Dynapac D.ONE User manual

Operang Instrucon
Original Operang Instrucons
D.ONE
Mul-purpose compactors
S/N 101 924 90 1001>
DL 008 203 58 EN
© 04/2018

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Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data...................................................................................................................................... 11
2.1 Noise data.................................................................................................................................... 15
3 Concerning your safety...................................................................................................................... 17
3.1 Basic prerequisites..................................................................................................................... 18
3.1.1 General...................................................................................................................................... 18
3.1.2 Explanation of signal words used:.............................................................................................. 18
3.1.3 Personal protective equipment................................................................................................... 19
3.1.4 Intended use.............................................................................................................................. 20
3.1.5 Improper use.............................................................................................................................. 21
3.2 Definition of responsible persons............................................................................................. 22
3.2.1 Operating company.................................................................................................................... 22
3.2.2 Expert / qualified person............................................................................................................ 22
3.2.3 Driver / operator......................................................................................................................... 22
3.3 Basic safety regulations for safe operation............................................................................. 24
3.3.1 Remaining dangers, remaining risks.......................................................................................... 24
3.3.2 Regular safety inspections......................................................................................................... 24
3.3.3 Modifications and alterations to the machine............................................................................. 24
3.3.4 Damage, defects, misuse of safety devices............................................................................... 24
3.4 Handling fuels and lubricants.................................................................................................... 25
3.4.1 Preliminary remarks................................................................................................................... 25
3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel............... 26
3.4.3 Safety regulations and environmental protection regulations for handling oil............................ 27
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil............. 28
3.4.5 Safety regulations and environmental protection regulations for handling coolants.................. 29
3.4.6 Safety regulations and environmental protection regulations for handling battery acid............. 30
3.5 Loading/transporting the machine............................................................................................ 31
3.6 Start-up procedure...................................................................................................................... 32
3.6.1 Prior to start-up.......................................................................................................................... 32
3.6.2 Starting the engine..................................................................................................................... 32
3.6.3 Starting the engine with jump leads........................................................................................... 33
3.7 Operation with radio remote control......................................................................................... 34
3.8 Driving the machine; working operation.................................................................................. 35
3.8.1 Persons in the danger zone....................................................................................................... 35
3.8.2 Driving the machine................................................................................................................... 35
3.8.3 Driving up and down slopes....................................................................................................... 35
3.8.4 Cross slope................................................................................................................................ 35
3.8.5 Working with vibration................................................................................................................ 36
3.8.6 Parking the machine.................................................................................................................. 36
3.9 Refuelling..................................................................................................................................... 37
3.10 Emergency procedures............................................................................................................ 38
3.10.1 Actuating the emergency stop switch....................................................................................... 38
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3.10.2 Disconnecting the battery......................................................................................................... 38
3.10.3 Recovering the machine.......................................................................................................... 38
3.11 Maintenance work..................................................................................................................... 39
3.11.1 Preliminary remarks................................................................................................................. 39
3.11.2 Working on hydraulic lines....................................................................................................... 39
3.11.3 Working on the engine............................................................................................................. 39
3.11.4 Maintenance work on electric components and battery........................................................... 40
3.11.5 Cleaning work........................................................................................................................... 40
3.11.6 After maintenance work............................................................................................................ 40
3.12 Repair......................................................................................................................................... 41
3.13 Signage...................................................................................................................................... 42
4 Indicators and control elements........................................................................................................ 51
4.1 Operating mode toggle switch................................................................................................... 52
4.2 Display module............................................................................................................................ 53
4.3 Main battery switch..................................................................................................................... 54
4.4 Remote control............................................................................................................................ 55
4.4.1 Steering lever............................................................................................................................. 55
4.4.2 Vibration pre-selection toggle switch.......................................................................................... 56
4.4.3 Toggle switch for travel ranges................................................................................................... 56
4.4.4 Engine speed toggle switch....................................................................................................... 56
4.4.5 Travel lever................................................................................................................................ 57
4.4.6 Starter switch............................................................................................................................. 57
4.4.7 Start button................................................................................................................................. 57
4.4.8 Vibration toggle switch............................................................................................................... 58
4.4.9 Emergency stop switch.............................................................................................................. 58
4.4.10 Button for warning horn............................................................................................................ 58
4.4.11 Radio operation control light..................................................................................................... 59
5 Checks prior to start up...................................................................................................................... 61
5.1 Notes on safety........................................................................................................................... 62
5.2 Visual inspections and function tests....................................................................................... 63
5.3 Checking the engine oil level..................................................................................................... 64
5.4 Checking the fuel level; topping up fuel................................................................................... 65
5.5 Checking the hydraulic oil level................................................................................................ 66
5.6 Checking the coolant level......................................................................................................... 67
5.7 Checking the rubber buffers...................................................................................................... 68
6 Operation............................................................................................................................................. 69
6.1 Preliminary remarks.................................................................................................................... 70
6.1.1 BOSS safety system.................................................................................................................. 71
6.1.2 Notes on radio operation............................................................................................................ 72
6.2 Start-up procedure...................................................................................................................... 74
6.2.1 Preparing the remote control...................................................................................................... 74
6.2.2 Checking the remote control...................................................................................................... 75
6.2.3 Checking the BOSS safety system............................................................................................ 79
6.2.4 Starting the engine..................................................................................................................... 81
6.3 Travel operation.......................................................................................................................... 83
6.3.1 Preliminary remarks and safety notes........................................................................................ 83
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6.3.2 Driving the machine................................................................................................................... 84
6.4 Working with vibration............................................................................................................... 86
6.4.1 Preliminary remarks and safety notes........................................................................................ 86
6.4.2 Vibration in automatic mode....................................................................................................... 86
6.4.3 Manual vibration......................................................................................................................... 88
6.5 Parking the machine in secured condition............................................................................... 90
6.6 Remote control battery (radio operation)................................................................................. 92
6.6.1 Changing the battery.................................................................................................................. 92
6.6.2 Charging the power pack in the machine................................................................................... 93
6.6.3 Charging the power pack with the external battery charger....................................................... 94
7 Loading / transporting the machine.................................................................................................. 95
7.1 Preparation for transport............................................................................................................ 96
7.2 Loading the machine.................................................................................................................. 97
7.3 Lashing the machine to the transport vehicle.......................................................................... 98
7.4 Loading by crane........................................................................................................................ 99
7.5 After transport........................................................................................................................... 100
8 Maintenance...................................................................................................................................... 101
8.1 Preliminary remarks and safety notes.................................................................................... 102
8.2 Preparations/concluding work................................................................................................. 103
8.2.1 Opening the protection hoods.................................................................................................. 103
8.2.2 Engaging/releasing the articulation lock................................................................................... 103
8.3 Fuels and lubricants................................................................................................................. 105
8.3.1 Engine oil................................................................................................................................. 105
8.3.2 Fuel.......................................................................................................................................... 106
8.3.3 Coolant..................................................................................................................................... 107
8.3.4 Oil for exciter shaft housing...................................................................................................... 108
8.3.5 Hydraulic oil.............................................................................................................................. 108
8.4 List of fuels and lubricants...................................................................................................... 109
8.5 Running-in instructions............................................................................................................ 110
8.5.1 General..................................................................................................................................... 110
8.5.2 After 50 operating hours........................................................................................................... 110
8.5.3 After 250 operating hours......................................................................................................... 110
8.6 Maintenance Table..................................................................................................................... 111
8.7 Weekly........................................................................................................................................ 112
8.7.1 Air filter maintenance................................................................................................................ 112
8.7.2 Checking and cleaning the water separator............................................................................. 115
8.8 Every 250 operating hours/annually........................................................................................ 116
8.8.1 Change engine oil and oil filter cartridge.................................................................................. 116
8.8.2 Checking, tensioning the V-belt................................................................................................ 117
8.8.3 Replacing the air filter............................................................................................................... 118
8.8.4 Check the air intake lines......................................................................................................... 119
8.8.5 Changing the oil in the exciter housing.................................................................................... 120
8.8.6 Replacing the fuel filter; bleeding the fuel system.................................................................... 122
8.8.7 Draining the fuel tank sludge.................................................................................................... 124
8.8.8 Checking radiator hoses and hose clamps.............................................................................. 124
8.8.9 Servicing the battery; checking the main battery shutoff.......................................................... 125
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8.9 Every 500 operating hours....................................................................................................... 127
8.9.1 Replacing the V-belt................................................................................................................. 127
8.10 Every 1000 operating hours................................................................................................... 128
8.10.1 Adjusting the valve clearance................................................................................................ 128
8.11 Every 2000 operating hours................................................................................................... 131
8.11.1 Changing the hydraulic oil and filter....................................................................................... 131
8.11.2 Changing the coolant............................................................................................................. 133
8.11.3 Replacing hoses..................................................................................................................... 135
8.11.4 Check the injection valves...................................................................................................... 135
8.12 Every 3000 operating hours................................................................................................... 136
8.12.1 Checking the fuel injection pump........................................................................................... 136
8.13 As required.............................................................................................................................. 137
8.13.1 Checking/adjusting the scrapers............................................................................................ 137
8.13.2 Cleaning the radiator module................................................................................................. 137
8.13.3 Checking the central screw of the drive hub.......................................................................... 139
8.13.4 Measures prior to extended shutdown period........................................................................ 139
9 Setting up / refitting.......................................................................................................................... 143
9.1 Drum extension......................................................................................................................... 144
9.1.1 Preliminary remarks and safety notes...................................................................................... 144
9.1.2 Removing the drum extension................................................................................................. 144
9.1.3 Attaching the drum extension................................................................................................... 145
9.2 Teaching the BOSS safety field system.................................................................................. 146
10 Troubleshooting................................................................................................................................ 149
10.1 Starting the engine with jump leads...................................................................................... 150
10.2 Switching off the machine manually..................................................................................... 151
10.3 Decrease in the hydraulic oil level........................................................................................ 153
10.4 Fuse assignment..................................................................................................................... 155
10.4.1 Notes on safety...................................................................................................................... 155
10.4.2 Fuse box................................................................................................................................ 155
10.4.3 Main fuse................................................................................................................................ 156
10.5 Engine faults............................................................................................................................ 157
10.6 Remote control faults (cable operation)............................................................................... 159
10.7 Remote control faults (radio operation)................................................................................ 161
10.8 Faults in BOSS safety system............................................................................................... 163
10.9 Fault code display................................................................................................................... 164
10.10 Entering input codes via the display unit........................................................................... 165
11 Disposal............................................................................................................................................. 167
11.1 Final shut-down of machine................................................................................................... 168
12 Appendix............................................................................................................................................ 169
12.1 List of fault codes................................................................................................................... 170
12.2 Input codes for BLM control.................................................................................................. 181
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1 Introduction
Introduction
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1.1 Foreword
These operating and maintenance instructions are part of your
machine.
They provide necessary information to operate your machine
safely and properly.
They also contain information on required operating, maintenance
and repair measures.
Carefully read the operating and maintenance instructions before
taking your machine into operation.
Please observe the safety regulations strictly and follow all instruc-
tions to ensure safe operation.
If you are not yet acquainted with the indicators and control ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter Ä Chapter 4 „Indicators and control ele-
ments“ on page 51.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter “Operation”
Ä Chapter 6 „Operation“ on page 69.
Before every start up, carry out all required visual inspections and
function tests Ä Chapter 5 „Checks prior to start up“ on page 61.
Ensure the compliance with the specified operating, maintenance
and repair measures to maintain the functional safety of your
machine.
A description of all necessary maintenance work, maintenance
intervals as well as information on fuels and lubricants can be
found in the chapter “Maintenance”
Ä Chapter 8 „Mainte-
nance“ on page 101.
Do not service or repair your machine by yourself to avoid harming
persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and
authorised personnel.
Contact our customer service to carry out the required mainte-
nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
For your own personal safety you should only use original parts
from Dynapac.
For your machine we offer service kits to make maintenance
easier.
In the course of technical development we reserve the right for
technical modifications without prior notification.
These operating and maintenance instructions are also available in
other languages.
Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
Introduction – Foreword
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The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of Dynapac GmbH.
We wish you successful work with your Dynapac machine.
Introduction – Foreword
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type (Fig. 1)
Engine number (2):
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Made in Germany
Ammerländer Str. 93
D-26203 Wardenburg
1
2
B-924-0001
Fig. 1: Machine type plate (example)
Fig. 2: Engine type plate (example)
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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H
L
A
W
D
S
K
W1
B-720-0110
Fig. 3
A D H K L S W W1
1000
(39)
520
(20.5)
1275
(50)
197
(7.8)
1897
(75)
16
(0.6)
850
(33.5)
610
(24)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (CECE) 1595
(3516)
kg
(lbs)
Basic weight 1585
(3494)
kg
(lbs)
Mean axle load (CECE) 798
(1759)
kg
(lbs)
Drum extension (610/850 mm) + 48
(+ 106)
kg
(lbs)
Dimensions
Technical data
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Travel characteristics
Travel speed (1) forward/reverse 1.2
(0.7)
km/h
(mph)
Travel speed (2) forward/reverse 2.8
(1.7)
km/h
(mph)
Max. gradability without/with vibration (soil dependent) 55/45 %
Drive
Engine manufacturer Kubota
Type D1005
Cooling Water
Number of cylinders 3
Rated power ISO 3046 14.5 kW
Rated speed 2600 min-1
Drive system hydrostatic
Driven drum 4
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
Steering
Type of steering Articulated joint
Steering operation hydrostatic
Exciter system
Vibrating drum front + rear
Drive system hydraulic
Frequency 42
(2520)
Hz
(vpm)
Amplitude 1/2 1.12/0.56
(0.044/0.022)
mm
(in)
Centrifugal force 1/2 72/36
(16186/8093)
kN
(lbf)
Technical data
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Filling capacities
Fuel (diesel) 24
(6)
l
(gal us)
Safety field system
Size of the safety field in front of/behind the machine 1.2
(1.3)
m
(yd)
Safety field control
Voltage 8 to 30 V
Current consumption at 12 V 1.5 A
IP rating IP 55
Safety field frequency 125 kHz
Transponder in remote control
Voltage (cable operation) 9 to 30 V
Voltage (battery operation) 3.6 V
Transmitting frequency range 868/916 MHz
Safety field antenna
IP rating IP 55
Transmitter
Frequency band F-band
Transmitting frequency range 868/916 MHz
Number of channels 1
Current consumption approx. 10 mA
Receiver
Receiver frequency range 868/916 MHz
Technical data
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Transmitter power pack
Voltage 3.6 V
Capacity 1.2 Ah
Charger (optional equipment)
Operating voltage 110/230
12-24
V (AC)
V (DC)
2.1 Noise data
The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
nEU Machine Directive edition 2006/42/EU
nNoise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
During operation these values may vary because of the prevailing
operating conditions.
LpA = 84 dB(A), determined acc. to ISO 11201 and EN 500.
WARNING!
Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
LWA = 109 dB(A), determined acc. to ISO 3744 and EN 500
Sound pressure level at the opera-
tor's stand
Guaranteed sound power level
Technical data – Noise data
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Technical data – Noise data
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3 Concerning your safety
Concerning your safety
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3.1 Basic prerequisites
3.1.1 General
This machine has been built in compliance with the latest technical
standard and complies with the applicable regulations and tech-
nical rules.
However, dangers for persons and property may arise from this
machine, if:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
3.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
Concerning your safety – Basic prerequisites
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CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical
information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
3.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
Concerning your safety – Basic prerequisites
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Safety goggles To protect the eyes against airborne particles and
squirting fluids.
Face protection To protect the face against airborne particles and
squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-
cles.
3.1.4 Intended use
This machine is only to be used for:
nCompaction of cohesive soils in trench construction
nConstruction backfills
nEarthwork in sewer and pipeline construction
nEarthwork in railway and dam construction
nEarthwork in landfill construction
nSubstructure and foundation works
The operator’s position is behind the machine.
When operating the machine from the opposite side, there is a dis-
crepancy between the actuation of the control devices for the travel
movements and the respective control movement of the machine.
The remote control must be carried in front of the body, as
intended.
Concerning your safety – Basic prerequisites
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