Dynapac DTR100 User manual

Operang Instrucon
Original Operang Instrucons
DTR100
Walk behind twin drum roller
S/N 861 924 75 1001> / S/N 861 924 76 1001>
DL8 203 77 EN
© 06/2018

2

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.............................................................................................................................. 18
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 diesel fuel............... 24
3.4.3 Safety regulations and environmental protection regulations for handling oil............................ 25
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil............. 26
3.4.5 Safety regulations and environmental protection regulations for handling battery acid............. 27
3.4.6 Safety regulations and environmental protection regulations when handling lubrication
grease........................................................................................................................................ 28
3.5 Loading / transporting the machine.......................................................................................... 29
3.6 Start-up procedure...................................................................................................................... 30
3.6.1 Prior to starting up...................................................................................................................... 30
3.6.2 Starting the engine..................................................................................................................... 30
3.7 Operation..................................................................................................................................... 31
3.7.1 Persons in the danger area........................................................................................................ 31
3.7.2 Operation................................................................................................................................... 31
3.7.3 Driving up and down slopes....................................................................................................... 31
3.7.4 Working with vibration................................................................................................................ 31
3.7.5 Parking the machine.................................................................................................................. 32
3.8 Refuelling..................................................................................................................................... 33
3.9 Emergency procedures.............................................................................................................. 34
3.10 Maintenance work..................................................................................................................... 35
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3.10.1 Preliminary remarks................................................................................................................. 35
3.10.2 Working on hydraulic lines....................................................................................................... 35
3.10.3 Working on the engine............................................................................................................. 35
3.10.4 Maintenance work on electric components and battery........................................................... 36
3.10.5 Cleaning work.......................................................................................................................... 36
3.10.6 After maintenance work........................................................................................................... 36
3.11 Repair......................................................................................................................................... 37
3.12 Signage...................................................................................................................................... 38
4 Indicators and control elements........................................................................................................ 43
4.1 Machine........................................................................................................................................ 44
4.1.1 Travel lever................................................................................................................................ 44
4.1.2 Throttle lever.............................................................................................................................. 44
4.1.3 Vibration lever............................................................................................................................ 44
4.1.4 Reversing protection.................................................................................................................. 45
4.1.5 Parking brake lever.................................................................................................................... 45
4.1.6 Starter switch............................................................................................................................. 45
4.1.7 Water spraying system............................................................................................................... 46
4.2 Engine.......................................................................................................................................... 47
4.2.1 Fuel valve................................................................................................................................... 47
4.2.2 Decompression lever................................................................................................................. 47
4.2.3 Recoil starter.............................................................................................................................. 47
5 Checks prior to start up...................................................................................................................... 49
5.1 Notes on safety........................................................................................................................... 50
5.2 Visual inspections and function tests....................................................................................... 51
5.3 Checking the engine oil level..................................................................................................... 52
5.4 Checking the fuel level; topping up fuel................................................................................... 53
5.5 Checking the hydraulic oil level................................................................................................ 54
5.6 Checking the rubber buffers...................................................................................................... 55
5.7 Checking the water level, topping up........................................................................................ 56
6 Operation............................................................................................................................................. 57
6.1 Adjusting the steering rod......................................................................................................... 58
6.2 Starting the engine...................................................................................................................... 59
6.3 Travel operation.......................................................................................................................... 62
6.4 Operation..................................................................................................................................... 64
6.4.1 Preliminary remarks and safety notes........................................................................................ 64
6.4.2 Working with vibration................................................................................................................ 64
6.5 Water spraying system............................................................................................................... 67
6.6 Parking the machine in secured condition............................................................................... 68
7 Loading / transporting the machine.................................................................................................. 71
7.1 Loading the machine.................................................................................................................. 72
7.2 Lashing the machine to the transport vehicle.......................................................................... 73
7.3 Loading by crane........................................................................................................................ 74
7.4 After transport............................................................................................................................. 75
8 Maintenance........................................................................................................................................ 77
8.1 Preliminary remarks and safety notes...................................................................................... 78
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8.2 Fuels and lubricants................................................................................................................... 79
8.2.1 Engine oil................................................................................................................................... 79
8.2.2 Fuel............................................................................................................................................ 79
8.2.3 Hydraulic oil................................................................................................................................ 80
8.2.4 Lubrication grease...................................................................................................................... 81
8.3 List of fuels and lubricants........................................................................................................ 82
8.4 Running-in instructions.............................................................................................................. 83
8.4.1 General...................................................................................................................................... 83
8.4.2 After 25 operating hours............................................................................................................. 83
8.5 Maintenance Table...................................................................................................................... 84
8.6 Weekly.......................................................................................................................................... 85
8.6.1 Checking, cleaning the air filter.................................................................................................. 85
8.6.2 Draining the fuel tank sludge...................................................................................................... 87
8.7 Semi-annually.............................................................................................................................. 88
8.7.1 Battery service........................................................................................................................... 88
8.7.2 Servicing the V-belt.................................................................................................................... 89
8.7.3 Servicing the toothed belt........................................................................................................... 90
8.7.4 Greasing the gears..................................................................................................................... 92
8.8 Annually....................................................................................................................................... 93
8.8.1 Checking, adjusting the valve clearance.................................................................................... 93
8.8.2 Changing engine oil and oil filter element.................................................................................. 94
8.8.3 Replacing the fuel filter............................................................................................................... 96
8.8.4 Replacing the V-belt................................................................................................................... 98
8.8.5 Replacing the toothed belt......................................................................................................... 99
8.8.6 Replacing the air filter.............................................................................................................. 101
8.9 Every 2 years............................................................................................................................. 103
8.9.1 Changing hydraulic oil and hydraulic oil filter........................................................................... 103
8.10 As required.............................................................................................................................. 105
8.10.1 Cleaning the water spraying system...................................................................................... 105
8.10.2 Adjusting the scrapers............................................................................................................ 107
8.10.3 Cleaning the machine............................................................................................................ 107
8.10.4 Cleaning the cooling fins and the cooling air intake openings............................................... 108
8.10.5 Measures if there is a risk of frost.......................................................................................... 109
8.10.6 Measures prior to extended shut-down period....................................................................... 109
9 Troubleshooting................................................................................................................................ 113
9.1 Preliminary remarks.................................................................................................................. 114
9.2 Starting the engine with the recoil starter.............................................................................. 115
9.3 Starting the engine with jump leads........................................................................................ 118
9.4 Engine malfunctions................................................................................................................. 119
10 Disposal............................................................................................................................................. 121
10.1 Final shut-down of machine................................................................................................... 122
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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 ele-
ments“ on page 43.
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 57.
Before every start up, carry out all required visual inspections and
function tests Ä Chapter 5 „Checks prior to start up“ on page 49.
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 77.
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:
Engine number:
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
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
ABCDHH1K L L1O S W
620
(24.4)
865
(34.1)
250
(9.8)
500
(19.7)
1100
(43.3)
1159
(45.6)
128
(5.0)
2910
(114.6)
3010
(118.5)
20
(0.8)
10
(0.4)
750
(29.5)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (CECE) 1040
(2293)
kg
(lbs)
Basic weight 1010
(2227)
kg
(lbs)
Mean axle load (CECE) 520
(1146)
kg
(lbs)
Average static linear load (CECE) 6.9
(39)
kg/cm
(pli)
Dimensions
Technical data
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Travel characteristics
Max. travel speed forward 5.0
(3.1)
km/h
(mph)
Max. travel speed reverse 2.5
(1.6)
km/h
(mph)
Max. gradability without/with vibration (soil dependent) 40/35 %
Drive
Engine manufacturer Yanmar
Type L100
Cooling Air
Number of cylinders 1
Rated power ISO 3046 6.2
(8.3)
kW
(hp)
Rated speed 3100 min-1
Drive system hydrostatic
Driven drums front + rear
Brakes
Service brake hydrostatic
Parking brake mechanical
Exciter system
Vibrating drum front + rear
Drive system mechanical
Frequency 55
(3300)
Hz
(vpm)
Amplitude 0.50
(0,020)
mm
(in)
Centrifugal force 22
(8992)
kN
(lbf)
Technical data
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Filling capacities
Fuel (diesel) 5.5
(1.5)
l
(gal us)
Water 60
(18.5)
l
(gal us)
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 = 89 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 = 3.6 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.6 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 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 must only be used for:
nSoil compaction
nPaving of walkways
nWork in trenches
nUnderfilling and compaction of hard shoulders
nCompaction of bituminous material (road surface layers)
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
3.1.5 Improper use
Dangers may arise with the machine if it is used other than for its
intended purpose.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
held liable.
Concerning your safety – Basic prerequisites
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Examples of improper use are:
nWork with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
nCleaning the drums while driving
The transport of persons is prohibited.
Do not use the steering rod as a seat when working.
Lifting tackle must be removed before starting work.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
The lifting and lashing points specified in these instructions must
be used. It is prohibited to use other lifting and lashing points (e.g.
guide handle, steering rod).
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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