Fayat Group DYNAPAX DRP45DX, Operating Instruction, Maintenance Instruction

Page 1: ...Operating Instruction Maintenance Instruction Original Operating Instructions DRP45DX Reversible plate S N 101 925 45 1001 DL8 207 06 EN 04 2021...

Page 2: ...ding 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...

Page 3: ...2 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 dies...

Page 4: ...Notes on safety 48 5 2 Visual inspections and function tests 49 5 3 Daily maintenance 50 5 3 1 Checking the engine oil level 50 5 3 2 Checking the fuel level topping up fuel 51 5 3 3 Checking the rubb...

Page 5: ...oil level 90 8 9 8 Replacing the starter rope 92 8 9 9 Lubricating the machine 94 8 10 Every 2 years every 500 operating hours 95 8 10 1 Changing the hydraulic oil 95 8 11 As required 97 8 11 1 Cleani...

Page 6: ...Table of contents DRP45DX 6...

Page 7: ...1 Introduction Introduction DRP45DX 7...

Page 8: ...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...

Page 9: ...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 Introduct...

Page 10: ...Germany Ammerl nder Str 93 D 26203 Wardenburg 1 2 B 924 0001 Fig 1 Machine type plate example EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ KG D 94099 RUHSTORF GMBH CO Model S N Power Displ Eng Fam...

Page 11: ...2 Technical data Technical data DRP45DX 11...

Page 12: ...7 7 650 25 6 750 29 5 Dimensions in millimetres Dimensions in inch Weights Operating weight W 440 970 kg lbs Operating weight W1 460 1014 kg lbs Operating weight W2 471 1038 kg lbs Basic weight 455 10...

Page 13: ...trifugal force 60 13489 kN lbf Amplitude 1 96 0 077 mm in Filling capacities Fuel diesel 5 0 1 3 l gal us 2 1 Noise and vibration data The following noise and vibration data were determined in accord...

Page 14: ...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 2 5 m s2 on crushed rock determined acc t...

Page 15: ...3 Concerning your safety Concerning your safety DRP45DX 15...

Page 16: ...n generally accepted safety and road traffic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regu lations and to apply these ac...

Page 17: ...tices 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 eq...

Page 18: ...is intended for commercial use only The machine must only be used for n Compaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and c...

Page 19: ...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 3 1 6 Estimated service life of the machine If th...

Page 20: ...egular 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 constr...

Page 21: ...perate the machine Persons under the influence of alcohol medication or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must...

Page 22: ...be informed about the dangers that arise from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert qualified person as required for the conditions the...

Page 23: ...name of substance n possible dangers n composition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitatio...

Page 24: ...fuel Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spille...

Page 25: ...used by contact with oil Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediatel...

Page 26: ...ntact with hot components Smoking and open fire is prohibited Wear your personal protective equipment pro tective gloves protective clothing CAUTION Health hazard caused by contact with hydraulic oil...

Page 27: ...for medical advice in case of cau terization WARNING Danger of injury caused by exploding gas mix ture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking and...

Page 28: ...act CAUTION Danger of slipping on lubrication grease Collect and remove excess lubrication grease immediately ENVIRONMENT Lubrication grease is an environmentally haz ardous substance Always keep lubr...

Page 29: ...e components Secure the machine on the transport vehicle against rolling slip ping and turning over Loads must only be attached and hoisted by an expert capable person Use only lifting gear and liftin...

Page 30: ...ed visual inspections and func tion tests If the following tests reveal damages or other faults the machine must not be operated until these deficiencies have been corrected Do not operate the machine...

Page 31: ...objects When reversing steer the machine using the side of the steering handle Watch out for unusual noises and development of smoke Perform trouble shooting and have the fault corrected Always keep...

Page 32: ...d by the static charging than diesel fuel with a higher sulphur content Apply measures against electrostatic charging Do not spill any fuel Collect leaking fuel do not let it seep into the ground Wipe...

Page 33: ...ials in a sepa rate specially marked container and dispose of environmentally 3 9 3 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconn...

Page 34: ...aintenance work must be carried out both before and after shut down Chapter 8 11 5 Measures prior to extended shut down period on page 99 It is not necessary to define a maximum storage period if thes...

Page 35: ...been repaired When replacing safety relevant components only original spare parts must be used Repairs must only be performed by an expert qualified person When performing welding work on the machine...

Page 36: ...eekly w chentlich hebdomadairement cada semana twice annual halbj hrlich tous les 6 mois cada 6 meses annual 250 h j hrlich 250 h annuellement 250 h anualmente 250 h DIESEL if available falls vorhande...

Page 37: ...er of injury due to defective starter rope n Before use check the starter rope for chafing n Do not use a defective starter rope Information sticker Lashing point Information sticker Lifting point Fig...

Page 38: ...r Operation sticker Throttle lever Brief operating instructions Instruction sticker Wear ear protection Instruction sticker Observe operating instructions Fig 14 Fig 15 Fig 16 START OPERATION STOP 0 1...

Page 39: ...twice annual halbj hrlich tous les 6 mois cada 6 meses annual 250 h j hrlich 250 h annuellement 250 h anualmente 250 h DIESEL if available falls vorhanden si existant si est disponible B DEC 0274 Fig...

Page 40: ...3 12 Safety Components 2 1 3 B 695 0036 Fig 20 1 Protection hood 2 Heat protection cover 3 Belt guard Concerning your safety Safety Components DRP45DX 40...

Page 41: ...4 Indicators and control elements Indicators and control elements DRP45DX 41...

Page 42: ...5 Shut off device 4 1 1 Dynapac Compaction Indicator DCI display The DCI displays the compaction status of the layer to be com pacted Description of display options Chapter 6 5 Dynapac Compaction Indi...

Page 43: ...on III Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed with a re start lock The ignition key must...

Page 44: ...engine oil level Chapter 5 3 1 Checking the engine oil level on page 50 n If necessary perform troubleshooting Chapter 9 7 Engine malfunctions on page 111 n Inform our Customer Service Depart ment 4...

Page 45: ...098 Fig 28 1 Height adjustment 2 Locking pawl lever 3 Throttle lever 4 Handle 4 2 1 Height adjustment Setting the steering rod height to the operator s level B 695 0097 Fig 29 Indicators and control e...

Page 46: ...e engine is shut down Position MIN Idle speed Engine start position Position MAX Maximum speed 4 2 4 Handle Shift forward Forward travel Middle position Neutral position Pull back Reverse travel B 695...

Page 47: ...5 Checks prior to start up Checks prior to start up DRP45DX 47...

Page 48: ...protec tion regulations must be followed when han dling fuels and lubricants Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting wo...

Page 49: ...nd fuel lines and for leaks 2 Check the bolted connections are tight and secure 3 Check the machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check the starter rope for...

Page 50: ...around the oil dipstick 2 Unscrew the dipstick and wipe it clean with a lint free clean cloth 3 Screw the dipstick back in and pull it out again to check the oil level The oil level must be between t...

Page 51: ...n fuel through a screen filter Use only fuel of the permitted specification Chapter 8 3 2 Fuel on page 69 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Clean the area aro...

Page 52: ...k the machine safely Chapter 6 4 Parking the machine in secured condition on page 59 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rub...

Page 53: ...6 Operation Operation DRP45DX 53...

Page 54: ...ering rod down Do not click the locking pawl lever into posi tion again The steering rod must be able to swing freely 2 Adjust the steering rod with the height adjustment to the required height B 695...

Page 55: ...n when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection n Working clothes...

Page 56: ...ion key through position II to position III The starter cranks the engine The warning buzzer must stop 6 If the warning buzzer does not stop after the engine has started n Park the machine safely Chap...

Page 57: ...caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine Protective equipment n Hearing protection n Working clothes n Safety shoes 1 Make s...

Page 58: ...ruptions you should always return the throttle lever to MIN position idle speed Vibration is switched off 7 For short work interruptions you should always park the machine in secured condition Chapter...

Page 59: ...mage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Set the throttle lever to position Stop The engine is shut down The warning buzzer sounds 4...

Page 60: ...y a is not always reached Due to fluctuations in the measuring value the dis play value can vary by one digit up down during a pass The average display value during the last pass is decisive The warni...

Page 61: ...7 Loading transporting the machine Loading transporting the machine DRP45DX 61...

Page 62: ...ve in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 4 Parking the...

Page 63: ...only in the specified loading direction Lifting tackle must not be damaged by machine parts Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Pull the lashing belts crosswise...

Page 64: ...Loading transporting the machine Lashing the machine to the transport vehicle DRP45DX 64...

Page 65: ...8 Maintenance Maintenance DRP45DX 65...

Page 66: ...personal protective equipment Do not touch hot components Park the machine on horizontal level firm ground Perform maintenance work only with the engine shut down Make sure that the engine cannot be...

Page 67: ...condition 8 2 1 Opening closing the protection hood 8 2 1 1 Opening the protection hood Protective equipment n Working clothes n Protective gloves 1 Remove the rear screws 2 on both sides of the machi...

Page 68: ...crews and their washers Protective equipment n Working clothes n Protective gloves 1 Loosen the screw 1 on both sides 2 Close the protection hood 3 Tighten the screw 1 on both sides 4 Screw in screws...

Page 69: ...dversely affects the properties of the engine oil especially at low ambient temperatures Optimal operating conditions can be achieved by using the oil vis cosity chart as reference 8 3 1 3 Oil change...

Page 70: ...n refuelling systems and fuel lines are not permitted Copper containing materials copper lines brass items should be avoided because they can cause catalytic reactions in the fuel with subsequent depo...

Page 71: ...hydraulic oil always use the same oil to top up and do not mix oil types When changing from mineral oil based hydraulic oil to an ester based biologically degradable hydraulic oil you should consult...

Page 72: ...2 Fuel on page 69 Exciter shaft housing SAE 10W 40 Specification Chapter 8 3 3 Oil for exciter shaft housing on page 70 Components may get damaged Do not use low ash engine oils for the exciter shaft...

Page 73: ...9 2 Checking adjusting the valve clearance on page 82 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exhaust and other attachments 5 Retighten the bolted connecti...

Page 74: ...ging the engine oil and cleaning the oil filter 84 8 9 4 Replacing the fuel filter 87 8 9 5 Replacing the air filter 87 8 9 6 Changing the oil in the exciter housing 88 8 9 7 Checking the hydraulic oi...

Page 75: ...se a damaged air filter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Chapter 6 4 Parki...

Page 76: ...by moving the gun up and down inside the element until it is free of dust 8 Examine the air filter with a torch for cracks and holes 9 Replace the air filter if it is damaged 10 Insert the air filter...

Page 77: ...Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page 59 2 Place the transparent container under the drain plug 3 L...

Page 78: ...n Safety goggles 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page 59 2 Remove the bracket 1 of the battery 3 Remove the battery 3 and the vibration damping mats...

Page 79: ...screw on the V belt pulley The locking lever prevents the V belt pulley from turning during work The screws and nuts are not included in the scope of delivery 1 Park the machine safely Chapter 6 4 Pa...

Page 80: ...belt pulley and screw in the screws 11 Insert the locking lever into the V belt pulley and tighten the V belt pulley tightening torque 35 Nm 26 ft lbf 12 Check the centre distance x between the centr...

Page 81: ...ent n Working clothes n Hearing protection n Safety shoes Tool n Sirometer 1 Park the machine on a rubber mat 2 Start the engine Chapter 6 2 Starting the engine on page 55 3 Run the machine at maximum...

Page 82: ...alve clearance let the engine cool down Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page...

Page 83: ...ance on the exhaust valve adjust if necessary 1 Loosen the screw 3 on the rocker arm 2 Adjust the hexagon nut 2 until the feeler gauge 1 can be inserted and pulled out with noticeable resistance after...

Page 84: ...8 3 1 Engine oil on page 69 Filling quantity Chapter 8 4 List of fuels and lubricants on page 72 Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the m...

Page 85: ...plug 7 Assemble the drain hose with the hose clamp 8 Loosen the screw for approx five turns and pull the oil filter out of the housing 9 CAUTION Danger of eye injuries caused by particles flying arou...

Page 86: ...ouch the oil filter with both ends 14 Tighten the screw 15 Fill with new engine oil 16 After a short test run check the oil level on the dipstick if nec essary top up to the top dipstick mark 17 Check...

Page 87: ...ng 5 Pull the fuel hose 3 off the fuel filter 2 6 Take the fuel filter out of the bracket 1 and replace it with a new one 7 Plug on the fuel line 8 Insert the fuel filter into the tank 9 Close the fue...

Page 88: ...ICE Danger of engine damage Ensure correct fit of air filter cover and seal Close the cap 3 8 9 6 Changing the oil in the exciter housing NOTICE Components may get damaged Use only oil of the permitte...

Page 89: ...sh engine oils for the exciter shaft housing Observe filling quantity Chapter 8 4 List of fuels and lubricants on page 72 8 Fill in new oil 9 Stand the machine horizontally and check the oil level Nom...

Page 90: ...rew the filler screw 4 Press the handle forward against the stop and secure it using suitable means 5 The oil level must reach the mark on the steering rod head if necessary fill in hydraulic oil Mark...

Page 91: ...eding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Fasten the filler screw tightening torque 45 Nm 33...

Page 92: ...crews 1 and disassemble the recoil starter 2 4 Pull the starter rope with the starter handle 1 out com pletely 5 Secure the coil 2 against winding up 6 Loosen the knot 3 in the starter rope and remove...

Page 93: ...starter handle hitting against your body Do not let the starter handle hit back Slowly guide the starter handle back to initial position 11 Pull the starter handle to check the function and light mov...

Page 94: ...3 NOTICE Inadequate lubrication will cause damage to components Use only grease of the permitted specifi cation Spare parts number of lubrication grease 924 109 63 Grease the mechanical parts between...

Page 95: ...2 Adjust the steering rod using the height adjustment so that the area with the filler screw is horizontal 3 Unscrew the filler screw 4 Press the handle forward against the stop and secure it in this...

Page 96: ...Slacken the bleeding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Fasten the filler screw tightening...

Page 97: ...enings How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions clean daily if necessary Protective equipment n Working clothes n Protective g...

Page 98: ...o cool down 3 Unscrew the V belt guard 1 4 Check condition and tension of V belt Compression measurement 10 25 mm 0 4 1 0 in 5 The V belt cannot be re tightened Replace the V belt if it is damaged or...

Page 99: ...alue Bottom edge of filling drain bore 7 Clean the bleed screw and filling drain plug and screw them in with a low strength sealing agent e g spare parts number DL 009 700 16 8 11 5 Measures prior to...

Page 100: ...ht 2 Measure the open circuit voltage of the battery at regular intervals at least 1 x per month Reference values 12 6 V fully charged 12 3 V dis charged to 50 3 Recharge the battery immediately after...

Page 101: ...hoses and lines for cracks and leaks 5 Check the service life of hydraulic hoses and replace if nec essary 6 Start the engine and run it for 15 to 30 minutes with idle speed 7 Check the oil levels 8 C...

Page 102: ...Maintenance As required DRP45DX 102...

Page 103: ...9 Troubleshooting Troubleshooting DRP45DX 103...

Page 104: ...e Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance If you cannot locate the cause of a fault or rectify it yourself by fol lowing th...

Page 105: ...ion in closed or partly closed rooms or ensure adequate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear prote...

Page 106: ...rter rope may tear off Do not pull the starter rope all the way against the end stop Pull the starter handle quickly and with power 7 Manually guide the starter handle back to initial position 8 If th...

Page 107: ...le of the external battery to the plus pole of the starter battery using the first jump lead 4 Next connect the second jump lead to the minus pole of the energizing external battery and then to the mi...

Page 108: ...njury by fire in the machine Do not use fuses with higher ampere ratings and do not bridge fuses Pos Amperage Designation 1 5 A DCI fuse optional equipment 2 25 A Main fuse B 692 0075 1 2 Fig 133 Trou...

Page 109: ...Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page 59 2 Press the handle forward against the end stop and hold i...

Page 110: ...in the event of a fault in the speed adjustment Keep feet and hands clear of the vibrating base plate Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Drive the machine ont...

Page 111: ...e Replace the recoil starter Spring broken Replace the recoil starter The starter rope does not return to the initial position Recoil starter dirty Clean the recoil starter Insufficient pretension of...

Page 112: ...rrect valve clearance Check the valve clearance adjust if nec essary Injection nozzle does not work correctly Have it checked by qualified expert per sonnel Engine overheats Engine oil level too high...

Page 113: ...on of the acceleration sensor Cable breakage Inform our Customer Service Department The displayed measuring values are not plausible The acceleration sensor is not fastened correctly Shut down the eng...

Page 114: ...Troubleshooting DCI faults DRP45DX 114...

Page 115: ...10 Disposal Disposal DRP45DX 115...

Page 116: ...any WARNING Health hazard caused by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Chapter 3 4 Han dling fuels a...

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