Dynapac DRP45DX User manual

Operang Instrucon/Maintenance Instrucon
Original Operang Instrucons
DRP45DX
Reversible plate
S/N 101 925 40 1001>
DL8 206 39 EN
© 01/2022

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 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 Work mode................................................................................................................................... 31
3.7.1 Persons in the danger area........................................................................................................ 31
3.7.2 Operation................................................................................................................................... 31
3.7.3 Parking the machine.................................................................................................................. 31
3.8 Refuelling..................................................................................................................................... 32
3.9 Maintenance work....................................................................................................................... 33
3.9.1 Preliminary remarks................................................................................................................... 33
3.9.2 Working on the engine............................................................................................................... 33
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3.9.3 Maintenance work on electric components and battery............................................................. 33
3.9.4 Cleaning work............................................................................................................................ 33
3.9.5 Measures for longer shut-down periods..................................................................................... 34
3.9.6 After maintenance work............................................................................................................. 34
3.10 Repair......................................................................................................................................... 35
3.11 Signage...................................................................................................................................... 36
3.12 Safety Components.................................................................................................................. 41
4 Indicators and control elements........................................................................................................ 43
4.1 Machine........................................................................................................................................ 44
4.1.1 Starter switch............................................................................................................................. 44
4.1.2 Oil pressure control light............................................................................................................ 45
4.1.3 Engine control light..................................................................................................................... 45
4.1.4 Operating hour meter................................................................................................................. 46
4.1.5 Recoil starter.............................................................................................................................. 46
4.1.6 Dynapac Compaction Indicator (DCI) display............................................................................ 46
4.2 Steering rod................................................................................................................................. 47
4.2.1 Height adjustment...................................................................................................................... 47
4.2.2 Locking pawl lever...................................................................................................................... 48
4.2.3 Throttle lever.............................................................................................................................. 48
4.2.4 Handle........................................................................................................................................ 48
5 Checks prior to start up...................................................................................................................... 49
5.1 Notes on safety........................................................................................................................... 50
5.2 Visual inspections and function tests....................................................................................... 51
5.3 Daily maintenance....................................................................................................................... 52
5.3.1 Checking the engine oil level..................................................................................................... 52
5.3.2 Checking the fuel level; topping up fuel..................................................................................... 53
5.3.3 Bleeding the fuel system............................................................................................................ 53
5.3.4 Checking the rubber buffers....................................................................................................... 55
6 Operation............................................................................................................................................. 57
6.1 Folding down and adjusting the steering rod.......................................................................... 58
6.2 Starting the engine...................................................................................................................... 59
6.3 Work mode................................................................................................................................... 61
6.4 Parking the machine in secured condition............................................................................... 63
6.5 Dynapac Compaction Indicator (DCI)........................................................................................ 64
7 Loading/transporting the machine.................................................................................................... 65
7.1 Loading the machine.................................................................................................................. 66
7.2 Lashing the machine to the transport vehicle.......................................................................... 67
8 Maintenance........................................................................................................................................ 69
8.1 Preliminary remarks and safety notes...................................................................................... 70
8.2 Preparations/concluding work................................................................................................... 71
8.2.1 Opening/closing the protection hood.......................................................................................... 71
8.3 Fuels and lubricants................................................................................................................... 73
8.3.1 Engine oil................................................................................................................................... 73
8.3.2 Fuel............................................................................................................................................ 73
8.3.3 Oil for exciter shaft housing........................................................................................................ 74
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8.3.4 Hydraulic oil................................................................................................................................ 74
8.4 List of fuels and lubricants........................................................................................................ 76
8.5 Running-in instructions.............................................................................................................. 77
8.5.1 General...................................................................................................................................... 77
8.5.2 After 25 operating hours............................................................................................................. 77
8.6 Maintenance Table...................................................................................................................... 78
8.7 Weekly.......................................................................................................................................... 79
8.7.1 Checking, cleaning the air filter.................................................................................................. 79
8.7.2 Checking and cleaning the water separator............................................................................... 81
8.8 Semi-annually.............................................................................................................................. 82
8.8.1 Battery service........................................................................................................................... 82
8.9 Annually / every 250 operating hours....................................................................................... 83
8.9.1 Replacing the V-belt................................................................................................................... 83
8.9.2 Checking, adjusting the valve clearance.................................................................................... 86
8.9.3 Changing the engine oil and cleaning the oil filter...................................................................... 88
8.9.4 Replacing the fuel filter............................................................................................................... 91
8.9.5 Replacing the air filter................................................................................................................ 92
8.9.6 Changing the oil in the exciter housing...................................................................................... 93
8.9.7 Checking the hydraulic oil level.................................................................................................. 95
8.9.8 Replacing the starter rope.......................................................................................................... 97
8.9.9 Lubricating the machine............................................................................................................. 99
8.10 Every 2 years/every 500 operating hours............................................................................. 100
8.10.1 Changing the hydraulic oil...................................................................................................... 100
8.11 As required.............................................................................................................................. 102
8.11.1 Cleaning the machine............................................................................................................. 102
8.11.2 Cleaning the cooling fins and the cooling air intake openings................................................ 102
8.11.3 Servicing the V-belt................................................................................................................ 103
8.11.4 Checking the oil level in the exciter housing.......................................................................... 104
8.11.5 Measures prior to extended shut-down period....................................................................... 104
9 Troubleshooting................................................................................................................................ 107
9.1 Preliminary remarks.................................................................................................................. 108
9.2 Starting the engine with the recoil starter.............................................................................. 109
9.3 Starting the engine with jump leads........................................................................................ 112
9.4 Fuse assignment....................................................................................................................... 113
9.5 Engine control light................................................................................................................... 114
9.6 Engine malfunctions................................................................................................................. 116
9.7 Malfunctions during operation................................................................................................. 118
9.8 DCI faults.................................................................................................................................... 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
DRP45DX
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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 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 ‘Maintenance’
on page 69.
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
DRP45DX
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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
DRP45DX
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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 plate (example)
Introduction – Machine type plate and engine type plate
DRP45DX
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