Fayat Group Dynapac CA25 User manual

Instruction manual
4812325897EN
Operating & Maintenance
Vibratory Roller
CA25 / 30 / 35
Engine
Cummins QSF 3.8
From the serial number
10000179xxB006062 –
10000181xxB005992 –
10000183xxB006276 –
Reservation for changes
Printed in Brasil

Introduction
3 4812325897EN 02-17-2021
TABLE OF CONTENTS
OPERATION Page
Introduction..............................................................................................................................4
Safety - General instructions....................................................................................................6
Safety - When operating..........................................................................................................8
Special Instructions..................................................................................................................9
Technical specifications.........................................................................................................12
Noise/Vibrations/Electrical.....................................................................................................12
Technical specifications - Dimensions ...................................................................................13
Technical specifications –Weights and volumes...................................................................15
Technical specifications –Working capacity..........................................................................16
Technical specifications –General ........................................................................................17
Machine description...............................................................................................................20
Product plate –Identification..................................................................................................22
Machine description –Decals................................................................................................24
Machine description –Instruments/Controls ..........................................................................27
A/C –System operation.........................................................................................................37
Operation - Starting ...............................................................................................................41
Operation - Driving.................................................................................................................45
Operation –Vibration.............................................................................................................46
Operation –Braking...............................................................................................................49
Miscellaneous.......................................................................................................................53
Operating instructions - Summary..........................................................................................57
Preventive maintenance ........................................................................................................58
Maintenance - Lubricants and symbols..................................................................................59
Maintenance - Maintenance schedule....................................................................................61
Scheduled maintenance and lubrication ................................................................................62
Every 10 hours of operation (Daily)........................................................................................62
Maintenance, after the FIRST 50 hours of operation..............................................................63
Every 50 hours of operation (Weekly)....................................................................................63
Maintenance, every 250/750 hours of operation....................................................................63
Maintenance, every 500 hours of operation...........................................................................64
Maintenance, every 1000 hours of operation.........................................................................64
Maintenance, every 2000 hours of operation.........................................................................65
Revision...............................................................................................................................105

Introduction
4 4812325897EN 02-17-2021
Introduction
The machine
CA25 / 30 / 35 are models of Dynapac's medium-heavy
soil compaction rollers. They are available in a D (smooth
drum) and PD (padfoot) version.
Intended use
All types of base courses and subbase courses can be
compacted. The PD version enables the use of either D or
PD drums, which ensures greater flexibility for a wider
range of applications.
Warning symbols
WARNING! Marks a danger or a hazardous
procedure that can result in life threatening
or serious injury if the warning is ignored
CAUTION! Marks a danger or hazardous
procedure that can result in damage to the
machine or property if the warning is ignored.
Safety information
The safety manual supplied with the machine
must be read by all roller operators. Always
follow the safety instructions. Do not remove
the manual from the machine.
We recommend that the operator reads the
safety instructions in this manual carefully.
Always follow the safety instructions. Ensure
that this manual is always easily accessible.
Read the entire manual before starting the
machine and before carrying out any
maintenance
Ensure good ventilation (extraction of air by
fan) where the engine is run indoors

Introduction
5 4812325897EN 02-17-2021
General
This manual contains instructions for machine
operation and maintenance.
The machine must be correctly maintained for maximal
performance.
The machine should be kept clean so that any
leakages, loose bolts and loose connections are
discovered at as early a point in time as possible.
Inspect the machine every day, before starting. Inspect
the entire machine so that any leakages or other faults
are detected.
Check the ground under the machine. Leakages are
more easily detected on the ground than on the
machine itself.
THINK ENVIRONMENT! Do not release oil, fuel
and other environmentally hazardous
substances into the environment. Always send
used filters, drain oil and fuel remnants to
environmentally correct disposal.
This manual contains instructions for periodic
maintenance, can be performed by the machine
operator.
Additional instructions for the engine can be
found in the manufacture's engine manual.
CE marking and Declaration of conformity
(Applies to machines marketed in EU/EEC)
Thismachine is CEmarked.This showsthat ondelivery
it complies with the basic health and safety directives
applicable for the machine in accordance with
machinery directive 2006/42/EC and that it also
complies with other regulations and directives
applicable for this machine.
A "Declaration of conformity" is supplied with this
machine, which specifies the applicable regulations and
directives with supplements, as well as the harmonized
standards and other regulations that are applied and
according to theregulations must be declared in writing.

Safety - General instructions
6 4812325897EN 02-17-2021
Safety - General instructions
(Also read the safety manual)
1. Read and understand this manual before starting and operate the
machine. The operator must be familiar with the contents of the
OPERATION section before starting the roller.
2. Ensure that all instructions in the MAINTENANCE section are followed.
3. Do not operate the machine if you are not qualified, by training or
experience. Only the operator is allowed to be on the roller. Remain seated
at all times when operating the roller.
4. Never use the roller if it is in need of adjustment or repair.
5. Only ascend and descend the roller when it is stationary. Use the intended
footsteps, grips and rails. Always use the three-point grip (both feet and
one hand, or one foot and both hands) when ascending or descending the
machine. Never jump down from the machine.
6. If the terrain stability conditions are irregular or dangerous, use the Roll
Over Protection Structure (ROPS). Always use the seat belt with "ROPS".
7. Drive slowly in sharp bends.
8. Avoid driving across slopes. Drive straight up or straight down the slope.
Operate the machine in first gear and always check the operation of the
brakes.
9. When operating the machine near the beginning of slopes or holes, make
sure that at least 2/3 of the machine width is under compacted material.
10. Make sure that there are no obstacles in the direction of travel, on the
ground, in front of or behind the roller, or overhead.
11. Drive particularly carefully on uneven ground.
12. Use the available safety equipment. On machines equipped with ROPS,
you must use the safety belt.
13. Keep the roller clean. Clean any dirt or grease that accumulates on the
operator platform immediately. Keep all signs and decals clean and legible.
14. Safety measures before refueling:
- -Stop the engine;
- Do not smoke;
- No naked flames in the vicinity of the roller;
- Earth the filling equipment nozzle to the tank opening to avoid sparks.

Safety - General instructions
7 4812325897EN 02-17-2021
15. Before repairs or service:
- -Chock the drums/wheels;
- -Lock the articulation if necessary.
16. Hearing protection is recommended if the noise level exceeds 85 dB(A).
The noise level can vary depending on the equipment on the machine and
the surface the machine is being used on.
17. Do not make any changes or modifications to the roller that could affect
safety. Changes are only to be made after written approval has been given
by Dynapac
18. Avoid using the roller before the hydraulic fluid has reached its normal
working temperature. Braking distances can be longer than normal when
the fluid is cold. See instructions in the STOP section.
19. For your own protection always wear:
- Helmet;
- Working boots with steel toecaps;
- Ear protectors;
- Reflecting clothing / high visibility jacket;
- Working gloves

Special instructions
02-17-2021 4812325897EN 8
Safety - When operating
Operating on slopes
When driving near the start of slopes, at least 2/3 of the
width of the machine should be on land with full load
capacity.
Keep in mind that the machine's center of gravity
moves outwards when steering. For example, the
center of gravity moves to the right when you steer
to the left.
Inclination
This angle was measured on a flat and hard base with the
machine stopped.
The steering angle is 0 with vibrations off and all reservoirs
full.
When driving themachine on a stablefloor, the application
of vibration, the speed of the machine on the ground and
the lifting of the center of gravity can cause the machine to
overturn, even on a lower slope indicated in this manual.
To exit the cab in an emergency, release the
hammer on the rear right post and break the
rear window.
When operating on slopes or unstable bases,
the use of ROPS (Roll Over Protection
Structure) or a ROPS approved cabin is
always recommended. Always use a seat
belt.
Avoid driving across slopes.
On slopes, drive straight up and down.
Fig. Positioning the rollers when
driving near the start of a slope.
Fig. Operação em declives
ₒ

Special instructions
02-17-2021 4812325897EN 9
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 - 105°F).
Higher ambient temperatures, above +40°C
(104°F)
For operation of the machine at higher ambient
temperatures, however maximum +50°C (122°F), the
following recommendations apply:
The Diesel engine can be run at this temperature using
normal oil, the following oils must be used:
Hydraulic system –mineral oil, Shell Tellus 15W40 or
equivalent.
Lower ambient temperatures - Risk of freezing
Make sure that the cooling system is emptied/ drained
(sprayer, hoses, tanks) or that anti-freeze has been added
to prevent the system from freezing.
Temperatures
The temperature limits apply to standard versions of
rollers.
Rollers equipped with additional equipment, such as noise
suppression, may need to be more carefully monitored in
the higher temperature ranges.

Special instructions
02-17-2021 4812325897EN 10
High pressure cleaning
Do not spray directly onto electrical components or control
panel.
Place a plastic bag over the reservoir lid and seal with a
rubber band. This prevents the water under pressure from
passing through the vent hole in the lid. This could cause
malfunctions, e.g. clogging of the filters.
When washing the machine, do not direct the water
jet directly into the tank cover. This is especially
important when using high-pressure jets.
Fire fighting
If the machine catches fire, use an BCD-class powder fire
extinguisher. A BC-class carbon dioxide fire extinguisher
can also be used.
Roll Over Protective 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 new ROPS
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
02-17-2021 4812325897EN 11
Battery handling
When removing batteries, always disconnect
the negative cable first.
When fitting batteries, always connect the positive
cable first.
Dispose of old batteries in an environmentally
friendly way. Batteries contain toxic lead.
Do not use a quick-charger for charging the
battery. This may shorten battery life.
Jump starting
Do not connect the negative cable to the negative
terminal on the 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 flat battery's positive terminal (2). Then connect the
jump start battery's negative terminal (3) to, for example,
a bolt (4) or the lifting eye on the machine with the flat
battery.
Start the engine on the power providing machine. Let it run
for a while. Now try to start the other machine. Disconnect
the cables in the reverse order.
Fig. Jump starting

Technical specifications –Noise/Vibrations/Electrical
02-17-2021 4812325897EN 12
Technical specifications
Noise/Vibrations/Electrical
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 also were below the action level of 2.5 m/s² specified in the
same directive. (Limit is 5 m/s²).
Electrical system
The machine was tested for electromagnetic
compatibility (EMC) in accordance with EN
13309:2000: "Construction machinery"
Noise level
The noise level is measured in accordancewith the maximum limit described in Resolução
Nº 433 do Conselho Nacional do Meio Ambiente –CONAMA, relative to compactor rollers,
considering the connected vibration (high amplitude).
Guaranteed sound power level, LwA 111 dB (A)
Sound pressure level at the operator's ear (cab), LpA 85 dB (A)
During normal operations, the values abovementioned may differ, depending on the work
specific conditions.

Technical specifications –Dimensions
02-17-2021 4812325897EN 13
Technical specifications - Dimensions
Dimensions –Side view
Dimensions
mm
pol
A
Wheelbase, drum and wheel
2990
117,7
L
Length, standard equipped roller
5560
218,9
H1
Height, with ROPS/cab (D)
2890
113,8
H1
Height, with ROPS/cab (PD)
2890
113,8
H2
Height, without ROPS (D)
2400
94,5
H2
Height, without ROPS (PD)
2400
94,5
D
Diameter, drum (D)
CA25, CA30
1500
59
CA35
1510
59,4
D
Diameter, drum (PD)
1694
66,7
S
Thickness, drum amplitude, Nominal (D)
CA 25, CA30
25
0,98
CA35
30
1,2
S
Thickness, drum amplitude, Nominal (PD)
20
0,79
K1
Clearance, tractor frame
460
18,1
K2
Clearance, drum frame (D, PD)
460
18,1

Technical specifications –Dimensions
02-17-2021 4812325897EN 14
Dimensions –Top view
Dimensions
mm
pol
B1
Width, front
CA25(PD/D), CA30(PD/D), and CA35 (PD)
2256
88,8
CA35D
2276
89,6
B2
Width, rear
2130
83,9
O1
Overhang, left frame side
CA25(PD/D), CA30(PD/D), and CA35(PD)
63
2,48
CA35 (D)
73
2,87
O2
Overhang, right frame side
CA25, CA30, and CA35 (PD)
63
2,48
CA35 (D)
73
2,87
R1
Turn radius, external
CA25, CA30
5650
222,4
CA35
5660
222,8
R2
Turning radius, inner
CA25(PD/D), CA30(PD/D), and CA35 (PD)
3255
128,1
CA35 (D)
3245
127,8
W
Width, drum
2130
83,9

Technical specifications –Weights and volumes
02-17-2021 4812325897EN 15
Technical specifications –Weights and volumes
Operational weight
Canopy
ROPS
Cab
CA25D
(kg)
10.300
10400
10500
(lb)
22707
22928
23148
CA25PD
(kg)
10.500
10600
23369
(lb)
23148
10700
23589
CA30D
(kg)
11.100
11.200
11.300
(lb)
22471
24691
24912
CA30PD
(kg)
11.300
11.400
11.500
(lb)
24912
25132
25353
CA35D
(kg)
12.100
12.200
12.300
(lb)
26676
26896
27117
CA35PD
(kg)
12.500
12.600
12.700
(lb)
27558
27778
27999
Fluid volumes
D/PD
Rear axle
- Differential
10
liters
10,6
qts
- Planetary gear (standard axle)
1,9
liters/each
2
qts/each
Drum gearbox
3
liters
3,2
qts
Cartridge
2,2
liters
2,3
qts/each
Hydraulic oil reservoir
55
liters
14,4
gal
Oil in the hydraulic system
80
liters
21,1
gal
Diesel engine oil
14,6
liters
15,4
qts
Diesel engine coolant
6,4
liters
1,7
gal
Fuel tank
250
liters
66
gal

Technical specifications –Working capacity
02-17-2021 4812325897EN 16
Technical specifications –Working capacity
Compaction data
Static linear load (D)
CA25
26
kg/cm
146
pli
CA30
30
kg/cm
168
pli
CA35
35
kg/cm
196
pli
Amplitude, High (D)
CA25, CA30
1,8
mm
0,071
pol
CA35
1,7
mm
0,07
pol
Amplitude, High (PD)
2,0
mm
0,079
pol
Amplitude, Low (D)
CA25, CA30
0,9
mm
0,035
pol
CA35
0,8
mm
0,031
pol
Amplitude, Low (PD)
1,1
mm
0,043
pol
Vibration frequency, amplitude high / low (D)
33
Hz
1.980
vpm
Vibration frequency, amplitude high / low (PD)
30
Hz
1.800
vpm
Centrifugal force, amplitude high (D)
250
kN
56,202
lb
Centrifugal force, amplitude high (PD)
270
kN
60,698
lb
Centrifugal force, amplitude low (D)
123
kN
27,651
lb
Centrifugal force, amplitude low (PD)
150
kN
33,721
lb

Technical specifications –General
02-17-2021 4812325897EN 17
Technical specifications –General
Engine
Manufacturer/Model
Cummins QSF 3.8
Water-cooled
turbo diesel
engine
Power (SAE J1995)
97
kW
130
hp
RPM engine, idling
900
rpm
RPM engine, loading/unloading
1.600
rpm
RPM engine, work/transport
2.200
rpm
Traction
Speed range
CA25
0 - 8
km/h (Dual Speed)
0 - 5
mph
CA30 e CA35
0 - 11
km/h (Traction Control)
0 - 6,8
mph
Electrical system
Battery
12V
170A
Alternator
12V
135A
Fuses
See the Electrical system section - fuses
Tire
Tire dimensions:
Tire dimensions
Std. type
18,4 x 26,0 10 ply
180 kPa (1.8 kg/cm2) (16psi)
Diamond type
23,1 x 26,0 12 ply
110 kPa (1.1 kp/cm2) (16psi)
Tractor type
23,1 x 26,0 8 ply
110 kPa (1.1 kp/cm2) (16psi)
Liquid-filled tires (extra weight up to 500 kg/tire,
1100 lbs/tire). When servicing, bear this extra
weight in mind.
Hydraulic
system
Opening pressure
Bar
Drive system
410
Supply system
25
Vibration system
370
Steering systems
160
Brake release
25

Technical specifications –General
02-17-2021 4812325897EN 18
ROPS bolts
Bolts dimensions:
Front fixing M20x150
(PN 903633)
Rear fixing M20x130
(PN 902282)
Strength class:
10.9
Tightening torque
800 Nm (With
Dacromet® treatment)
The ROPS bolts that will be tightened should be dry.
Air Conditioning / Automatic Climate Control
(ACC) (Optional)
The system described in this manual is an AC/ACC type
(Automatic Climate Control). ACC is a system that
maintains the set temperature in the cab, provided windows
and doors are kept closed.
Coolant weight when full: 1.2 kg

Technical specifications –General
02-17-2021 4812325897EN 19
Tightening torque
Tightening torque in Nmfor oiled or dry bolts tightened with
a torque wrench
Metric coarse screw thread, bright galvanized (fzb):
STRENGTH CLASS:
M - Thread
8,8 - Oiled
8,8 - Dry
10,9 - Oiled
10,9 - Dry
12,9 - Oiled
12,9 - Dry
M6
8,4
9,4
12
13,4
14,6
16,3
M8
21
23
28
32
34
38
M10
40
45
56
62
68
76
M12
70
78
98
110
117
131
M14
110
123
156
174
187
208
M16
169
190
240
270
290
320
M20
330
370
470
520
560
620
M22
446
497
626
699
752
839
M24
570
640
800
900
960
1080
M30
1130
1260
1580
1770
1900
2100
Metric coarse thread, zinc-treated (Dacromet/GEOMET):
STRENGTH CLASS:
M - Thread
10,9 - Oiled
10,9 - Dry
12,9 - Oiled
12,9 - Dry
M6
12
15
14,6
18,3
M8
28
36
34
43
M10
56
70
68
86
M12
98
124
117
147
M14
156
196
187
234
M16
240
304
290
360
M20
470
585
560
698
M22
626
786
752
944
M24
800
1010
960
1215
M30
1580
1990
1900
2360

Machine description
02-17-2021 4812325897EN 20
Machine description
Diesel engine
The machine is equipped with a water-cooled, in-line four
cylinders, four-stroke, turbocharged Diesel engine with
direct injection and a charge air cooler.
Electrical system
The machine has the following control units (ECU,
Electronic Control Unit) and electronic units.
•ECU (for the machine)
• Diesel engine control unit (ECM)
• Main display
Propulsion system/Transmission
The propulsion system is a hydrostatic system with a
hydraulic pump supplying two motors connected in
parallel, one for the rear axle and one for the drum.
The speed of the machine is proportional to the angle of
the control lever (the deflection of the forward/reverse
lever regulates the speed). A speed selector and anti-spin
system are available as options.
Brake system
The brake system comprises a service brake, secondary
brake and parking brake. The service brake system
produces retardation of the propulsion system, i.e.
hydrostatic braking.
Secondary/Parking brake
The secondary and parking brake system comprises
sprung disc brakes on the rear axle and the drum gear
which are disengaged by hydraulic pressure.