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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