Fayat Group DYNAPAC CA25 Instruction Manual
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Fayat Group DYNAPAC CA25 Instruction Manual

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Instructions Manual
4812331840EN-Rev 5
Operating & Maintenance
Vibratory Roller
CA25/30/35
Engine
Cummins QSF 3.8
Starting with series
10300181KLE000072-
Reservation for changes
Printed in India

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Summary of Contents for Fayat Group DYNAPAC CA25

  • Page 1 Instructions Manual 4812331840EN-Rev 5 Operating & Maintenance Vibratory Roller CA25/30/35 Engine Cummins QSF 3.8 Starting with series 10300181KLE000072- Reservation for changes Printed in India...
  • Page 2 Manual Revisions Table 1: Revision History Sr No Date Revision Jan 2020 New Released Sept 2021 Updated for Hitch tightening in 1000Hrs and 2000hrs Lubrication chart updated Oct 2021 Updated for Drum cartridge - Cleaning the ventilation screw in every 250hrs March 2022 Updated for CMV display Oct 2023...

  • Page 3: Table Of Contents

    Introduction 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 ...............................

  • Page 4: Introduction

    Introduction 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 –...
  • Page 5 Introduction 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 ............................
  • Page 6 Introduction 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 ..........................
  • Page 7 Introduction 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 –...
  • Page 8 Introduction 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 .........................
  • Page 9 Introduction Rear axle's planetary gears – Draining the oil ..................98 Rear axle's planetary gears – Oil change – Oil filling ................98 4812331840EN-Rev 2 10-03-2022...

  • Page 10: The Machine

    Introduction 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.

  • Page 11: General

    Introduction 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.

  • Page 12: Safety - General Instructions

    Safety – General instructions Safety - General instructions (Also read the safety manual) Read and understand this Manual before starting and operating the machine. The operator should be fully familiar with the equipment before running it. Follow and observe all instructions on regular lubrication and maintenance in the Maintenance Section.
  • Page 13 Safety – General instructions 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.

  • Page 14: Safety - During Operation

    Special instructions 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.

  • Page 15: Special Instructions

    Special instructions 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).

  • Page 16: High Pressure Cleaning

    Special instructions 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.

  • Page 17: Battery Handling

    Special instructions 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.
  • Page 18 Special instructions 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.

  • Page 19: Technical Specifications

    Technical specifications – Noise/Vibrations/Electrical 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.

  • Page 20: Technical Specifications - Dimensions

    Technical specifications – Dimensions Technical specifications – Dimensions Dimensions – Side view Dimensions Wheelbase, drum and wheel 2990 117.7 Length, roller with standard equipment 5560 218.9 Height, with ROPS/cab (D) 2890 113.8 Height, with ROPS/cab (PD) 2890 113.8 Height, with folded canopy (D) 2400 94.5 Height, with folded canopy (PD)

  • Page 21: Dimensions - Top View

    Technical specifications – Dimensions Dimensions – Top view Dimensions Front width CA25/30 2256 88.8 CA35 2276 89.6 Back width 2130 83.9 Overhang, left frame side CA25/30 2.48 CA35 2.87 Overhang, right frame side CA25/30 2.48 CA35 2.87 Turning radius, outside 5650 222.4 Turning radius, inside...

  • Page 22: Technical Specifications - Weights And Volumes

    Technical specifications – Working capacity Technical specifications – Weights and Volumes Weight Service Weight Canopy ROPS 10500 CA25D 10300 10400 23148 22708 22928 CA25 PD Shell 11900 12000 12100 26235 26455 26676 11300 CA30D 11100 11200 24912 24471 24691 12900 CA30 PD shell 12700 12800...
  • Page 23 Technical specifications – Working capacity Vibration frequency, high amplitude (PD Shell) 1,980 vpm Centrifugal force, high amplitude (D) 56.202 lb Centrifugal force, high amplitude (PD Shell) 56.202 lb Centrifugal force, low amplitude (D) 27.651 lb Centrifugal force, low amplitude (PD Shell) 27.651 lb 10-03-2022 4812331840EN...

  • Page 24: Technical Specifications - General

    Technical specifications – General Technical specifications – General Engine Manufacturer/Model Cummins QSF 3.8 Turbo diesel engine, water-cooled Power (SAE J1995) Engine speed, idling Engine speed, loading/unloading 1,600 Engine speed, working/transport 2,200 Electrical system Battery 170Ah Alternator 135A Fuses See section “Electrical system” – fuses Tire Tire dimensions: Tire pressure...

  • Page 25: Hydraulic System

    Technical specifications – General Hydraulic System Opening pressure Drive system Supply system Vibration system Steering systems Release the brakes ROPS bolts Bolt dimensions: Front mount M20x150 (PN 903633) Back mount M20x130 (PN 902282) Strength class: 10.9 585 N/m (Dacromet Tightening torque: treated) ROPS bolts that are tightened should be dry 10-03-2022...

  • Page 26: Torque

    Technical specifications – General Torque Tightening torque in Nm (lbf.ft) for oiled or dry bolts tightened with a torque wrench. Metric coarse screw thread, bright galvanised (fzb): STRENGTH CLASS: M – thread 8.8 – oiled 8.8 – dry 10.9 – oiled 10.9 – dry 12.9 – oiled 12.9 – dry 13.4 14.6 16.3...

  • Page 27: Machine Description

    Machine description Machine description Diesel engine The machine is equipped with a water-cooled, straight four cylinder, four-stroke, turbocharged diesel engine with direct injection and a charge air cooler Electrical system The machine has the following control units. • Electronic Control Unit (ECU) •...

  • Page 28: Vibration System

    Machine description Vibration system The vibration system is a hydrostatic system in which a hydraulic motor drives the eccentric shaft, which generates the drum's vibrations. High amplitude or low amplitude are determined by the hydraulic motor's direction of rotation. Optional systems for variable amplitude are available.

  • Page 29: Machine Plate - Identification

    Machine plate – Identification Machine plate – Identification Product identification number on frame The machine’s product identification number (1) is punched on the right side of the front frame. Fig. Front frame Machine type plate The machine type plate (1) is attached to the front left of the back frame, beside the articulated joint.

  • Page 30: Engine Identification Plate

    Machine plate – Identification Engine identification plate The plate (1) is affixed to the top of the engine. It indicates the engine type, serial number and specifications. Please specify the engine serial number when ordering spare parts. See also the engine manual. Fig.

  • Page 31: Machine Description - Decals

    Machine description – Stickers Machine description – Decals Location – Decals 1. Warning - Crush zone Hydraulic fluid 15. Coolant Warning, rotating engine Lift point 16. Hydraulic fluid level components 3. Warning, very hot surfaces Fixing point 17. Locking the articulation 4.
  • Page 32 Machine description – Stickers 10/9/17 1. Warning - Crush zone Hydraulic fluid 15. Coolant Warning, rotating engine Lift point 16. Hydraulic fluid level components 3. Warning, very hot surfaces Fixing point 17. Locking the articulation 4. Warning, ballasted tire Main switch Safety manual 6.

  • Page 33: Safety Decals

    Machine description – Stickers Safety decals 4700903422 Warning – Crush zone, articulation/drum. Keep a safe distance from the crush zone. 4700903423 Warning – Rotating engine components. Keep your hands at a safe distance from the danger zone. 4700903424 Warning – Hot surfaces in the engine compartment. Keep your hands at a safe distance from the danger zone.

  • Page 34: Information Decals

    Machine description – Stickers Information Decals Coolant Diesel Fuel Lift point Lifting plate Manual compartment Master switch Hydraulic fluid Tire pressure Fixing point Hydraulic fluid level Fire extinguisher Grease 10-03-2022 4812331840EN...

  • Page 35: Machine Description - Instruments/Controls

    Machine Description – Instruments/Controls Machine Description – Instruments/Controls Locations – Instruments and controls Fig. Instruments and control panel Ignition key Membrane panel Emergency Stop Traffic lights Vibration Switch Hazard lights Handbook compartment Direction indicators Forward/reverse control Switch Parking brake Seat switch Display Instrument guard 10-03-2022...
  • Page 36 Machine Description – Instruments/Controls No. Designation Symbol Function Ignition key Positions 1-2: Shut off position, key can be removed. Position 3a: All instruments and electric controls are supplied with power. The machine is equipped with automatic glowing which occurs in this position. Position 3c: Actuation of starter motor.
  • Page 37 Machine Description – Instruments/Controls No. Designation Symbol Function 10. Turn indicators, switch When pressed in one of the two directions, the (optional) respective light will blink with green illumination. In central position, the function is switched off. 11. Parking brake switch Push the button to activate the parking brake;...

  • Page 38: Functional Description - Membrane Panel

    Machine Description – Instruments/Controls Functional Description – Membrane panel Working mode Amplitude, hight/low Working lights Rotating beacon Low speed switch High speed switch Engine speed selector Horn (Not applicable for T1 machine) Symbol Designation Function LED colour Activates working mode, which makes it possible to use vibration and edge cutter (optional).
  • Page 39 Machine Description – Instruments/Controls Symbol Designation Function LED colour Press to activate the rotating beacon Rotating beacon LED OFF  (Option) LED LEFT  On Yellow LED OFF  Working mode Low speed switch LED LEFT  Tortoise mode on the drum Activate the change function of the machines LED OFF Hi speed switch...

  • Page 40: Functional Description - Display

    Machine Description – Instruments/Controls Below graphic applicable for Old black and white Display up to machine sr. no E010242 Functional Description – Display When the ignition key is activated to position 1, the start screen appears on the display (Fig. 1). This is shown for a two seconds and then switches over to the status screen.

  • Page 41: User Setting

    Machine Description – Instruments/Controls User settings Users can change the lighting configurations (6), Brightness & contrast. Temperature systems (7). SW: - 4812330988_A – Display 4812330987_A – ECU software Fig. User settings Working mode – Vibration Different Vibration modes are chosen by pressing the corresponding button (2) on the membrane panel.

  • Page 42: Sub Menu - Error Code

    Machine Description – Instruments/Controls Sub menu – Error codes 1. The alarm symbols are shown on the left hand side of the display. At the top is the red warning symbol and at the bottom the yellow (1). 2. The side menu is displayed, when the sub-menu is selected. Fig.
  • Page 43 Machine Description – Instruments/Controls Functional Description – Tell- Tales & Alarms Battery Charging When battery voltage is low i.e. <13.5V, the charging symbol Appears with orange triangle alert as per beside snap. Engine Coolant Temp. High When the Engine Temp high: immediately symbol will come with red color alert as per beside slide Hydraulic Oil Temp high When Hydraulic oil temp high;...
  • Page 44 Machine Description – Instruments/Controls Symbolic representation of Vibration 'ON' in low amplitude Switched 'ON' vibration in low amplitude & check symbol as per beside snap with single curve below drum (this will appear whenever machine running in Vibration low mode only) Symbolic representation of Vibration 'ON' in high amplitude...
  • Page 45 Machine Description – Instruments/Controls Below graphic applicable for new coloured display from machine sr. no E010243 Functional Description – Display When the ignition key is activated to position 1, the start screen appears on the display (Fig. 1). This is shown for a two seconds and then switches over to the status screen.
  • Page 46 Machine Description – Instruments/Controls Transport with machine speed (Applicable to DCM) User can see the machine speed (12) in travel and working mode. It’s applicable in DCM machine. User settings Users can change the lighting configurations (6), Brightness & contrast. Machine speed (7) Applicable in Compaction meter. SW: - 4812332072_A–...
  • Page 47 Machine Description – Instruments/Controls Sub menu – Error codes 10. The alarm symbols are shown on the left hand side of the display. At the top is the red warning symbol and at the bottom the yellow (1). 11. The side menu is displayed, when the sub-menu is selected. Fig.
  • Page 48 Machine Description – Instruments/Controls Functional Description – Tell- Tales & Alarms Battery Charging When battery voltage is low i.e. <13.5V, the charging symbol Appears with orange triangle alert as per beside snap. Engine Coolant Temp. High When the Engine Temp high: immediately symbol will come with red color alert as per beside slide Hydraulic Oil Temp high When Hydraulic oil temp high;...
  • Page 49 Machine Description – Instruments/Controls Low Fuel When fuel is low-symbol should come with Orange tell-tale Parking Brake When the parking brake applied symbol should come red tell-tale Parking light When the parking light applied symbol should come in green Parking Brake When the parking brake released and try to start the machine, symbol should appear to indicate the Parking switch need to applied in machine starting.
  • Page 50 Machine Description – Instruments/Controls Symbolic representation of working mode Switched ‘ON’ Low speed button and check symbol as per beside with tortoise curve inside the drum (this will appear when low speed activated) Symbolic representation of Travel mode Switched ‘ON’ High speed button and check symbol as per beside with rabbit curve inside the drum (this will appear when high speed activated) Symbolic representation of Vibration 'ON' in low...
  • Page 51 Machine Description – Instruments/Controls Instruments and control, Cab No. Designation Symbol Function AC/Heater control Turn to right increase heating. Turn to centre reduce heating. Turn to left Increase the cooling. Ventilation fan, Switch In the left position, the fan is off. Turning the knob to the right increases the volume of air entering the cab Air conditioning switch...
  • Page 52 Machine Description – Instruments/Controls Front wiper switch Press to operate the screen wiper. Front windshield washers Press the button on top to activate the front windshield switch washers. Fuse box Contains fuses for the electrical system in the cab. 14. Air vents Position the air vents in the best way for you.

  • Page 53: A/C - System Operation

    Machine Description – Instruments/Controls A/C – System operation Introduction This air conditioning system was designed to provide safety and comfort for the equipment operator while working, consequently improving productivity. Using the cab Controls Defroster To Quickly remove ice or mist, make sure that only the front and rear air nozzle are open.

  • Page 54: Electronic Control Unit

    Machine description – Electrical system Electronic control unit The electronic control unit (ECU) (14) is place behind Left side the operator’s seat. The ECU controls, Vibration, Engine, start-stops & machine safety interlocks. Fig. Driving compartment 14. Control unit (ECU) 15,16,17 Main fuses There are three main fuses These are on the battery...

  • Page 55: Relays

    Machine description – Electrical system Relays The table below shows fuse amperage and function. Fig. Relays and fuse board Fuse Amperage Function Spare Spare Display, Keypad, Dyn@link, P-Brake Switch Neutral switch, Seat switch, alternator, vibration switch (joystick) Compaction Meter (Option) Front Working Lights Relay Rear Working Lights Relay Spare...

  • Page 56: Operation - Start-Up

    Operation – Start-up Operation – Start-up Before starting Master switch – Activation Always perform daily maintenance. See the maintenance instructions. The battery master switch is located in the engine compartment. Open the engine cover and set the key (20) to the ON position. The whole circuit of the machine gets electric power.

  • Page 57: Before Starting

    Operation – Start-up Before starting Make sure that the emergency stop (2) is pulled out. When the roller is in neutral or there is no load on the operator's seat, the automatic brake function is engaged. Fig. Instrument panel: Pull out the emergency stop (2). Emergency stop;...

  • Page 58: View

    Operation – Start-up View Before starting, make sure that the view forwards and backwards is unobstructed. All cab windows must be clean and rear-view mirrors properly adjusted. Interlock The machine is equipped with a locking system. The engine switches off 4 seconds after the operator rises from the seat at the same time as the forward/reverse lever Fig.

  • Page 59: Start Of Diesel Engine

    Operation – Start-up Operation – Start-up Start of diesel engine Make sure that the emergency stop (2) is pulled out. Make sure that the parking brake switch (12) is activated. Set the forward/reverse lever (5) in neutral. The engine can only be started when the lever is in neutral.

  • Page 60: Operation - Driving

    Operation - Driving Operation – Driving Operating the roller The machine should never be controlled from the ground. The operator should remain seated at all times. Set speed selector (26) in high operation position. Release the parking brake (12). Fig. Control panel: Check that the steering is working properly by turning the Ignition key;...

  • Page 61: Operation - Vibration

    Operation - Vibration Operation – Vibration Vibration switch To activate or deactivate the vibration, activate the high or low amplitude selector (8). The operator should activate it using the vibration switch, located under the forward/reverse lever (5). Fig. Control panel: Amplitude switch.

  • Page 62: Dynapac Compaction Meter (Dcm) Including Dynapac Bouncing Control (Dbc) - Optional

    Operation - Vibration Dynapac Compaction Meter (DCM) including Dynapac Bouncing Control (DBC) – Optional The Compaction Meter is an accessory used to improve compaction efficiency and efficacy. Its system allows to choose different types of materials as a parameter, adapting the system to the material being compacted. If the machine is equipped with the meter, an extra display indicates the stiffness of the surface as CMV (compaction meter value).
  • Page 63 Operation - Vibration Some reference CMV for some compacted materials: Material Rockfill 40 - 200 Rock fill 25 - 100 Sand 20 - 60 Silt 5 -30 Clay 0 - 80 The water content in the compacted soil, except for rockfill, has a large influence on stiffness;...

  • Page 64: Operation - Stopping

    Operation – Stopping CMV actual value Under 80% = 80-99% = Yellow 100-119%= Green 120% + =Blue Buttons to set + or – CMV Target value Double jumping CMV target value Inclination Angle Value Horiz. & Verticle in Deg or % 10-03-2022 4812331840EN...

  • Page 65: Braking

    Operation – Stopping Operation – Stopping Braking Emergency braking Braking is normally activated using the forward/reverse lever. The hydrostatic transmission brakes the machine when the lever is moved to the neutral position. There is also a brake in the Drum motor and rear axle of the machine that acts as an emergency brake during operation.

  • Page 66: Switching Off

    Operation – Stopping Switching off Check the controls and warning lights to see if any faults are indicated (29). Switch off all lights and other electrical functions. Set Speed selector (26) in low idle position and let the engine run for about one minute. Activate the parking brake (12).

  • Page 67: Long-Term Parking

    Long-term parking Long-term Parking The following instructions should be followed for long-term parking (more than one month). These measures apply when parking for a period of up to 6 months. Wash the machine and touch up the paint finish to avoid rusting.

  • Page 68: Hoods, Tarpaulin

    Long-term parking Hoods, tarpaulin Place the control cover over the control panel. Cover the whole machine with protective tarpaulin. A gap must be left between the tarpaulin and the ground. If possible, store the machine indoors and ideally in a building where the temperature is constant.

  • Page 69: Miscellaneous

    Miscellaneous Miscellaneous Lifting Locking the steering articulation Steering articulation must be locked to prevent inadvertent turning before lifting the machine. Turn the steering wheel so the direction is straight forward. Press the emergency/parking brake button. Pull out the lowermost safety pin with a wire (35). Fig.

  • Page 70: Unlocking The Articulation

    Miscellaneous Unlocking the articulation Remember to unlock the articulation before the start of operation. Fold the locking arm (31) back and secure it in the locking articulation (33) with the locking pin (30). Install the safety pin with the cable (31) to attach the locking pin (32). The locking articulation (33) is located on the frame of the machine.

  • Page 71: Towing The Roller

    Miscellaneous Towing the Roller When the roller is towed/recovered, the towing vehicle will have to break it. If necessary, use a towing bar, since the machine will have no breaks. The machine has to be towed slowly at a max. speed of 3 km/h (2 mph), and only for short distances, of max.

  • Page 72: Securing In Closed Container For Loading

    Miscellaneous Securing in closed Container for loading Securing the CA25-35D/PD Vibratory roller from Dynapac for transport. 1 – 3= Double lashing, i.e one lashing with two parts secured to two different lashing mounts, symmetrically located on the right and left sides. 4 –...

  • Page 73: Operating Instructions - Summary

    Operating instructions - Summary Operating instructions – Summary 1. Follow the SAFETY INSTRUCTIONS specified in the safety manual; 2. Make sure that all instructions in the MAINTENANCE section are followed; 3. Activate the battery switch; 4. Set the forward/reverse lever in neutral; 5.

  • Page 74: Preventive Maintenance

    Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost. The Maintenance section includes periodic maintenance that must be carried out on the machine. The recommended maintenance intervals assume that the machine is used in a normal environment and working conditions.

  • Page 75: Maintenance - Lubricants And Symbols

    Maintenance – Lubricants and symbols Maintenance – Lubricants and symbols Always use high-quality lubricants in the recommended amounts. Too much grease or oil can cause overheating, resulting in premature wear. Ambient temperature 0°C +50°C Shell Rimula Super 15W40, API CH4 or equivalent. ENGINE OIL Ambient temperature -20°C +20°C Valvoline Premium Blue Extreme 5W-40...

  • Page 76: Maintenance Symbols

    Maintenance – Lubricants and symbols Maintenance symbols Engine, oil level Tire pressure Engine, oil filter Air cleaner Hydraulic reservoir Battery Hydraulic fluid, filter Recycling Transmission, oil level Fuel filter Drum, oil level Coolant Oil for lubrication 10-03-2022 4812331840EN...

  • Page 77: Maintenance - Planned Maintenance

    Maintenance – Planned maintenance Maintenance – Planned maintenance Service and inspection points Carefully read this section of the manual before performing any maintenance service or lubrication of the machine. Get in the habit of examining the areas around and under the equipment.

  • Page 78: Scheduled Maintenance And Lubrication

    Maintenance – Planned maintenance Scheduled maintenance and lubrication The maintenance and lubrication services should be performed firstly based on the number of operation hours, and secondly, based on periods of time such as days, weeks, etc. Always clean around covers, caps, fittings or plugs before opening them or applying grease.

  • Page 79: Service And Maintenance Point

    Maintenance – Planned maintenance Service and maintenance point Check the Dobbs meter on the machine to know what type of maintenance is needed. Every 10 hours of operation (Daily) Refer to the contents to find the page number of the sections referred to ! Pos.

  • Page 80: Every 250/750/1250/1750 Hours Of Operation (Monthly)

    Maintenance – Planned maintenance Change the oil in the gearbox Applicable for CA25/CA30/CA35PD machines and CA35D with traction control. Oil change not required - CA35D Steering Hitch tightening Every 250/ 750/ 1250/ 1750 hours of operation (Monthly) Refer to the contents to find the page number of the sections referred to ! Pos.

  • Page 81: Every 1000 Hours Of Operation (Every Six Months)

    Maintenance – Planned maintenance Every 1000 hours of operation (Every six months) Refer to the contents to find the page number of the sections referred to ! Pos. in Action Comment Replace the air cleaner's main filter and backup filter Change the hydraulic fluid filter Drain the condensate from hydraulic reservoir Drain condensate from fuel tank...
  • Page 82 Maintenance – Planned maintenance Change the oil in the Drum Gear box Applicable for CA25/CA30/CA35PD machines and CA35D with traction control. Oil change not required - CA35D Change oil in rear axle differential Change oil in the rear axle planetary gearing Check belt tension for Engine drive Refer to the engine manual...

  • Page 83: Every 10 Hours Of Operation (Daily)

    Maintenance – Planned maintenance Maintenance, 10h Every 10 hours of operation (Daily) Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.

  • Page 84: Air Circulation

    Maintenance – Planned maintenance Air circulation Ensure that the engine has free circulation of cooling air through the protective grille in the hood. To open the engine hood, turn the hood latch (1) upward. Raise the hood to its fully open position, checking that the red safety catch on the left gas spring is latched.

  • Page 85: Fuel Tank Filling

    Maintenance – Planned maintenance Fuel tank – Filling Refuel daily with diesel fuel up to the lower edge of the filler pipe (1). Follow the engine manufacturer’s specifications with respect to fuel quality. Stop the engine. Short-circuit the filler gun against a non-insulated part of the machine before refuelling, and against the filler pipe (1) while refuelling.

  • Page 86: Emergency Stop

    Maintenance – Planned maintenance Emergency stop Drive the machine slowly forward. Hold the steering wheel firmly and brace yourself for a sudden stop. Press the emergency stop (1). The machine will stop abruptly and the engine will be switched off. After testing the brakes, set the forward/reverse lever in neutral.

  • Page 87: Every 50 Hours Of Operation (Weekly)

    Maintenance – Planned maintenance Maintenance - 50h Every 50 hours of operation (Weekly) Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.

  • Page 88: Articulated/Steering Joint - Lubrication

    Maintenance – Planned maintenance Air cleaner – Cleaning Wipe the inside of the cover and filter housing. Wipe also both surfaces of the outlet pipe. Check that the hose clamps between the filter housing and the suction hose are tight and that the hoses are intact.

  • Page 89: Air Conditioning (Optional) - Cleaning/Filter Change

    Maintenance – Planned maintenance Tires – Air pressure – Wheel nuts – Tightening Check the tire pressures using a pressure gauge. When the tire is filled with fluid, the valve (1) should be positioned at “12 o’clock”, once the specified pressure is reached.

  • Page 90: Change The Hydraulic Fluid Filter

    Maintenance – Planned maintenance Maintenance – First 50h Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.
  • Page 91 Maintenance – Planned maintenance Rear axle differential – Change oil level Do not work under the roller with the engine running. Park on a level surface. Clean and remove the three filler/level plugs (1) and (3) and the three drain plugs (2). The filler/level plugs are located in the front and back of the axle and the drain plugs are located on the lower and back part.

  • Page 92: Steering Hitch - Tightening

    Maintenance – Planned maintenance Drum gearbox (D/PD) – Changing the oil (Applicable for CA25/CA30/CA35PD machines and CA35D with traction control) (Oil change not required-CA35D) Wipe clean, unscrew the plugs (1, 2 and 3) and drain the oil into a suitable receptacle with a capacity of about 5.0 litres (5.3 qts). Refit the drainage plug (1) and top up with oil up to the level plug (3).
  • Page 93 Maintenance – Planned maintenance Maintenance – 250/750/1250/1750h Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.

  • Page 94: Drum - Checking The Oil Level

    Maintenance – Planned maintenance Drum – Checking the oil level Place the roller on a level surface so that the plug (1) and the drum's number plate are visible on the right side. The oil level should now reach the sight glass (3). If necessary, remove the plug (1) and fill to halfway up the sight glass.

  • Page 95: Bolted Joints - Checking Tightening

    Maintenance – Planned maintenance Bolted joints – Checking tightening Steering pump for the diesel engine (1) 55 Nm, lightly oiled. Rear axle suspension (2), 330 Nm (243 ft/lbf) oiled. Engine shock mount (3). Check that all the M12 bolts (20 pieces) are tightened with 70 Nm and lightly oiled.
  • Page 96 Maintenance – Planned maintenance Discard used batteries appropriately. Batteries contain 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. Drum cartridge - Cleaning the ventilation screw Clean the drum's ventilation hole and ventilation screw (1).
  • Page 97 Maintenance – Planned maintenance Maintenance – 500/1500h Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.

  • Page 98: Hydraulic Reservior-Bleeder Filter Check

    Maintenance – Planned maintenance Hydraulic reservoir – bleeder filter check If passage in either direction is blocked, clean the filter with a little diesel oil and blow through with compressed air until the block is removed, or replace the cap with a new one. Always wear protective goggles when working with compressed air.

  • Page 99: Replacing The Main Air Filter

    Maintenance – Planned maintenance Maintenance - 1000h Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.
  • Page 100 Maintenance – Planned maintenance Draining the hydraulic fluid tank Condensate in the hydraulic tank is drained via the plug (2). Drainage must be performed when the machine has been stationary for an extended period, e.g. overnight. Drain as follows: Remove the plug (2); Place an empty container under the Knob;...
  • Page 101 Maintenance – Planned maintenance Rear axle differential – Oil change Do not work under the machine with the engine running. Park on a level surface. Lock the wheels. Clean and remove the three filler/level plugs (1) and (3) and the three drain plugs (2). The filler/level plugs are located in the front and back of the axle and the drain plugs are located on the lower and back part.

  • Page 102: Diesel Engine - Oil And Filter Change

    Maintenance – Planned maintenance Diesel engine – Oil and filter change Take great care when draining fluid and oil at high temperatures. Wear protective gloves and goggles. It is easier to handle the oil drain plug (1) from under the engine.
  • Page 103 Maintenance – Planned maintenance Check the engine belt tension Check positioning of the belt on the tensioner, which should be centred, and if the belt shows signs of too much wear, it should be replaced. Check the engine manual for more information. Fig.

  • Page 104: Hydraulic Reservior - Fluid Change

    Maintenance – Planned maintenance Maintenance - 2000h Park the roller on a level surface. When checking and making adjustments, the engine should be switched off and the emergency/parking brake should be applied, if not otherwise specified. Ensure that there is good ventilation (air extraction) if the engine is run indoors.

  • Page 105: Control - Lubrication

    Maintenance – Planned maintenance Controls – Lubrication Lubricate the forward/reverse throttle mechanism. Remove the external cover at the bottom of the seat by loosening the screws (2). Lubricate the drive elements. Fig. Forward/reverse control Screws Automatic Climate Control Regular inspection and maintenance are necessary to ensure satisfactory long term operation.
  • Page 106 Maintenance – Planned maintenance Fuel filter and fuel prefilter replacement Remove the threaded fuel filter using the filter wrench. Lubricate the O ring with clean lubricating oil. Do not prefill the engine fuel filter. Install the filter on the filter head. Press the filter until the seal touches the surface of the filter head.

  • Page 107: Change The Hydraulic Fluid Filter

    Maintenance – Planned maintenance Change the hydraulic fluid filter Always wear protective goggles when working with compressed air. Carefully clean around the hydraulic filter. Remove the filter (1) and take to an environmentally- compliant waste disposal station. The filter is of the disposable type and cannot be cleaned.
  • Page 108 Maintenance – Planned maintenance Rear axle differential – Check oil level Do not work under the roller with the engine running. Park on a level surface. Wipe clean and remove the level plug (1) and check that the oil level reaches the lower edge of the opening. Top off with oil to the right level if the level is low.
  • Page 109 Maintenance – Planned maintenance Steering hitch – Tightening The easiest way to identify if you have this type of steering hitch is that it has a new type of nut (1) at the top as shown. Actual torque (Nm) should be when the machines position is straight ahead Drum cartridge - Cleaning the ventilation screw Clean the drum's ventilation hole and ventilation screw...
  • Page 110 Dynapac Road Construction Equipment (India) Pvt. Ltd. Plot no 01, Gat no. 163-168, Alandi Markal road, Village: Fulgaon, Taluka: Haveli, Dist: Pune- 412216, India www.dynapac.com...

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Dynapac ca30Dynapac ca3510300181kle000072

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