2). “A The gross weight of the machine is noted on the lifting plate (1). See also technical specifications in the maintenance instruc tions. 1 Lifting gear, such as chains, steel wires, . straps, and lifting hooks must be dimensioned in conformance with current regulations. Keep well clear of the lifted machine! Make sure that lifting hooks are securely anchored. cause Fig. 25 Articulation in open mode 1. Locking arm 2. Locking cotter 3. Locking stud 4, Looking lug Remember to restore the articulation interlock 1] toits open mode before driving again. Fold back the locking arm (1) and secure it in the locking lug (4) with the locking stud (3). Insert the lowermost locking cotter (2) fitted with a wire, to secure the locking stud (3). The locking lug (4) is located on the tractor frame. BIYMIAPAC CA 250 O250EN2€ Alternative 1 Towing short distance with engine working Fig. 26 Propulsionpump 1. Towing valve 2. Locknut Alternative 2 Towing short distance with engine not working The roller may be moved a distance of up to 300 metres (330 yards) using either of the following alternatives. "ZX. Pross the reservelparking brake knob, and ‘stop the engine temporarily. Chock the drums to prevent the machine from rolling, Tur both towing valves (1) (middle hexagonal nut) three turns anticlockwise, holding against on the ‘multifunction valve (2) (lowermost hexagonal nut). The valves are located on top of the propulsion pump, Start the engine and allow it to idle. ‘The roller can now be towed and can also be steered if the steering system is in action. “Chock the drums to prevent the roller from moving when the brakes are mechanically disengaged. First, open both of the towing valves according to alternative 1 above, Rear axle brake Undo the locknut (3) and adjust the adjustment screws: (4) by hand until resistance increases, and then one additional turn. The adjustment screws are located on the rear axle, two screws on each side of the differential housing. Fig.27 Rear axle 3. Locknut 4. Adjusting screw DVNABAE CA 250 0250EN2 After towing, remember to tighten the towing 1] valves (1). Screw out the adjusting screws (4) to their initial position 34 mm (1,34 in) from the contact surface, and tighten the locknuts (3). Tighten the four hexagonal socket screws (5). 24Fig, 26 Retrieval towing, Use a towbar because the roller j\ The roller must be counter-braked when will have no ability to brake. The roller must be towed slowly, max. 3 km/h ¥| (2 mph) and for a short distance only, max. 300 m (330 yards). When a machine is towed/retrieved, the towing device must be connected to bath lifting holes. Pulling forces shall act longitudinally on the machine as illustrated. T | _ Restore the items for towing according to Y] alternative 1 or 2 on the preceding page. Roller prepared for transport Fig. 29. Transportation 1. Chocks 2, Supporting blocks 3. Lashing wire 2B we" interlock the articulation before lifting and transportation. Follow the instructions under the respective heading. Chock the drums (1) and secure the chocks to the transport vehicle. Block up under the drum frame (2), to avoid overload on the rubber suspension of the drum when lashing. Clamp down the roller with lashing strap (3) at all four corners; decals indicate the fixing points. FET Remember to rostore the articulation iteriock ¥ | toits open mode before starting the roller again. DBYMABAE CA 250 0250EN21, Follow the SAFETY INSTRUCTIONS in the Safety Manual. 2. Ensure that all instructions in the maintenance manual are followed 3. Turn the battery disconnecter to ON. 4. Move the forward/reverse lever to neutral. é 5. Set the vibration selector to the O mode. 6. Set the revs control to the idling mode. 7. Start the engine and allow it to warm up. 8. Set the revs control in the operating mode. 9. Put the reserve/parking brake knob in the pulled-out position. 10. Drive the roller. Operate the forward/reverse controls with care. “X"* 411, Test the brakes. Remember that the braking distance will be longer if the roller is cold. € 12. Use the vibration only when the roller is in motion, 13. IN AN EMERGENCY: - Push in the reservelparking brake knob. - Hold the steering wheel firmly. € - Brace yourself for a sudden stop. 14, Parking: Push in the reservelparking brake knob. Stop the engine and chock the drums. 15. Lifting: = See the operation manual. 16. Towing = See the operation manual. 17. Transport: ~ See the operation manual. 18. Retrieval: — See the operation manual DIYMUAPAE CA 250 0250EN2 23DYNAPAC CA 250 MAINTENANCE M250EN2DYNAPAC CA 250: Cummins 4BTA 3.9¢ | Vibratory roller I CA 250 i Maintenance f M2S50EN2, June 2001 i | Diese! engine: These instructions apply from: CA 250 PIN (S/N) *65X20597* € Dynapac’s medium heavy vibratory soil compactor is the CA 250. It is available in versions D (smooth drum) and PD (padfoot). The PD version is used mainly on cohesive material and disintegrated rock. All types of base courses and subbase courses can be compacted deeper, and the interchange able drums ~ D and PD ~ 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, tachograph and CCS/RA field computer, are described in separate instructions. We reserve the Hight to change specications velthout venice, | Printed in Sven, |Lubricants and symbols Technical specifications Maintenance schedule Maintenance measures Every 10 hours of operation (Daily) Every 50 hours of operation (Weekly) Every 250 hours of operation (Monthly) ...nn-v Every 500 hours of operation (Every three months) Every 1000 hours of operation (Every six months) Every 2000 hours of operation (Yearly)... Long-term storage . ay Special instructions ..-..- Electrical system, fuses... Safety instructions—Personal safety 1] Special caution—Machine or component damage Read the entire manual before starting any service work. "Ensure that ventilation (extraction) is adequa- te if the engine is run indoors. {tis 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, betore starting up, of checking the roller to detect any leakage or damage. Also check the ground underneath the roller, where itis most often easier to detect any leakage. TAKE CARE OF THE ENVIRONMENT Do not leave behind any oil, fuel or other substances that are detrimental to the environment. This manual contains instructions for periodic measures that should normally be performed by the operator. eaon The manufacturer's instructions noted in the ‘engine manual also apply. This is placed under a separate flap in the roller’s product folder. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State ‘of California to cause cancer, birth defects, and other reproductive harm. BYNMAPAC CA 250 M250EN2 | | |© ENGINE OIL 4, HYDRAULIC FLUID | ambienttemperature “10° C - 440° C (14°F - 104°F) TRANSMISSION OIL ambient temperature. -15°C - +40°C (5°F - 104°F) ambienttemperature higher than +40°C (above 104°F) DRUM-CARTRIDGE OIL, GREASE FUEL ambient temperature higher than+40°C_ Shell Tellus T100 or equivalent Always use high-quality lubricants in the recommended ¥] amounts. Too much grease or allan eauce ‘overheating . and subsequent increased wear. Shell Rimula SAE 15W/40 or equivalent API Service CF-4/SG (CD/CE) Shell Tellus TX68 or equivalent Shell Spirax SAE 80W/90, HD API, GL-5 Shell Spirax HD85W/140 or equivalent Synthetic oil, MOBIL SHC 629 ‘Shell LGHB2 (NLGI-class 2) or equivalent for the articulation. Shell Retinax LX2 or equivalent for other grease points. ‘See engine manual Q 4 RR COOLANT 50/50 mixture with water Shell Anti Freeze 402 or equivalent. Anti-freeze down to about -35°C (-31°F). Other lubricants ara required for driving in extremely high U | orlow ambient temperatures. See tne "Special instructions” chapter, or consult Svedala Dynapac. Engine, oil level ©). Airtiter woe4 ee Engine, oil filter [7] Battery *¢) Tire pressure 77 JO] Hydraulic reservoir, level = a} Hydraulictluid filter © Drum, oil level = eee z a bXOe Transmission, oil level Coolant, level ts 4 Lubricating oi LYS Fecyeing Fuel filter DVMARAC CA 250 M250EN2Weight and sizes A250 CA250D — CA250PD_——CA250P- (Operating mass wih ROPS, ENSO0, kg (bs) 10600 (23,400) 10800 (28,800) 12200 (26.200) 12000 (26,500) Operating mass without ROPS, kg (Ibs) . 10235 (22,600) 40435 (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) 5650(219) §550(219) 5850(219) — §850(219) Width, standard-equipped roller, mm (in) . 2984(94) 2384(84) _2384(94) 2 384(94) Height, with ROPS, mm. (in) ..... 2922(115) 2922(115) 2977 (117) 2977 (117) Height, with ROPS/silencer, mm (in) .... 2 190 (86) 2 190 (86) 2.210 (87) 2.210 (87) Height, with cab, mm (in)... 29s2(116) 2.952(116) 2.965(117) 2965(117) Fluid volumes (Liters) (gal or qts) Rear axle: * Differential . 12 (12.7 ats) + Planetary gearint 4,7/side (1.8 ats) /each side Drum gearing -3,0 (3.2 qts) Cartridge, vibration generator side (2.8 ats) /each side Hydraulic reservoi 52 (13.7 ga!) Fluid in hydraulic system .. 23 (6 gal) Lubricating oil, Diesel engine 310 (10.6 ats) Goolant, Diesel engine ...... 4 (63gal) Fuel tank .. 250 (66 gal) Electrical system Battery... 12.V, 170 An Alternator. 14.V, 639A Fuses .... See under main heading: Electrical system Tires Tire size ... 1.28.1 x 26.0 8 Ply, 600/60-30,5 Air pressur 1.110 kPa (1,1 kp/cm’) (16 psi) a ‘As extra equipment, the tires can be filled with liquid (extra weight up to 700 kgitire) (1543 Ibelire) Remember this extra weight when you perform service. Compaction data CA250 CA250D CA250PDIP Static linear load Amplitude (High) Amplitude (Low) kg/om (pli) 28,1(157.4) 29,1 (163) - mm (in) 1,7 (0.067) 1,7 (0.067) 1,6 (0.063) mm(in) 0,8 (0.031) —-0,8(0.031) 0,8 (0.031) Frequency (High amplitude) .......Hz (pm) 30 (1800) 30 (1800) 30 (1800) Frequency (Low amplitude) Hz (vpm) 30 (1800) 30 (1800) 30 (1800) Centrifugal force (High amplitude) .. KN (lb) 203 (45,636) 203 (45,636) 249 (55,977) Centrifugal force (Low amplitude).....kN (Ib) 98 (22,031) 98 (22,031) 121 (27,202) a DVMAPAC A260 M250EN2Tightening torque ROPS Hydraulic system Vibration ~ Operator's station (iSO 2631) Noise level - Operator's station (ISO 6394) DYMAPAE CA 250 M250EN2 Tightening torque in Nm (\bt.) for oiled, bright galvanized bolts tightened with a torque wrench. M36 1960(1445.7) 2800(2065.3) M STRENGTH CLASS thread 88 10.9 12.9 M6 8,416.2) 1289) 14,6(10.8) MB 21(15.5) 2820.7) 84(21.1) uo 40(155) 56(41.3) 6825.1) M2 7061.6) 98(72.3)__117(66.3) mis | 1691247) 240(177) 290(213.9) Meo | © 930(243.4) 470(346.7) 560(413.1) Moa 570(420.4) _800(590.t) _960(708.1) M30 1190(833.5) 1580(1165.4) 1900(1401.4) ' ROPS bolts must always be tightened dry. Bolt size: Mad (PIN 90 39 64) Strength class: 10.9 Tightening torque: 800 Nm (590 ibf.tt) (for Dacromet treated) 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) foam-rubber mat, standard roller. Measured with vibration switched ON and on a with cabin. The limit value is 0,5 mis, Vibration on the operator's seat is 0,08 m/s* without cabin. Vibration on the operator's seat is 0,08 mvs? Noise levels with vibration switched OFF Measured on hard surface, standard roller. (aB(A)). Operators station, (with cab) LpA: 90 dB(A) Operator's station, (without cab) LpA: 83 dB(A) ‘Seven metres from the machine: LpA: 86 dB (A)chaste | \\ \ > \ iy \\\ \ 9 3310 4 307 29 28 13 2 2625 2322 621 2019: 8 7 6 16 4 Fig. 1 Service points 1 Radiator grille 12 Drum gearbox 23 Rear axle suspension, two sides 2 Oil level, hese! engine 18 Serapers 24 Oi Hter, case! engine 3 Fuel fiter, fuel pre-fiter 14 Drum cartridge ol, level plug, x2 25 Draining, fuel tank 4 Air filter 15 Rubber elements and fastening sorews 26 Engine suspension, x4 5 Hydraulic reservoir, sight olas5 +6 Steering joint 27 Feed pump, fuel 6 Breather fiter 17 Steering cylinder, x2 26 Diesel fuel, filing 7 Hydraulic fiter, x1 18 Flywheel casing, hydraulic pumps 29 Battery 8 Drairy hydraulic reservoir 19 Wheel nuts 30 Radiator 8 Hydraut fui, fing 20 Tire pressure 31 Hydraulic fd cooler 10 Fuse box 21 Rear axle, ferential 32 Drive bats, cooling, alternator 11 Drury cartidge oil ier, x2 22 Rear axle, planetary gearing, x2 39 ForwardReverse lever IBYIMIAPAC A250 M250EN2Perform periodic maintenance measures daily, weekly, etc, whichever comes first, or alter the stipulated hours of operation, [!] | Remove all dirt before filling, when checking ails 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 Seepage Comments fig. 1 Before starting up 13 Check the scraper setting 9,10 1 ‘Check for free circulation of cooling air 10 30 ‘Check coolant level 10 See engine instruction manual 2 Check oil level in the engine 11 See engine instruction manual 28 Refuel 11 5 Check the hydraulic reservoir level "1 Test the brakes 12 Every 50 hours of operation (weekly) Items in Measure Seepage Comments fig. 1 Check that hoses and connections are tight 6 Controlclean the fiter element in the aircleaner 13 Replace as required 16 Grease the steering joints 14 7 Grease the steering cylinder brackets 14 19 Cheek tightness of the wheel nuts 18 20 Check the tire pressure 15 4} | After the first 50 hours of operation, change # J allthe oil filters and oil, except the hydraulic fluid, WVMAPAE CA 250 M250EN2Every 250 hours of operation (monthly) ltemsin Measure ‘See page Comments fig. 1 22 CCheok the oi levelin the rear axle/planetary gearing 16 2 Check oil level in the gearbox 16 Accessory D/PD 14 Check oil level in the drum cartridge 17,18 31 Clean the coolers 18 19,23 Inspect tightening of bolted joints: 18 Applies only to new or renovated component. 16 Check rubber elements and bolted joints 19 24 Change the engine oil and oi filter 19 Seeengine instruction manual 29 Check the battery 19 Every 500 hours of operation (every three months) ttemsin - Measure Seepage Comments fig. 1 3 Replace fuel fiter ‘See engine instruction manual 3 Clean the initial fuel fitter 2 6 Inspect breather filter on the hydraulic reservoir 22 Every 1000 hours of operation (every six months) Check engine valve clearance Check belt tension of drive system 8 ltemsin Measure Seepage Comments fig. 1 7 Change the hydraulic filter 22 8 Drain condensation from the hydraulic reservoir22 25 Drain condensation from the fuel tank 23 4 Replace main filter in the air cleaner 23 at Change oll in the rear axle differential 23 23 Ghange oil in the rear axle planetary gearing 24 ‘See engine instruction manual See engine instruction manual Every 2000 hours of operation (yearly) items in Measure ‘See page Comments fig. 1 33 Lubricate the Forward/Reverse controls 21 8,9 Change the hydraulic fluid 25 12 ‘Change the drum cartridge 25 12 Change oil in the drum gearbox 26 Accessory D/PD a DBVMIARAC CA 250 M250EN2Fig.2 Scrapers 1. Scraper blade 2. Sorens (x4) Fig. 3 Sorapers 1, Scraper blade 2 Screws Fig.4 Scrapers 1. Scrows 2. Scraper beam 3. Scraper tooth DVMAPAE CA 250 M250EN2 1] _ Remember that the drum tends to move as the [!] machine turns, Consequently, if adjustments ate made closer than the values noted below, the scrapers may be damaged or the drum may wear more than usual.v 'f required, adjust distance to the drum as follows: Loosen the screws (2) and adjust to 20 mm (0.8 in).. Tighten the screws. 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. 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.5 Scrapers 1, Scraper blade 2 Screws Fig.6 Coolingairgrille Check 1 3 Coolant level © CA 250 Soft scrapers (Optional) Loosen the screws (2) and adjust to give light contact with the drum. Tighten the screws. Ensure that the engine has unimpeded circulation of cooling air through the protective grille to the engine. Ensure that coolant level is between the max/min marks. Take great care if the radiator cap must be opened while the engine is hot. Danger of being burned. Wear gloves and safety goggles. 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 tree passage through the radiator. Fig. 7 Radiator 1. Max. level 2 Min level 3. Filler cap ROE z DYMAPAC CA 250 M250EN2Engine — Checking the oil level ies Fig. 8 Engine compartment 1. Oil dpstick Fuel tank - Refueling &® 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. 7X" Beware of hot parts of the engine and hot A radiator when taking out the oil dipstick. Danger of being burned. ‘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 manual for further details. 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). Fig.9 Fuel tank 1. Filler pipe 2. Fuel pro-iter Hydraulic reservoir | = Checking the fluid level a Fig. 10 Hydraulic reservoir 1. Sight glass 2 Filler pipe DYMAPAE CA 250 M250EN2 ‘Check that there is no sediment or water in the Y| tact pre-fiter (2). = Clean the presilterif required, see under "500 hours of operation". 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. "1Brakes - Check OD) simne Check brake operation as follows: Drive the roller slowly forward. Press down the reservelparking brake knob (1). The brake warning lamp (3) on the instrument pane! 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 Controlpanet 1. Reservefparking brake knob 2, Forwardiraverse lever 3. Brake warning lamp 2 DDVMIAPAE CA 250 M250EN2Fig. 12 Air cleaner 1. Locking braces 2 Cover 3. Main titer 4. Backup fiter 5. Filer housing Main filter — Cleaning with ev) compressed air Fig. 13 Main fiter Backup filter — Replacement © Fig. 14 Air fttor 4. Backup iter DYMAPAE CA 250 M250EN2 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 cover (2) and take out the main fiter (3). Do not remove the backup filter (4), To clean the main fier, 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 a Wipe the inside of the cover (2) and filter housing (5). Check that the hose clamps between the filter 1] housing and suction hose are tight and that the hoses are intact. Inspect all hoses all the way to the engine. 1 Change the main filter at the latest after 5 L#] cleanings. Replace the backup fitter 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, 13~ Lubrication 1 AL \ Fig. 18 Steering joint, right side Steering joint - Lubricati _ Fig. 16 Steering, 1. Grease nipples, steering joint (x4) 2, Grease nipple, cylinder moun! (x1) Steerimg cylinders ~ Lubrication _ Fig. 17° Steering cylinder, right side 3. Lubricant nipple right rear steering cylinder mount (x1) 4, Lubricant nipple lett rear steering cylinder mount (xt) 4 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. “4"S Allow no one to get near the steering joint when the engine is running. Danger of being crushed when steering is operated. Push the reservelparking brake knob be- fore lubricating. Tum the steering whee! fully o the left to gain access to all six nipples on the right side of the steering system. GSS Use grease according to the lubricant specification. 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. euros If grease does not penetrate the bearings, it V] may be necessary to relieve the articulation LET joint with a jack while repeating the greasing process. ‘Wipe the nipples clean from grease and dirt. Grease the nipples (3 and 4) with five strokes of the grease gun. ‘Tum the steering wheel fully to the right to gain access to the forward grease nipple on the lett 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. BYNWAPAC CA250 M250EN2Tire pressure Wheel nuts Fig. 18 Wheels 4. Air valve 2. Whee! nut DBYIMAPAE CA 250 M250EN2_ 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 Speci tions. Check both tires. FF] When you change the tires, its important that ¥| both tires have the same rolling radius, to ensure proper operation of the anti-slip device in the rear axle. ‘Check tightening torque of the wheel nuts (2) at 470 Nm (350 lb-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. 15Rear axle differential —Chec king the oil level Fig.19. Level check—differential housing 1. Levelfiller plug Rear axle planetary gearing Checking the oil level Fig. 20 Level check—planetary gearing 1. LevelFiller plug Drum gearbox — Checking the oil level cH SEE at Fig.21 Level check—drum gearbox 1. Level plug 2. Filler plug 3. Drain plug 16 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. > we" 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. 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. Position the roller with the level plug (1) at 9 o'clock. 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. DYMAPAE CA 250 M250EN2Drum cartridge — Checking the oil level Fig. 22 Lett side of drum 1. Indicator pin Drum cartridge = Checking the Fig.23- Roller, right-hand side 1. Filer plug 2. Drain plug Drum cartridge Fig. 24 Drum cartridge 2.Drain plug 3.Level plug BIVIAPAE A250 M250EN2 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, Wipe the filing plug and level plug clean from dirt. Unscrew the filling plug (1). 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. T]_ Ensure that only MOBIL SHC 629 is used in the cartridges. Clean and refit the plugs. Repeat the procedure on the opposite side. 1] Donot overfill with oil ~ risk for overheating. 7Drum cartridge — Cleaning the ventilation screw = ToT iA aes \ SNe eS ey Fig.25. Drum 1. Ventilated screw Coolers - Checking/cleai Fig. 26 Hydraulic cooler 1, Water cooler 2. Hydraulle Mid cooler Bolted joints ~ Tightening check Fig. 27 Right side of machine 1. Steering pump 2. Rear axie 2. Engine suspension 4. Wheel nuts 18 Clean the drum ventilation hole. The hole is required to eliminate excess pressure inside the drum. Open the engine cover to gain access to the water and hydraulic coolers. Ensure that the flow of air through the coolers (1) and (2) 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. nurow Take care when using a high-pressure water [iy jet; do not hold the nozzle too near the cooler. ‘The cooler may otherwise be damaged. "Wear protective goggles when working with compressed air or high-pressure water jet. Steering pump against diesel engine (1) 38 Nm (28 tbs). Rear axle suspension (2) 330 Nm (243 ft.Ibs) 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 ftibs), oiled. (The above applies only to new or replaced components.) DVMARPAC CA 250 M250EN2Rubber elements and fastening screws ~ Check Fig. 28 Drum, vibration side 1. Rubber element 2, Fastening screws Diesel engine () — Oil and filter change Fig. 29 Left side ofengine 1. Drain plug 2 Oilfiter Battery Checki Fig. 30 Battery box 1. Quickserews 2, Battery cover 3. Batlery DYNWABAE CA250 1250EN2 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. "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 undemeath the engine. Drain off the oil while the engine is warm. Place a receptacle that holds at least 15 liters(16 gts) under the drain plug, “° Danger of being burned when draining hot A oil. Protect your hands, Fill oil according to the engine manual. Replace the engine oil filter (2) at he same time. See also engine instruction manual. 1. Dispose of the drained oll and fiter in an aq » approved manner. 7X" Never use an open flame when checking A 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. A" Wear safety goggles. The battery contains acid. Rinse with water if electrolyte comes into contact with the body. 19Fig. 31 Electrolyte level in battery 1. Cell cap 2. Electrolyte level 3. Plate 20 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. 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 acid-free Vaseline. 7] _ When disconnecting the battery, always 1} cisconnect 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. AN" Before doing any electric welding on the machine, disconnect the battery ground cable and then all electrical connections to the alternator. IDVIVAPAE CA 250 M250EN2CA 250 M250EN2 DyYwapac seen 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 bow! (2). Take out the filter (3) and clean in a non-flammable fluid. Replace the filter as required. Fit the filter and bow. Start the engine and check that the pre-flter does not leak. Make sure there is adequate ventilation A (extraction) if the diesel engine is run in- doors. Risk of carbon monoxide poisoning. tl CAS _ Discard the fitter (3) in an approved manner. 24Hydraulicfilter - Replacement Fig.33 Hydraulic reservoir 2. Filler eap/Breather fiter Fig. 34 Engine compartment 1. Hydraulic filler (x1) 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 rolieve 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 and blow with compressed air until free passage is assured, or replace the cap with a new one. “X"° Wear protective goggles when working with compressed air. Clean thoroughly round the hydraulic filter, Remove the hydraulic fiter (1) and scrap it, They are of the expendable type and cannot be cleaned. rma" Ensure that the old sealing ring is not left on [1] the filter holder. Leakage may otherwise occur between the new and the old seals. Thoroughly clean the sealing surface of the filter holder. Apply a thin coat of fresh hydraulic fluid on. the new filter seal. 1] __ fitst screw on until the fiter seal les against 1] the fiter 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 fiuid 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. DVIMWAPAE CA 250 M250EN2oe Fig. 35 Hydraulic reservoir, underneath 1. Drain cock 2 Plug Fuel tank ~ Draining cM Fig. 36 Fuel tank 1. Drain plug Fig.37 Air cleaner 1. Locking flaps 2 Cover 3. Main fiter 4. Backup fiter 5. Fiter housing 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. Refit the plug. Water and sediment in the fuel tank are drained via the drain plug in the bottom of the fuel tank FF) Take great care when draining. Do not drop ¥] the piug so that all the fuel runs out. Drain only after the roller has stood still during @ 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. Drain as follows: Hold a suitable receptacle under the plug (1). Loosen the plug and drain off the water and sediment until only pure fuel flows from the plug. Tighten the plug again. 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. DYMWARPAC CA 250 M250EN2 23Rear axle differential -Oil change Fig. 38 Rear axle 1. LevelFiller plug 2 Drain plugs Rear axle planetary gearing = Oil change | © 4. Plug Fig. 40 Planetary goaring/filing position 1. Plug 24 weX"S Never work under the roller with the engine running. Park on a level surface and block the wheels securely. Wipe clean and remove the level/fller plug (1) and all five drain plugs (2) and drain the cil into a suitable receptacle. The volume is almost 12 litres (12.7 qts). Save the oil and deposit it in an approved fr ES tanner Refit the drainage plugs and top up with fresh oil until the: correct level is reached. Refit the oil-level/iller plug. Use transmission oil, see the lubrication specification. Position the roller with the plug (1) at its lowest position. Wipe clean, unscrew the plug (1) and drain the cil into a suitable receptacie. The volume is about 2 litres (2.1 gts). Save the oil and deposit it in an approved t* CS ramen 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. DVMAPAC A250 M250EN2Hydraulic reservoir ra — Changing the fluid Ia} Fig. 41 Hydrauite reservoir, underneath 4. Stop cock 2 Plug Drum cartridge - Oil change “Fig 42 Left side. 1. Ingiator pin Drum cartridge ~ Oil change a 34 By o> eK OF i Fig. 43 Drum, right side 1. Filler plug 2, LevelDrain plug DVMABRAE CA 250 M250EN? wins 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. wagons Danger of being burned when dr: oil. Protect your hands. 1g hot 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 simi- lar 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. ran ae Fill up with fresh hydraulic fluid as per the instructions under the heading “Hydraulic reservoir — Check fluid level” Replace the hydraulic fluid filters at the same time. Save the oil and deposit it in an approved manner. Start the diesel engine and operate the various hydrau- lic functions. "A Make sure there is adequate ventilation (extraction) if the diesel engine is run indoors. Risk of carbon monoxide poison- Ag 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. Place a receptacle for about § litres (5.3 qts) undemeath the level/drain plug (2). {Save the oil and deposit itin an approved GO 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 lever’ Repeat the procedure on the opposite side. 1] Ensure that only MOBIL SHC 629 is used in 2 the cartridges. 25Drum gearbox - Oil change Fig.44 Drum gearbox 1. Drain plug 2 Filler plug 3. Level plug Steering joint - Check Fig.45 Steeringjoint Controls and pivoted joints Lubrication Fig.45 Operator's station 1, Fonard/Reverse lever 2 Screws 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 oll into a suitable receptacle, capacity about 3,5 liters (8.7 ats). Refit th plug (1) and fill with oil up to the level plug (3), according to “Drum gearbox ~ Checking the oll level”. Use transmission oil, see Lubricant Specification. Clean and refit the level plug (3) and filler plug (2). Inspect the steering joint to detect any damage or cracks. Check and correct any loose bolts. Check also for any stiffness and play. 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. DBVWARAE CA250 M250EN2ig.47 Roller protected against the weather Diesel engine Battery Air cleaner, exhaust pipe Fuel tank Hydraulic reservoir Steering cylinder, hinges, etc. Tires (All weather) Hoods, tarpaulin 1] _ 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. ‘See manufacturer's instructions in the engine ma- ‘ual that accompanies the roller. Remove the battery from the roller, clean it, check that the electrolyte level is correct and trickle charge the battery once a month. 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. Fill the fuel tank completely to prevent condensation. Drain off any condensation from the hydraulic reservoir. Grease the steering-joint bearings and both bearings of the steering cylinder. Grease the piston rod of the steering cylinder with inhibitor grease. Also grease the engine hood hinges, rev control and the forward/reverse mechanism. Ensure that tire pressure is 110 kPa (1.1 kp/ erm’). Lower the instrument shield on the steering column. Cover the entire roller with a tarpaulin that is clear of the ground. Store the roller indoors if possible, preferably on premises with an even temperature. DYNIAPAC 250 M250EN2 a7Standard oils and other recommended fluids Higher ambient temperature max. +50°C (122°F) Temperature High-pressure washing Fire fighting Protective structure (ROPS) Starting aid 28 Upon delivery from the factory, the various systems and components are filed 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) V] applies for biological hydraulic fluid. When operating in hotter ambient temperatures, but up to max. +50°C (122°F), the following instructions apply: 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 of corresponding. Other components using transmission oil: Shell Spirax HD 85W/140 or corresponding. The temperature limits apply to standard versions of the roller. Rollers that are fitted with additional equipment, such as noise suppression, efc., may require extra observa tion in the higher temperature ranges, 1] _ When washing the machine, do not direct the 1] jetof 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 extinguisher if possible. A BE type carbon dioxide fire extinguisher may also be used. if the roller is equipped with a Roll Over Protective Structure, (ROPS), it must on no account be subjected to welding and holes must never be dried in the structure. Never attempt to repair a damaged structure, it must be replaced with a new one. 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. DYMAPAC CA 250 M250EN2