Dynapac CA280 User manual

DYNAPAC
CA280
Box 504, SE-371 23 Karlskrona, Sweden
Phone: [phone], Fax: [phone]
www.dynapac.com
M280EN1
MAINTENANCE

19
ILF015WO1

Vibratoryroller
CA280
Maintenance
M280EN1, June 2003
Diesel engine:
CA280: Cummins 4BTAA 3.9C
CA280: Cummins 4BTA 3.9C
These instructions apply from:
CA280 PIN (S/N) *68620280*
CA280D PIN (S/N) *68720280*
CA280 PIN (S/N) *68820280*
CA280D PIN (S/N) *68920280*
Reservation for changes.
Printed in Sweden.
KEEP THIS MANUAL FOR
FUTURE REFERENCE
One of Dynapac’s medium heavy vibratory soil compactors is the CA280.
It is available in a solely wheel-driven version and in a wheel-and-drum-driven version,
called CA280D.
All types of base courses and reinforcement courses can be compacted to considerable depth.
The cab and safety-related accessories are described in this manual.
Other optional items are described in separate instructions.

2CA280 M280EN1
CONTENTS
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
substances that are detrimental to the
environment.
This manual contains instructions for periodic measures
that should normally be performed by the operator.
The manufacturer’s instructions noted in the
engine manual also apply. This is placed under a
separate flap in the roller’s product folder.
GENERAL
Safety instructions—Personal safety
Special caution—Machine or component damage
WARNING SYMBOLS
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.
Page
Lubricants and symbols ................................................... 3
Technical specifications ................................................ 4-6
Maintenance schedule ..................................................... 7
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) ...... 22
Every 1000 hours of operation (Every six months) .. 23-26
Every 2000 hours of operation (Yearly) .................... 27-28
Long-term Storage ......................................................... 29
Special instructions ........................................................ 30
Electrical system, fuses ........................................... 31, 32

3
CA280 M280EN1
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
LUBRICANTS AND SYMBOLS
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 SKF LGHB2 (NLGI-class 2) or equivalent for
the articulation.
Shell Retinax LX2 or equivalent for other
grease points.
FUEL See engine manual
COOLANT GlycoShell or equivalent.
50/50 mixture with water Anti-freeze down to about -35°C (-31°F).
Always use high-quality lubricants in the recommended amounts. Too much
grease or oil can cause overheating and subsequent increased wear.
Other lubricants are required for driving in extremely high or low ambient
temperatures. See the “Special instructions” chapter, or consult Dynapac.

4CA280 M280EN1
TECHNICAL SPECIFICATIONS
Weight and sizes CA280 CA280D
Operating mass with ROPS, EN500, kg (lbs) 12300 (27,100) 12500 (27,600)
Operating mass without ROPS, kg (lbs) 11950 (26,300) 12150 (26,800)
Operating mass with cab, kg (lbs) 12450 (27,450) 12650 (27,900)
Length, standard-equipped roller, mm (in) 5 550 (219) 5 550 (219)
Width, standard-equipped roller, mm (in) 2 384 (94) 2 384 (94)
Height, with ROPS, mm (in) 2 922 (115) 2 922 (115)
Height, with ROPS/silencer, mm (in) 2 190 (86) 2 190 (86)
Height, with cab, mm (in) 2 952(116) 2 952 (116)
Fluid volumes (Liters) (gal or qts)
Rear axle:
• Differential ................................................. 12 (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 ...................................... 52 (13.7 gal)
Fluid in hydraulic system............................. 23 (6 gal)
Lubricating oil, Diesel engine ....................... 10 (10.6 qts)
Coolant, Diesel engine ................................ 18 (4.8 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 CA280 CA280D
Static linear load ......................... kg/cm (pli) 31,7 (177.5) 32,7 (183.1)
Amplitude (High).............................. mm (in) 1,7 (0.067) 1,7 (0.067)
Amplitude (Low) .............................. mm (in) 0,8 (0.031) 0,8 (0.031)
Frequency (High amplitude) ......... Hz (vpm) 33 (1980) 33 (1980)
Frequency (Low amplitude) .......... Hz (vpm) 33 (1980) 33 (1980)
Centrifugal force (High amplitude) .... kN (lb) 246 (55,350) 246(55,350)
Centrifugal force (Low amplitude)..... kN (lb) 113 (25,425) 113 (25,425)

5
CA280 M280EN1
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)
Tightening torque
Hydraulic system
ROPS
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) –
Tightening torque in Nm (lbf.ft) for oiled, bright
galvanized bolts tightened with a torque wrench.
Bolt size: M24 (P/N 90 39 64)
Strength class: 10.9
Tightening torque: 800 Nm (for Dacromet treated)
ROPS bolts must always be tightened dry.
TECHNICAL SPECIFICATIONS

6CA280 M280EN1
CA280 109 90 83
The acoustic values are measured in conformance with the operation
cycle described in EU directive 2000/14/EC on EU-equipped
machines, on soft polymer material with vibration switched ON and
operator’s seat in the transport mode.
Acoustic values
Model Guaranteed
acoustic
power level
dB(A) LwA
Acoustic
pressure level,
operator’s ear
(platform)
dB(A) LpA
Acoustic
pressure level,
operator’s ear
(cab) dB(A)
LpA
Noise level can vary when driving on different
courses and with different seat positions.
The vibration values are measured in conformance
with the operation cycle described in EU directive
2000/14/EC on EU-equipped machines, on soft
polymer material with vibration switched ON and
operator’s seat in the transport mode.
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.
Vibrations – Drivers seat
(ISO 2631)
Vibration levels may vary when driving on
different courses and with different seat
positions.
TECHNICAL SPECIFICATIONS

7
CA280 M280EN1
1 2 3 4 5 6 7 8 9 33 10 11 12
26 25 24 23 22 21 20 19 18 17 16 15 14
13
32
31
30
29
28
27
MAINTENANCE SCHEDULE
Fig.1 Service points
1. Radiator grille
2. Oil level, diesel engine
3. Fuel filter, fuel pre-filter
4. Air filter
5. Hydraulic reservoir, sight glass
6. Breather filter
7. Hydraulic filter, x1
8. Drain hydraulic reservoir
9. Hydraulic fluid, filling
10..Fuse box
11. Drum cartridge oil filler, x2
12. Drum gearbox
13. Scrapers
14. Drum cartridge oil, level plug, x2
15. Rubber elements and fastening screws
16. Steering joint
17. Steering cylinder, x2
18. Flywheel casing, hydraulic pumps
19. Wheel nuts
20. Tire pressure
21. Rear axle, differential
22. Rear axle, planetary gearing, x2
23. Rear axle suspension, two sides
24. Oil filter, diesel engine
25. Draining, fuel tank
26. Engine suspension, x4
27. Feed pump, fuel
28. Diesel fuel, filling
29. Battery
30. Radiator
31. Hydraulic fluid cooler
32. Drive belts, cooling, alternator
33. Forward/Reverse lever

8CA280 M280EN1
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.
MAINTENANCE MEASURES
Items in Measure See page Comments
fig. 1
Before starting up
13 Check the scraper setting 10
1 Check for free circulation of cooling air 11
30 Check coolant level 11 See engine instruction manual
2 Check oil level in the engine 12 Seeengine instruction manual
28 Refuel 12
5 Check the hydraulic reservoir level 12
Test the brakes 13
Every 10 hours of operation (daily)
Items in Measure See page Comments
fig. 1
4 Check that hoses and connections are tight 14
6 Control/clean the filter element in the air cleaner 14 Replace as required
16 Grease the steering joints 15
17 Grease the steering cylinder brackets 15
19 Check tightness of the wheel nuts 16
20 Check the tire pressure 16
After the first 50 hours of operation change only the drum oil and all the oil filters.
Every 50 hours of operation (weekly)

9
CA280 M280EN1
MAINTENANCE MEASURES
Itemsin Measure See page Comments
fig. 1
22 Check the oil level in the rear axle/planetary gearing 17
12 Check oil level in the gearbox 18 Accessory D
14 Check oil level in the drum cartridge 18, 19
31 Clean the coolers 20
19, 23 Inspect tightening of bolted joints 20 Applies only to new or
renovated component.
15 Check rubber elements and bolted joints 21
29 Check the battery 21
Every 250 hours of operation (monthly)
Itemsin Measure See page Comments
fig. 1
7 Change the hydraulic filter 23
8 Drain condensation from the hydraulic reservoir 24
25 Drain condensation from the fuel tank 24
4 Replace main filter in the air cleaner 24
21 Change oil in the rear axle differential 25
22 Change oil in the rear axle planetary gearing 26
Check engine valve clearance See engine instruction manual
32 Check belt tension of drive system See engine instruction manual
Every 1000 hours of operation (every six months)
Itemsin Measure See page Comments
fig. 1
8, 9 Change the hydraulic fluid 27
12 Change oil in the drum cartridge 27
12 Change oil in the drum gearbox 28 Accessory D
33 Lubricate the Forward/Reverse controls 28
Every 2000 hours of operation (yearly)
Itemsin Measure See page Comments
fig. 1
24 Change engine oil and oil filter 22 See engine instruction manual
3 Replace fuel filter See engine instruction manual
3 Clean the initial fuel filter 22
6 Inspect breather filter on the hydraulic reservoir 23
Every 500 hours of operation (every three months)

10 CA280 M280EN1
2
1
12
2 1 1 2
CA280 Soft scrapers (Optional)
Loosen the screws (2) and adjust to give light contact
with the drum. Tighten the screws.
Fig.4 Scrapers
1. Scraper blade
2. Screws
EVERY 10 HOURS OF OPERATION (Daily)
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.
Scrapers
– Checking/Adjusting
Fig.2 Scrapers
1. Scraper blade
2. Screws (x4)
Fig.3 Scrapers
1. Scraper blade
2. Screws
CA280 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.

11
CA280 M280EN1
13
2
2
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.
Air circulation – Check
Fig.5 Coolingairgrille
1. Filler cap (coolant)
EVERY 10 HOURS OF OPERATION (Daily)
Fig.6 Radiator
1. Max. level
2. Min. level
3. Filler cap
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
passage through the radiator. To bleed the
system, run the engine warm and increase
speed to maximum revs, then switch off the
engine and top up to the correct level.

12 CA280 M280EN1
1
1
2
1
2
Hydraulic reservoir
– Checking the fluid level
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).
EVERY 10 HOURS OF OPERATION (Daily)
Engine
– Checking the oil level
Fig.7 Engine compartment
1. Oil dipstick
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
manual for further details.
Fig.8 Fuel tank
1. Filler pipe
2. Fuel pre-filter
Fuel tank – Refueling
Check that there is no sediment or water in the
fuel pre-filter (2).
Clean the pre-filter if required, see under "500
hours of operation".
Fig.9 Hydraulic reservoir
1. Sight glass
2. Filler pipe
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.

13
CA280 M280EN1
13
2
EVERY 10 HOURS OF OPERATION (Daily)
Brakes – Check
Fig.10 Controlpanel
1. Reserve/parking brake knob
2. Forward/reverse lever
3. Brake warning lamp
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.

14 CA280 M280EN1
23
1 4 5
4
EVERY 50 HOURS OF OPERATION (Weekly)
Air cleaner
– Checking/cleaning
Main filter – Cleaning with
compressed air
Fig. 12 Main filter
Fig.11 Air cleaner
1. Locking braces
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
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
cover (2) and take out the main filter (3).
Do not remove the backup filter (4).
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.13 Air filter
4. Backup filter
Backupfilter
– Replacement
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
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.

15
CA280 M280EN1
1
1
2
3 4
1
Steering cylinders
– Lubrication
Steeringjoint
– Lubrication
Steering joint/Steering cylinders
– Lubrication
Fig.14 Steering joint, rightside
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.
Use grease according to the lubricant
specification.
Fig. 16 Steering cylinder, right side
3. Lubricant nipple right rear
steering cylinder mount (x1)
4. Lubricant nipple left rear steering
cylinder mount (x1)
Fig.15 Steering joint, rightside
1. Grease nipples, steering joint (x4)
2. Grease nipple, cylinder mount (x1)
EVERY 50 HOURS OF OPERATION (Weekly)
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.
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.

16 CA280 M280EN1
12
EVERY 50 HOURS OF OPERATION (Weekly)
Tire pressure
Wheel nuts – Tightening Check the tire pressure with a pressure gauge.
Since the tires are filled with liquid, the air pressure
valve (1) must be set at ”12 o’clock” when you check
or pump air.
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.
Check tightening torque of the wheel nuts (2) at 470
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.
Note: The tires are filled with liquid, so
they are heavier than normal.
Fig.17 Wheels
1. Air valve
2. Wheel nut

17
CA280 M280EN1
1
1
1
EVERY 250 HOURS OF OPERATION (Monthly)
Rear axle differential
– Checking the oil level
Fig. 18 Level check—differential housing
1. Level/Filler plug
Rear axle planetary gearing
–Checkingthe oillevel
Fig.19 Level check
- planetary gearing, std
1. Level/Filler plug
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.
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, accessory
1. Level/Filler plug

18 CA280 M280EN1
1
1
2
3
1
2
3
EVERY 250 HOURS OF OPERATION (Monthly)
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.22 Left side of drum
1. Indicator pin
Fig.23 Roller,right-hand side
1. Filler plug
2. Drain plug
3. Level plug
Drum cartridge
– Checking the oil level
Wipe the filling plug and level plug clean from dirt.
Unscrew the filling plug (1).
Fig.21 Level check - drum gearbox
1. Level plug
2. Filler plug
3. Drain plug
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.