Dynapac CA25 User manual

Instructions Manual
4812331840EN-Rev 4
Operating & Maintenance
Vibratory Roller
CA25/30/35
Engine
Cummins QSF 3.8
Starting with series
10300181KLE000072-
Reservation for changes
Printed in India

Manual Revisions
Table 1: Revision History
Sr No
Date
Revision
1
Jan 2020
New Released
2
Sept 2021
Updated for Hitch tightening in
1000Hrs and 2000hrs
Lubrication chart updated
3
Oct 2021
Updated for
Drum cartridge -
Cleaning the ventilation screw
in every 250hrs
4
March 2022
Updated for CMV display

Introduction
3 4812331840EN-Rev 2 10-03-2022
CONTENT
OPERATION Page
Introduction............................................................................................................................10
The machine...........................................................................................................................................10
Intended use ..........................................................................................................................................10
Warning symbol. ....................................................................................................................................10
Safety information .................................................................................................................................10
General...................................................................................................................................................11
Safety - General instructions..................................................................................................12
Safety – During operation ......................................................................................................14
Operation near edges.............................................................................................................................14
Slope.......................................................................................................................................................14
Special instructions................................................................................................................15
Standard lubricants and other recommended oils and fluids................................................................15
Higher ambient temperatures, above +40°C .........................................................................................15
Lower ambient temperature – Risk of freezing .....................................................................................15
Temperatures.........................................................................................................................................15
High pressure cleaning...........................................................................................................................16
Fire extinguisher.....................................................................................................................................16
Roll Over Protection Structure (ROPS), ROPS-approved cab. ................................................................16
Welding ..................................................................................................................................................16
Battery handling.....................................................................................................................................17
Jump starting..........................................................................................................................................17
Technical specifications .........................................................................................................19
Noise/Vibrations ....................................................................................................................19
Vibrations - Operator station .................................................................................................................19
(ISO 2631)...............................................................................................................................................19
Noise level ..............................................................................................................................................19
Technical specifications – Dimensions...................................................................................20
Dimensions – Side view..........................................................................................................................20
Dimensions – Top view ..........................................................................................................................20
Technical specifications – Weights and volumes ..................................................................22
Technical specifications – Working capacity ..........................................................................22
Technical specifications – General ........................................................................................24
Tire water blasting procedure................................................................................................................24
Hydraulic system ....................................................................................................................................24
ROPS bolts ..............................................................................................................................................25
Torque ....................................................................................................................................................26
Machine description...............................................................................................................27

Introduction
4 4812331840EN-Rev 2 10-03-2022
Diesel engine ......................................................................................................................................... 27
Electrical system.................................................................................................................................... 27
Propulsion/Transmission system........................................................................................................... 27
Brake system ......................................................................................................................................... 27
Secondary and parking brake ................................................................................................................ 27
Steering system ..................................................................................................................................... 27
Vibration system.................................................................................................................................... 28
Cab......................................................................................................................................................... 28
Emergency exit ...................................................................................................................................... 28
FOPS and ROPS ...................................................................................................................................... 28
Machine plate – Identification ................................................................................................ 29
Product identification number on frame .............................................................................................. 29
Machine type plate................................................................................................................................ 29
Explanation of serial number (17PIN) ................................................................................................... 29
Engine identification plate..................................................................................................................... 30
Machine description – Decals ...............................................................................................30
Location – Decals................................................................................................................................... 30
Safety decals.......................................................................................................................................... 33
Information decals................................................................................................................................. 34
Machine description – Instruments/Controls .......................................................................... 35
Locations – Instruments and controls ................................................................................................... 35
Functional description – Membrane panel ........................................................................................... 38
Functional description – Display ........................................................................................................... 40
Transport mode ................................................................................................................................. 39
Direction of work............................................................................................................................... 39
Hour meter ........................................................................................................................................ 39
Fuel level............................................................................................................................................ 39
User setting........................................................................................................................................ 40
Working mode - Vibration ................................................................................................................. 40
Vibration status ................................................................................................................................. 40
Automatic vibration control - AVC..................................................................................................... 40
Sub menu – Error code ...................................................................................................................... 41
Function description.......................................................................................................................... 41
Locations – Control panel/controls/cab................................................................................................ 42
A/C – System operation.........................................................................................................53
Introduction....................................................................................................................................... 53

Introduction
5 4812331840EN-Rev 2 10-03-2022
Using the cab Controls .......................................................................................................................53
•Defroster ....................................................................................................................................53
•Heat ............................................................................................................................................53
•AC ...............................................................................................................................................53
Electronic control unit............................................................................................................................54
Main fuses ..............................................................................................................................................54
Relays .....................................................................................................................................................55
The table below shows fuse amperage and function. .......................................................................55
Operation – Start-up ..............................................................................................................56
Before starting .......................................................................................................................................56
Master switch – Activation.....................................................................................................................56
Operator's seat (standard) – Adjustments.............................................................................................56
Before starting .......................................................................................................................................48
Operator position...................................................................................................................................48
View........................................................................................................................................................58
Interlock .................................................................................................................................................58
Operation – Start-up ..............................................................................................................50
Start of diesel engine .............................................................................................................................50
Operation – Driving................................................................................................................51
Roller operation .....................................................................................................................................51
Operation – Vibration.............................................................................................................52
Vibration switch .....................................................................................................................................52
Vibration – Activation ............................................................................................................................52
Dynapac Compaction Meter (DCM) including Dynapac Bouncing Control (DBC) – Optional............62
Setting the CMV limits........................................................................................................................53
Operation CMV...................................................................................................................................53
Operation – Stopping.............................................................................................................64
Braking ...................................................................................................................................................65
Emergency braking.............................................................................................................................65
Normal braking...................................................................................................................................66
Switching off.......................................................................................................................................66
Parking of the machine ..........................................................................................................................66
Master switch.....................................................................................................................................66
Chocking the drums............................................................................................................................66
Long-term parking..................................................................................................................................67
Engine.................................................................................................................................................57

Introduction
6 4812331840EN-Rev 2 10-03-2022
Battery ............................................................................................................................................... 67
Air cleaner, exhaust pipe ................................................................................................................... 67
Fuel tank ............................................................................................................................................ 67
Hydraulic reservoir ............................................................................................................................ 67
Steering cylinder, hinges, etc............................................................................................................. 67
Hoods, tarpaulin ................................................................................................................................ 68
Tires (all-weather) ............................................................................................................................. 68
Miscellaneous........................................................................................................................ 69
Lifting..................................................................................................................................................... 69
Locking the steering articulation ....................................................................................................... 69
Lifting the roller ................................................................................................................................. 69
Unlocking the articulation ................................................................................................................. 60
Towing ................................................................................................................................................... 60
Alternative 1 ...................................................................................................................................... 60
Short distance towing with the engine running. ............................................................................... 60
Alternative 2 ...................................................................................................................................... 60
Towing Short distance when the engine is in-operative. .................................................................. 60
Towing the roller ............................................................................................................................... 61
Preparation of the machine for transport......................................................................................... 61
Securing in closed container for loading ........................................................................................... 62
Operating instructions – Summary......................................................................................... 73
Preventive maintenance ........................................................................................................ 74
Acceptance and delivery inspection...................................................................................................... 74
Warranty................................................................................................................................................ 74
Maintenance – Lubricants and symbols................................................................................. 75
Maintenance symbols ........................................................................................................................... 76
Maintenance – Planned maintenance.................................................................................... 77
Service and inspection points................................................................................................................ 77
Scheduled maintenance and lubrication ........................................................................... 78
Scheduled ........................................................................................................................... 798
Service and maintenance point.............................................................................................. 79
Every 10 hours of operation (Daily)................................................................................................... 69
Every 50 hours of operation (weekly) ............................................................................................... 69
After the First 50 hours of operation ................................................................................................ 69
Every 250/750/1250/1750 hours of operation (Monthly) ................................................................ 70
Every 500/1500 hours of operation (Every three Months) ............................................................... 70

Introduction
7 4812331840EN-Rev 2 10-03-2022
Every 1000 hours of operation (Every six Months)............................................................................70
Every 2000 hours of operation (weekly) ............................................................................................71
Every 10 hours of operation (Daily) .......................................................................................................84
Scrapper adjustment ..........................................................................................................................84
Pad foot drum.....................................................................................................................................84
Air Circulation.....................................................................................................................................84
Check fluid levels ................................................................................................................................84
Coolant Level check ............................................................................................................................84
Engine oil level....................................................................................................................................84
Fuel tank filling ...................................................................................................................................84
Hydraulic fluid resersior – check fluid level ........................................................................................84
Check functioningof the breaks ..........................................................................................................84
Parking brakes....................................................................................................................................84
Emergency stop ..................................................................................................................................84
Articulated/steering joint - Lubrication..............................................................................................84
Maintenance 50 Hrs...............................................................................................................................76
Every 50 hours of operation (Weekly) ................................................................................................76
Air Cleaner ..........................................................................................................................................76
Checking – the main filter...................................................................................................................76
Back up filter change..........................................................................................................................76
Air Cleaning ........................................................................................................................................77
Articulated/steering joint - Lubrication..............................................................................................77
Tire – Air pressure – wheel nut - tightening .......................................................................................78
Air conditioning (optional) – Cleaning/filter change..........................................................................78
After the first 50 hours of operation ..................................................................................................79
Change the hydraulic fluid filter.........................................................................................................79
Rear Axle differential – change the oil ...............................................................................................80
Rear Axle planetary gears– change the oil.........................................................................................80
Drum Gearbox (D/PD) – change the oil..............................................................................................80
Steering hitch – tightening .................................................................................................................81
Maintenance 250/750/1250/1750 Hrs ..................................................................................................82
Rear Axle differentail – Check the oil..................................................................................................82
Rear Axle Planetary gears - Check the oil...........................................................................................82
Drum – Checking the oil level .............................................................................................................83

Introduction
8 4812331840EN-Rev 2 10-03-2022
Radiator – Check/cleaning................................................................................................................. 83
Bolted joints – Checking tightening................................................................................................... 84
Rubber element and fastening screws .............................................................................................. 84
Check battery cell............................................................................................................................... 85
Maintenance 500/1500 Hrs (Every three months) ............................................................................... 87
Fuel filter & pre fuel filter replacement ............................................................................................ 87
Fuel strainer replacement ................................................................................................................. 88
Hydraulic reservior-bleeder filter check............................................................................................ 88
Diesel engine – oil and filter change.................................................................................................. 88
Maintenance 1000Hrs (Every six months)............................................................................................. 89
Replacing the main air filter .............................................................................................................. 89
Change the hydraulic fluid filter ........................................................................................................ 89
Draining the hydraulic fluid filter....................................................................................................... 90
Fuel tank drainage ............................................................................................................................. 90
Rear Axle differential – change the oil .............................................................................................. 91
Rear Axle planetary – Draining the oil............................................................................................... 91
Rear Axle planetry – oil change- Oil filling......................................................................................... 91
Diesel engine – oil and filter change.................................................................................................. 92
Fuel filter & pre fuel filter replacement ............................................................................................ 92
Belt tension check engine drive system ........................................................................................... 92
Water separator repalcement........................................................................................................... 93
Maintenance 2000Hrs (Yearly).............................................................................................................. 94
Hydraulic reservior – fluid change..................................................................................................... 94
Drum – oil change.............................................................................................................................. 94
Control - lubrication........................................................................................................................... 95
Automatic climate control................................................................................................................. 95
Diesel engine – oil & filter change..................................................................................................... 95
Fuel filter & pre fuel filter replacement ............................................................................................ 96
Belt tension check engine drive system .......................................................................................... 96
Water separator repalcement........................................................................................................... 96
Change the hydraulic fluid filter ........................................................................................................ 97
Drum gearbox (D/PD) – Changing the oil .......................................................................................... 97
Rear axle differential – Oil change..................................................................................................... 98

Introduction
9 4812331840EN-Rev 2 10-03-2022
Rear axle's planetary gears – Draining the oil....................................................................................98
Rear axle's planetary gears – Oil change – Oil filling..........................................................................98

Introduction
10 4812331840EN 10-03-2022
Introduction
The machine
Dynapac CA30D is a single drum roller in the 11 tons class
respectively, with a useful drum width of 2130 mm.
Intended use
CA30D is commonly our for compaction during work on road
construction, airports, ports, and industrial areas, etc. It is
available with a smooth drum or padfoot shell assembled on
Drum.
Warning symbol.
WARNING! Identifies a dangerous or risky
procedure that could lead to danger to life or
serious damage, if ignored.
CAUTION! Identifies a risky procedure that could
lead to damage to machine or property, if
ignored.
Safety information
The Safety Manual supplied with the
machine must be read by all roller operators.
Always follow the safety instructions and do
not remove the manual from the roller.
It is recommended that the operator
carefully reads the safety instructions in this
manual and follows these instructions. Make
sure that the manual is always available.
Read the manual before starting on the
machine.
Make sure there is good ventilation when the
engine is on in closed spaces.

Introduction
11 4812331840EN 10-03-2022
General
This Manual contains instructions for machine operation and
maintenance.
Machine maintenance should be performed correctly to
achieve maximum performance.
The machine should be kept clean, so that leakages, loose
screws or connections can be identified as quickly as
possible.
Inspect the machine every day before starting it, so that
possible leakages or other problems can be detected.
Check the ground under the machine. Leakages can be
detected more easily on the ground under the machine.
THINK ABOUT THE ENVIRONMENT: Do not
discard lubricating oil or fuel in places where
it can contaminate soil or the environment.
Always discard used filters, oil, and fuel
residue correctly.
This manual contains instructions for periodic maintenance,
which should normally be carried out by the operator.
Other instructions for the engine may be found in
the manufacturer’s manual.

Safety – General instructions
12 4812331840EN 10-03-2022
Safety - General instructions
(Also read the safety manual)
1. Read and understand this Manual before starting and operating the machine. The
operator should be fully familiar with the equipment before running it.
2. Follow and observe all instructions on regular lubrication and maintenance in the
Maintenance Section.
3. Only trained and/or experienced operators are to operate the roller. Passenger are
not permitted on the roller. Remain seated at all times when operating the roller
4. Do not operate the machine if it needs repairs or adjustments.
5. Only mount and discount the roller when it is stationery. Use the intended
footsteps, grip & rails. Always use the three point grip (both feet and one hand, or
one foot and both hands) when mounting or dismounting the machine. Never jump
down from the machine.
6. If the terrain stability conditions are abnormal or dangerous, use the Rollover
Protection Structure (ROPS). Always use a ROPS seat belt.
7. Drive slowly in sharp bends.
8. Avoid driving across slopes. Drive Straight up or straight down the slope.
9. When operating the machine near edges or holes, make sure that at least 2/3 of
the machine width is on compacted materials.
10. Make sure that there are no obstacles in the direction of travel, both on the ground,
and in front, behind, or on top of the roller.
11. Drive extra carefully on uneven ground.
12. Use the safety equipment provided. The seat belt must be worn on machines fitted
with ROPS & Cab.
13. Keep machine clean. Immediately remove any type of dirt or grease accumulated
on the operator's platform, all signs and decals.
14. Safety measures before refuelling:
- Stop the engine;
- Do not smoke;
- Do not allow sparks or flames next to the machine;
- Earth the filling equipment nozzle to the tank operating to avoid sparks.

Safety – General instructions
13 4812331840EN 10-03-2022
15. Before performing any maintenance:
- Chock the drums/wheels and the strike-off blade;
- If necessary, lock the articulation.
-
16. Use adequate hearing protection if the machine’s noise level exceeds 85 dB(A).
The noise level may vary depending on the type of work the machine is performing.
17. Do not modify the machine for any reason, because this could affect the safety of
people and the machine. Any changes to the machine require prior written
approval of DYNAPAC.
18. Do not use the machine until the hydraulic fluid has reached its normal working
temperature. Braking distance can be longer than usual if the fluid is cold. Refer
to the operating instructions in the STOP section.
19. For the operator’s protection, use:
- A helmet;
- Working boots with steel toecaps;
- Hearing protection;
- Reflective clothing/reflective vest;
- Working gloves.

Special instructions
10-03-2022 4812331840EN 14
Safety – During operation
Operation near edges
When driving near edges, at least 2/3 of the machine’s width
should be on ground with full bearing strength.
Remember that the machine’s centre of gravity
moves outward when steering. For example: it
moves right when you steer left.
Slopes
This angle has been measured on a hard, flat surface with the
machine stationary.
The steering angle was zero, the vibration was switched off and
all tanks were full.
Always take into consideration that loose ground, steering the
machine, vibration on, machine speed across the ground and
raising the centre of gravitycan all cause the machine to topple
at smaller slope angles than those specified here.
To exit the cab in an emergency, release the
hammer located on the rear right post and
break the rear window.
It is recommended that ROPS (Roll Over
Protective Structure) or a ROPS approved
cab is always used when driving on slopes or
unstable ground. Always wear a safety belt.
Avoid driving across slopes.
Always drive straight up and down on slopes.
Fig. Positioning of the drums when
driving near an edge of a slope.
Fig. Operation on slopes
ₒ
Minimum 2/3
or

Special instructions
10-03-2022 4812331840EN 15
Special instructions
Standard lubricants and other recommended oils and
fluids
Before leaving the factory, the systems and components are
filled with the oils and fluids specified in the lubricant
specification. These are suitable for ambient temperatures in the
range -15°C to +40°C (5°F -104°F).
Higher ambient temperatures, above +40°C (104°F)
For operation of the machine at higher ambient temperatures,
but not exceeding +50°C (122°F), the following
recommendations apply:
The diesel engine works at this temperature with standard oil,
but the following oils must be used in the other components:
Hydraulic system – Shell Tellus S2V100mineral oil or equivalent.
Lower ambient temperature – Risk of freezing
Make sure that the cooling system is empty/drained (sprinkler,
hoses, tanks) or that anti-freeze has been added, to prevent
system freezing.
Temperatures
The temperature limits apply to standard versions of the
machine.
Machines with additional equipment, such as noise suppression
equipment, may require special care when operating at higher
temperatures.

Special instructions
10-03-2022 4812331840EN 16
High pressure cleaning
Do not aim the water jet directly onto electrical components or
instrument panels.
Put a plastic bag over the filling cap of the fuel tank and secure
with an elastic band. This is to avoid pressurised water entering
the vent hole in the filler cap. This could cause malfunctions,
such as blocking of filters.
When washing the machine, do not aim the water jet
directly at the fuel tank cap. This is particularly
important when using a high-pressure jet.
Fire extinguisher
If the machine catches fire, use a ABC-class powder fire
extinguisher. It is also possible to use a BE-class CO2
extinguisher.
Roll Over Protection Structure (ROPS), ROPS-
approved cab.
If the machine is fitted with a Roll Over Protective
Structure (ROPS, or ROPS-approved cab), never
carry out any welding or drilling in the structure or
cab.
Never attempt to repair a damaged ROPS structure
or cab. These must be replaced with a new structure
or cabs.
Welding
When carrying out welding on the machine, the
battery must be disconnected and the electronics
disconnected from the electrical system.
If possible, remove the part(s) to be welded from the machine.

Special instructions
10-03-2022 4812331840EN 17
Battery handling
When removing batteries, always disconnect the
negative cable first.
When fitting batteries, always connect the positive
cable first.
Dispose of used batteries in an environmentally
friendly manner. Batteries contain toxic lead.
Never use fast charge to charge the battery. This may
shorten battery life.
Ignition key & Battery Dis-connector key removal in
transit
While transporting the machine on the trailer or container or in
long term parking always ensure that
1. Ignition key should be removed from the ignition switch.
2.Battery dis-connector key should be removed.
This will avoid static parasitic current consumption & saves the
battery life & potential battery drain issue.
Jump starting
Do not connect the negative cable to the negative
terminal on a dead battery. A spark can ignite the
oxy-hydrogen gas formed around the battery.
Check that the battery used for jump starting has the
same voltage as the dead battery.
Turn the ignition and all power consuming equipment off. Switch
off the engine on the machine which is providing jump start
power.
First connect the jump start battery’s positive terminal (1) to the
dead battery’s positive terminal (2). Then connect the jump start
battery’s negative terminal (3) to, for example, a bolt (4) or
hoisting ring on the machine with the dead battery.
Start the engine on the machine providing the power. Let the
engine run a little. Now try to start the other machine. Disconnect
the cables in reverse order.
Fig. Jump starting

Special instructions
10-03-2022 4812331840EN 18
Orientation of Rotating beacon on the Machine
The beacon should be fitted with then lens (amber coloured)
mounted at uppermost (sky direction) i.e. never bend the
beacon towards the down
This will avoid rainwater entry & its accumulated through its
drain holes if beacon bended at bottom.
However, wherever heights constraints observed (like
machine in container) – the same beacon light to be removed,
packed safety & send along with machine.

Technical specifications – Noise/Vibrations/Electrical
10-03-2022 4812331840EN 19
Technical specifications
Noise/Vibrations
Vibrations - Operator station
(ISO 2631)
The vibration levels are measured in accordance with the operational cycle described
in EU Directive 2000/14/EC on machines equipped for the EU market, with vibration
switched on, on soft polymer material and with the operator's seat in the transport
position.
Measured whole-body vibrations are below the action value of 0.5 m/s2, as specified in
Directive 2002/44/EC. (Limit is 1.15 m/s2)
Measured hand/arm vibrations were also below the action level of 2.5m/s2specified in the
same directive. (Limit is 5 m/s
2
)
Noise level
The noise level is measured in accordance with the operational cycle described in EU
directive 2000/14/EC on machines equipped for the EU market, on soft polymer material
with vibration switched on and the operator's seat in the transport position.
Guaranteed sound power level, LwA 107 dB (A)
Sound pressure level at the operator's ear (platform), LpA 90 ±3 dB (A)
Sound pressure level at the operator's place (cab), LpA 85 ±3 dB (A)
During operation the above values may differ because of the actual operational
conditions.

Technical specifications – Dimensions
10-03-2022 4812331840EN 20
Technical specifications – Dimensions
Dimensions – Side view
Dimensions
mm
in
A
Wheelbase, drum and wheel
2990
117.7
L
Length, roller with standard equipment
5560
218.9
H1
Height, with ROPS/cab (D)
2890
113.8
H1
Height, with ROPS/cab (PD)
2890
113.8
H2
Height, with folded canopy (D)
2400
94.5
H2
Height, with folded canopy (PD)
2400
94.5
D
Diameter, drum
1500
59
S
Thickness, drum amplitude, Nominal
CA25/30
25
0.98
CA35
30
1.18
K1
Clearance, machine frame
460
18.1
K2
Height clearance, drum frame (D, PD)
460
18.1