Page 1
DYNAPAC
CA280
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00, Fax: +46 455 30 60 30
www.dynapac.com
M280EN1
MAINTENANCE
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19
ILF015WO1
Page 3
Vibratory roller
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.
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2
CA280 M280EN1
CONTENTS
Read the entire manual before starting any
service work.
Ensure that ventilation (extraction) is adequate 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
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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.
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CA280 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/cm
2
)
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)
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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
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6
CA280 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
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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
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8
CA280 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 See engine 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)
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9
CA280 M280EN1
MAINTENANCE MEASURES
Items in 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)
Items in 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)
Items in 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)
Items in 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)
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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.
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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 Cooling air grille
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.
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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.
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13
CA280 M280EN1
1
3
2
EVERY 10 HOURS OF OPERATION (Daily)
Brakes – Check
Fig. 10 Control panel
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.
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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 instrument 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
Backup filter
– 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.
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15
CA280 M280EN1
1
1
2
3 4
1
Steering cylinders
– Lubrication
Steering joint
– Lubrication
Steering joint/Steering cylinders
– Lubrication
Fig. 14 Steering joint, right side
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 before 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, right side
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.
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16
CA280 M280EN1
1
2
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 Specifications.
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
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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
– Checking the oil level
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 engine 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 transmission 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 planetary gearing of the rear axle.
Fig. 20 Level check
- planetary gearing, accessory
1. Level/Filler plug
Page 20
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 transmission oil according to the lubricant specification.
Clean and screw in the plugs tight.
Page 21
19
CA280 M280EN1
1
3
2
EVERY 250 HOURS OF OPERATION (Monthly)
Fig. 25 Drum
1. Ventilated screw
Drum cartridge
– Cleaning the ventilation screw
Clean the drum ventilation hole. The hole is required to
eliminate excess pressure inside the drum.
Unscrew the level plug (3) at the bottom of the cartridge
until the hole in the middle of the plug becomes visible.
Top off with oil through the filling plug (1), until oil begins
to run out from the level-plug hole. The level is correct
when it stops running.
Ensure that only MOBIL SHC 629 is used in
the cartridges.
Clean and refit the plugs. Repeat the procedure on the
opposite side.
Do not overfill with oil – risk for overheating.
Drum cartridge
Fig. 24 Drum cartridge
2.Drain plug
3.Level plug
Page 22
20
CA280 M280EN1
1
2
3
2
1
4
12
3
EVERY 250 HOURS OF OPERATION (Monthly)
Check all rubber elements (1), replace all of the
elements if more than 25% of them on one side of the
drum are cracked deeper than 10–15 mm (0.4-0.6 in).
Use the blade of a knife or pointed object to assist
when checking.
Ensure that the fastening screws (2) are tightened.
Fig. 28 Drum, vibration side
1. Rubber element
2. Fastening screws
Rubber elements and fastening
screws – Check
Fig. 26 Hydraulic cooler
1. Water cooler
2. Hydraulic fluid cooler
3. Intercooler
Open the engine cover to gain access to the water and
hydraulic coolers, and the intercooler.
Ensure that the flow of air through the coolers (1), (2)
and (3) is unobstructed.
Clean a dirty radiator using compressed air or a highpressure water jet. Blow or wash the radiator in the
opposite direction to that of the cooling air.
Take care when using a high-pressure water
jet; do not hold the nozzle too near the cooler.
The cooler may otherwise be damaged.
Wear protective goggles when working
with compressed air or high-pressure
water jet.
Coolers
– Checking/cleaning
Bolted joints
– Tightening check
Fig. 27 Right side of machine
1. Steering pump
2. Rear axle
3. Engine suspension
4. Wheel nuts
Steering pump against diesel engine (1) 38 Nm
(28 ft.lbs).
Rear axle suspension (2) 330 Nm (243 ft.lbs) oiled.
Engine suspension (3). Check that all M12 bolts (x20),
are tightened (20 off), 78 Nm (57 ft.lbs).
Wheel nuts (4). Check that all nuts are tightened, 470
Nm (347 ft.lbs), oiled.
(The above applies only to new or replaced
components.)
Page 23
21
CA280 M280EN1
1
2
3
10 mm
123 1
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 temperature 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.
When disconnecting the battery, always
disconnect the negative cable first. When
connecting the battery, always connect the
positive cable first.
Discard used batteries in a proper way.
Batteries contains lead, which is detrimental to
the environment.
Before doing any electric welding on the
machine, disconnect the battery ground
cable and then all electrical connections to
the alternator.
Battery cell
Fig. 30 Electrolyte level in battery
1. Cell cap
2. Electrolyte level
3. Plate
EVERY 250 HOURS OF OPERATION (Monthly)
Never use an open flame when checking
the electrolyte level. Explosive gas is generated when the alternator is charging.
Open the cover and release the quick-screws (1).
Lift the battery cover (2).
Wipe the top of the battery dry.
Wear safety goggles. The battery contains
acid. Rinse with water if electrolyte comes
into contact with the body.
Battery – Checking the
electrolyte level
Fig. 29 Battery box
1. Quick-screws
2. Battery cover
3. Battery
Page 24
22
CA280 M280EN1
32 1
21
EVERY 500 HOURS OF OPERATION (Every three months)
Fig. 31 Engine
1. Screw
2. Glass bowl
3. Strainer
Fuel pre-filter
– Cleaning
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Loosen the screw (1) and remove the bowl (2).
Take out the strainer (3) and clean in a non-flammable
fluid. Replace the filter as required. Fit the strainer and
bowl.
Start the engine and check that the pre-filter does not
leak.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning.
Fig. 32 Left side of engine
1. Drain plug
2. Oil filter
Diesel engine
– Oil and filter change
Place the roller on a level surface. Switch
off the engine and apply the parking brake/
Reserve brake.
The oil drain plug (1) is most easily accessible from
underneath the engine. Drain off the oil while the engine
is warm. Place a receptacle that holds at least 15
liters(16 qts) under the drain plug.
Observe caution when draining hot oil.
Protect your hands.
Fill oil according to the engine manual. Replace the
engine oil filter (2) at the same time. See also engine
instruction manual.
Dispose of the drained oil and filter in an
approved manner.
Page 25
23
CA280 M280EN1
3
2
1
Place the roller on a level base. The engine
must be switched off and the parking brake
applied for all checking and adjustments
on the roller unless stated otherwise.
Loosen the cap/breather filter (2) on top of the reservoir
to relieve any excess pressure inside.
Ensure that the breather filter (2) is not clogged, air
must have unobstructed passage through the cap in
both directions.
If clogged in either direction, clean with a little diesel oil
and blow with compressed air until free passage is
assured, or replace the cap with a new one.
Wear protective goggles when working
with compressed air.
Clean thoroughly round the hydraulic filter. Remove the
hydraulic filter (1) and scrap it. They are of the
expendable type and cannot be cleaned.
Ensure that the old sealing ring is not left on
the filter holder. Leakage may otherwise occur
between the new and the old seals.
Thoroughly clean the sealing surface of the filter holder.
Apply a thin coat of fresh hydraulic fluid on the new
filter seal. Screw on the filter by hand.
First, screw on until the filter seal lies against
the filter holder. Then screw a further half turn.
Do not tighten the filter too hard, which could
damage the gasket.
Start the engine and ensure that there is no leakage of
hydraulic fluid from the filter. Check the fluid level in the
sight glass (3) and top off as required.
Ensure that ventilation (extraction) is
adequate if the engine is run indoors.
Risk of carbon monoxide poisoning.
Fig. 34 Engine compartment
1. Hydraulic filter (x1)
Fig. 33 Hydraulic reservoir
2. Filler cap/Breather filter
3. Sight glass
EVERY 1000 HOURS OF OPERATION (Every six months)
Hydraulic filter
– Replacement
Page 26
24
CA280 M280EN1
1
2
1
23
1 4 5
Water and sediment in the fuel tank are drained via the
drain plug in the bottom of the fuel tank.
Take great care when draining. Do not drop
the plug so that all the fuel runs out.
Drain only after the roller has stood still during a long
period, for example, overnight. The fuel level should be
as low as possible.
The roller should preferably have stood sloping so that
water and sediment are concentrated over the drain
plug (1). Drain as follows:
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.
EVERY 1000 HOURS OF OPERATION (Every six months)
Fig. 36 Fuel tank
1. Drain plug
Fuel tank – Draining
Replace the main filter of the air cleaner, even if it has
not yet been cleaned five times, see every 50 hours of
operation for changing the filter.
Fig. 37 Air cleaner
1. Locking flaps
2. Cover
3. Main filter
4. Backup filter
5. Filter housing
Air filter – Changing
Hydraulic reservoir
– Draining
Condensation in the hydraulic reservoir is drained via
the drain plug (1).
Drain only after the roller has stood still during a long
period, for example, overnight.
Drain as follows:
Remove the plug (2).
Hold a suitable receptacle under the tap.
Open the tap (1) and drain off any condensation.
Close the drain tap.
Refit the plug.
Fig. 35 Hydraulic reservoir, underneath
1. Drain cock
2. Plug
Page 27
25
CA280 M280EN1
1
2
EVERY 1000 HOURS OF OPERATION (Every six months)
Fig. 38 Rear axle
1. Level/Filler plug
2. Drain plugs
Rear axle differential
– Oil change
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/filler plug (1) and all
five drain plugs (2) and drain the oil into a suitable
receptacle. The volume is almost 12 litres (12.7 qts).
Save the oil and deposit it in an approved
manner.
Refit the drainage plugs and top up with fresh oil until
the correct level is reached.
Note: It takes a while for the oil to flow into the axle. Do
not fill the entire volume all at once.
Refit the oil-level/filler plug. Use transmission oil, see
the lubrication specification.
Page 28
26
CA280 M280EN1
1
1
1
1
Std.
Std.
Rear axle planetary gearing
– Oil change
Fig. 39 Planetary gearing / draining position
1. Plug
Fig. 40 Planetary gearing / filling position
1. Plug
EVERY 1000 HOURS OF OPERATION (Every six months)
Position the roller with the plug (1) at its lowest position.
Wipe clean, unscrew the plug (1) and drain the oil into a
suitable receptacle.
The volume is about 2 litres (2.1 qts).
Save the oil and deposit it in an approved
manner.
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.
Accessory
Accessory
Page 29
27
CA280 M280EN1
1
1
2
3
1
2
Hydraulic reservoir
– Changing the fluid
Fig. 41 Hydraulic reservoir, underneath
1. Stop cock
2. Plug
EVERY 2000 HOURS OF OPERATION (Yearly)
Drum cartridge
– Oil change
Fig. 43 Drum, right side
1. Filler plug
2. Drain plug
3. Level plug
Place a receptacle that will hold about 5 liters (about 41/2 quarts) under the drain plug (2).
Save the oil and deposit it in an approved
manner.
Clean and unscrew the filler plug (1) and the
drain plug (2).
Allow all of the oil to drain off. Fit the drain plug, and fill
with fresh synthetic oil according to instructions under
the heading “Drum cartridge – Checking the oil level”.
Repeat the procedure on the opposite side.
Ensure that only MOBIL SHC 629 is used in
the cartridges.
Place the roller on a level surface. Switch the
engine off and push in the reserve/parking
brake knob for all checking and adjustments
on the roller, unless otherwise specified.
Observe caution when draining hot oil.
Protect your hands.
Obtain a container for collecting the used fluid. The container 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,
after the plug (2) has been removed and the tap opened.
Save the oil and deposit it in an approved
manner.
Fill up with fresh hydraulic fluid as per the instructions
under the heading “Hydraulic reservoir – Check fluid
level”.
Replace the hydraulic fluid filters at the same time.
Start the diesel engine and operate the various hydraulic
functions.
Make sure there is adequate ventilation
(extraction) if the diesel engine is run indoors. Risk of carbon monoxide poisoning.
Check the fluid level and top up if necessary.
Position the machine level so that the indicator pin (1)
on the inside of the drum is aligned with the top of the
drum frame.
Fig. 42 Left side of drum
1. Indicator pin
Drum cartridge
– Oil change
Page 30
28
CA280 M280EN1
2
1
3
2
1
EVERY 2000 HOURS OF OPERATION (Yearly)
Drum gearbox
– Oil change
Fig. 44 Drum gearbox
1. Drain plug
2. Filler plug
3. Level plug
Place the roller on a level surface with the plugs (1) and
(2) as illustrated.
Wipe clean, unscrew the plugs (1, 2 and 3) and drain
the oil into a suitable receptacle, capacity about 3 liters
(3.2 qts).
Refit the plug (1) and fill with oil up to the level plug (3),
according to “Drum gearbox – Checking the oil level”.
Use transmission oil, see Lubricant Specification.
Clean and refit the level plug (3) and filler plug (2).
Steering joint – Check
Inspect the steering joint to detect any damage or
cracks.
Check and correct any loose bolts.
Check also for any stiffness and play.
Fig. 45 Steering joint
Fig. 46 Operator’s station
1. Forward/Reverse lever
2. Screws
Controls and pivoted joints
– Lubrication
Lubricate the forward/reverse control mechanism.
Unscrew the two screws (2) and take off the protective
cover (1). Oil the mechanism.
Refit the cover and screws.
Page 31
29
CA280 M280EN1
LONG-TERM STORAGE
* See manufacturer’s instructions in the engine ma-
nual 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 water and fill the hydraulic reservoir to the upper mark.
Lubricate the steering joint bearings and the steering
cylinder’s two bearings with grease.
Grease the steering cylinder’s piston with
conservation grease.
Grease also the engine compartment cover’s hinges, the seat slide rails, the engine-speed control
and the forward/reverse control mechanism.
Ensure that tire pressure is 110 kPa (1.1 kp/ cm
2
).
* Place the instrument cover on the steering column.
Cover the entire machine with a tarpaulin, which
should hand some way off the ground. If possible,
store the roller indoors, preferably in a building with a
uniform temperature.
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.
Battery
Diesel engine
Air cleaner, exhaust pipe
Fuel tank
Hydraulic reservoir
Steering cylinder, hinges, etc.
Hoods, tarpaulin
Tires (All weather)
Fig. 47 Roller protected against the
weather
Page 32
30
CA280 M280EN1
SPECIAL INSTRUCTIONS
The temperature limits apply to standard versions of
the roller.
Rollers that are fitted with additional equipment, such
as noise suppression, etc., may require extra observation in the higher temperature ranges.
When washing the machine, do not direct the
jet of water directly at the fuel or hydraulic fluid
tank covers. This is particularly important
when using a high-pressure washing unit.
Do not spray water directly on electric components or
the instrument panel. Put a plastic bag over the filler
cap of the fuel tank and secure with a rubber band.
This will prevent water from entering the venting hole in
the filler cap. This could otherwise cause operational
disturbance, for example, a clogged filter.
In the event of fire in the machine, use an ABE-powder
fire extinguisher if possible. A BE type carbon dioxide
fire extinguisher may also be used.
If the roller is equipped with a protective structure
(ROPS, Roll Over Protective Structure), or protective
cab, never subject the structure or cab to welding or
drilling. Never attempt to repair a damaged structure or
cab; they must be replaced with new ones.
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.
Starting aid
Protective structure (ROPS)
Fire fighting
High-pressure washing
Temperature
Standard oils and other
recommended fluids
Higher ambient temperature
max. +50°C (122°F)
Upon delivery from the factory, the various systems
and components are filled with the oils specified see
lubricant specification and they can be used at ambient
temperatures from -10°C to +40°C (14°F - 104°F).
A maximum temperature of +35°C (95°F)
applies for biological hydraulic fluid.
When operating in hotter ambient temperatures, but up
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
or corresponding.
Other components using transmission oil:
Shell Spirax HD 85W/140 or corresponding.
Page 33
31
CA280 M280EN1
2
2
1
56 7 8
34
ELECTRICAL SYSTEM, FUSES
The electrical regulating and control system is
protected by fuses and relays. The number depends on
how much additional equipment the machine is
prepared for.
The two fuse boxes (3, 4) and the relays (5, 6, 7, 8) are
located behind the lower instrument plate, which is
removed by unscrewing the screws (1 and 2).
The machine is equipped with a 12 V electrical system
and an alternator.
Connect the battery to the correct polarity
(– to ground). The cable between battery
and alternator must not be disconnected
when the engine is running.
Fig. 48 Instrument panel
1. Screws
2. Screws
Fuses and relays
Fig. 49 Instrument panel
3,4. Fuse box
5. VBS relay
6. Main relay
7. Hourmeter relay
8. Lights relay
= Optional
Fuse boxes in steering column
Fig. 50 Fuse box, left side
7.5A 1. Hourmeter
7.5A 2. VBS relay
7.5A 3. Warning lamp
7.5A 4. Horn, Fuel gauge
7.5A 5. 10A 6. Front wiper, cab
Fig. shows the rating and function of the different fuses.
All fuses are flat pin fuses.
Fuse box, right side
7.5A 1. High/Low gear
3A 2. Compaction meter
7.5A 3. Hazard beacon
3A 4. Reversing alarm
20A 5. Working lights
20A 6. Working lights
= Optional
Page 34
32
CA280 M280EN1
15
13
2
2 3 4
5
There is one main fuse (4), located behind the battery
disconnector. Unscrew the screws (1) to release the
plastic cover.
ELECTRICAL SYSTEM, FUSES
Main fuses/Relay
Fig. 51 Cooler location
1. Screws
5. Control box for engine preheater
Fig. 53 Engine compartment
(Cummins stage 1 engine)
1. Main fuse
2. Fuel solenoid relay
3. Start relay
There is one main fuse (1), located behind the battery
disconnecter. Unscrew the screws to release the
plastic cover.
The fuses are of the flat pin type.
The fuel solenoid relay (2) and the start relay (3) are
also located here.
Main fuse 30 A (Green)
Fig. 52 Relay box viewed from the rear
(Cummins stage 2 engine)
2. Preheating relays
3. Start relay
4. Main fuse
5. Control box for engine preheater
(Applies to Cummins stage 2 engine only)
There is one main fuse (1), located behind the battery
disconnecter. Unscrew the screws to release the
plastic cover.
The preheater relays (2) and the start relay (3) are also
located here. The control box for the engine preheater
(5) is mounted underneath the battery disconnecter.
Main fuse 30 A (Green)
Page 35
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