Dynapac DR7 User manual

Operang Instrucon/Maintenance Instrucon
Original Operang Instrucons
DR7
Rammer
S/N 101 924 09 1001>
DL8 204 41 EN
© 08/2022

terminals, tank trucks and other facilities and equipment.
plants, transport and storage operations such as pipelines, marine
For more information go to www.P65Warnings.ca.gov/petroleum.
These exposures can occur in and around oil fields, refineries, chemical
WARNING: Crude oil, gasoline, diesel fuel and other petroleum
products can expose you to chemicals including toluene and benzene,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
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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 and vibration data............................................................................................................ 14
2.1.1 Noise data.................................................................................................................................. 14
2.1.2 Vibration data............................................................................................................................. 14
3 Concerning your safety...................................................................................................................... 15
3.1 Basic prerequisites..................................................................................................................... 16
3.1.1 General...................................................................................................................................... 16
3.1.2 Explanation of signal words used............................................................................................... 16
3.1.3 Personal protective equipment................................................................................................... 17
3.1.4 Intended use.............................................................................................................................. 18
3.1.5 Improper use.............................................................................................................................. 19
3.1.6 Estimated service life of the machine......................................................................................... 19
3.2 Definition of responsible persons............................................................................................. 20
3.2.1 Operating company.................................................................................................................... 20
3.2.2 Expert / qualified person............................................................................................................ 20
3.2.3 Driver / operator......................................................................................................................... 20
3.3 Basic safety regulations for safe operation............................................................................. 22
3.3.1 Remaining dangers, remaining risks.......................................................................................... 22
3.3.2 Regular safety inspections......................................................................................................... 22
3.3.3 Modifications and alterations to the machine............................................................................. 22
3.3.4 Damage, defects, misuse of safety devices............................................................................... 22
3.4 Handling fuels and lubricants.................................................................................................... 23
3.4.1 Preliminary remarks................................................................................................................... 23
3.4.2 Safety regulations and environmental protection regulations for handling gasoline.................. 24
3.4.3 Safety regulations and environmental protection regulations for handling fuel stabiliser........... 25
3.4.4 Safety regulations and environmental protection regulations for handling oil............................ 26
3.5 Loading/transporting the machine............................................................................................ 27
3.6 Start up procedure...................................................................................................................... 28
3.6.1 Prior to starting up...................................................................................................................... 28
3.6.2 Starting the engine..................................................................................................................... 28
3.7 Operation..................................................................................................................................... 29
3.7.1 Persons in the danger area........................................................................................................ 29
3.7.2 Operation................................................................................................................................... 29
3.7.3 Parking the machine.................................................................................................................. 29
3.8 Refuelling..................................................................................................................................... 30
3.9 Maintenance work....................................................................................................................... 31
3.9.1 Preliminary remarks................................................................................................................... 31
3.9.2 Working on the engine............................................................................................................... 31
3.9.3 Working on the tamper foot........................................................................................................ 31
3.9.4 Cleaning work............................................................................................................................ 31
3.9.5 Measures for longer shut-down periods..................................................................................... 31
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3.9.6 After maintenance work............................................................................................................. 32
3.10 Repair......................................................................................................................................... 33
3.11 Signage...................................................................................................................................... 34
3.12 Safety Components.................................................................................................................. 38
4 Indicators and control elements........................................................................................................ 39
4.1 Operating hour meter/engine rpm-meter.................................................................................. 40
5 Checks prior to start up...................................................................................................................... 41
5.1 Notes on safety........................................................................................................................... 42
5.2 Visual inspections and function tests....................................................................................... 43
5.3 Daily maintenance....................................................................................................................... 44
5.3.1 Checking the engine oil level..................................................................................................... 44
5.3.2 Checking the fuel level; topping up fuel..................................................................................... 44
5.3.3 Checking the rubber buffers....................................................................................................... 45
6 Operation............................................................................................................................................. 47
6.1 Adjusting the guide handle........................................................................................................ 48
6.2 Starting the engine...................................................................................................................... 49
6.3 Work mode................................................................................................................................... 53
6.4 Parking the machine in secured condition............................................................................... 55
6.5 Operating hour meter/engine rpm-meter.................................................................................. 56
7 Loading / transporting the machine.................................................................................................. 59
7.1 Loading the machine.................................................................................................................. 60
7.2 Lashing the machine to the transport vehicle.......................................................................... 62
8 Maintenance........................................................................................................................................ 63
8.1 Preliminary remarks and safety notes...................................................................................... 64
8.2 Fuels and lubricants................................................................................................................... 65
8.2.1 Engine oil................................................................................................................................... 65
8.2.2 Fuel............................................................................................................................................ 65
8.2.3 Gear oil SAE 75W-90................................................................................................................. 66
8.3 List of fuels and lubricants........................................................................................................ 67
8.4 Running-in instructions.............................................................................................................. 68
8.4.1 General information.................................................................................................................... 68
8.4.2 After the first 25 operating hours................................................................................................ 68
8.5 Maintenance Table...................................................................................................................... 69
8.6 Weekly.......................................................................................................................................... 70
8.6.1 Checking, cleaning the air filter.................................................................................................. 70
8.7 Monthly........................................................................................................................................ 72
8.7.1 Checking the tamper foot........................................................................................................... 72
8.8 Semi-annually.............................................................................................................................. 74
8.8.1 Changing the engine oil............................................................................................................. 74
8.9 Annually / every 100 operating hours....................................................................................... 75
8.9.1 Checking, adjusting the valve clearance.................................................................................... 75
8.9.2 Replacing the spark plug............................................................................................................ 78
8.9.3 Replacing the fuel filter............................................................................................................... 79
8.9.4 Cleaning the fuel strainer........................................................................................................... 80
8.9.5 Replacing the air filter................................................................................................................ 82
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8.9.6 Checking, adjusting the engine speed....................................................................................... 83
8.9.7 Replacing the starter rope.......................................................................................................... 86
8.9.8 Changing the oil in the rammer foot........................................................................................... 88
8.10 As required................................................................................................................................ 90
8.10.1 Cleaning the machine.............................................................................................................. 90
8.10.2 Checking, cleaning the spark plug........................................................................................... 90
8.10.3 Measures prior to extended shut-down period......................................................................... 91
9 Setting up / refitting............................................................................................................................ 95
9.1 Changing the tamper foot plate................................................................................................. 96
10 Troubleshooting.................................................................................................................................. 97
10.1 Preliminary remarks.................................................................................................................. 98
10.2 Engine malfunctions................................................................................................................. 99
10.3 What to do if the engine has flooded.................................................................................... 101
11 Disposal............................................................................................................................................. 105
11.1 Final shut-down of machine................................................................................................... 106
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Table of contents
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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 elements’
on page 39.
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 47.
Before every start up, carry out all required visual inspections and
function tests Ä Chapter 5 ‘Checks prior to start up’ on page 41.
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 ‘Maintenance’
on page 63.
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 (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 and engine
number
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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L
W
H
B
L1
B-541-0063
Fig. 3
B H L L1W
350
(13.8)
1030
(40.6)
728
(28.7)
335
(13.2)
280
(11.0)
Dimensions in millimetres
(Dimensions in inch)
Weights
Basic weight 66
(146)
kg
(lbs)
Operating weight 67
(148)
kg
(lbs)
Dimensions
Technical data
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Travel characteristics
Max. working speed 20
(66)
m/min
(ft/min)
Max. surface coverage 336
(3616)
m2/h
(ft2/h)
Step height 70
(2.76)
mm
(in)
Drive
Engine manufacturer Honda
Type GX 100
Cooling Air
Number of cylinders 1
Displacement 98 cm3
Rated power SAE J 1349 2.3
(3.1)
kW
(hp)
Rated speed 4200 min-1
Exciter system
Drive system mechanical
Frequency 10 – 11.8
(600 - 708)
Hz
(bpm)
Impact force 16
(3597)
kN
(lbf)
Filling capacities
Fuel (gasoline) 3.0
(0.8)
l
(gal us)
Technical data
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2.1 Noise and vibration 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
nVibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing
operating conditions.
2.1.1 Noise data
LpA = 92 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 = 108 dB(A), determined acc. to ISO 3744 and EN 500.
2.1.2 Vibration data
Vector total of the weighted effective acceleration in three orthog-
onal directions:
Total vibration value ahv = 5.2 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.5 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
Sound pressure level at the opera-
tor's stand
Guaranteed sound power level
Hand-arm vibration
Technical data – Noise and vibration 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 They protect against heavy falling parts and slipping on
slippery ground.
Protective gloves They protect the hands against scrapes, punctures or
deeper injuries, irritating and caustic substances and
burns.
Concerning your safety – Basic prerequisites
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Safety goggles They protect the eyes against airborne particles and
squirting fluids.
Face protection This protects the face against airborne particles and
squirting fluids.
Hard hat This protects the head against falling parts and injuries.
Hearing protection This protects against extreme noise.
Fine dust mask For protection against particulate pollutants.
Respiratory protection This protects the airways against substances or parti-
cles.
3.1.4 Intended use
This machine is intended for commercial use only.
The machine must only be used for:
nCompaction of all types of soils
nRepair work on all types of soil
nPaving of walkways
nWork in trenches
nUnderfilling and compaction of hard shoulders
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
Concerning your safety – Basic prerequisites
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3.1.5 Improper use
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
nWorking in horizontal direction
nRamming of poles
nVibrating of paving blocks
It is not permitted to stand on the machine while working.
starting and operation of the machine in explosive environments
and in underground mining is prohibited.
3.1.6 Estimated service life of the machine
If the following general conditions are met, the service life of the
machine is usually in the range of several thousand operating
hours:
nRegular safety inspections by an expert / qualified person
nPerformance of the prescribed maintenance work within the
specified time
nImmediate performance of necessary repair work
nExclusive use of original spare parts
Concerning your safety – Basic prerequisites
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3.2 Definition of responsible persons
3.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
3.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of this machine.
3.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
Concerning your safety – Definition of responsible persons
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