Fayat DYNAPAC DFP8, Operating Instructions And Maintenance

Page 1: ...Operating Instruction Maintenance Instruction Original Operating Instructions DFP8 Forward plate S N 861 924 28 1001 S N 861 924 34 1001 DL8 203 78 EN 05 2019...

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: ...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 e...

Page 4: ...50 5 6 Checking the water level topping up 51 6 Operation 53 6 1 Mounting the guide handle 54 6 2 Starting the engine 55 6 3 Operation 59 6 4 Switching the water spraying system on off 61 6 5 Parking...

Page 5: ...ousing 90 8 9 As required 92 8 9 1 Cleaning the cooling fins and the cooling air intake openings 92 8 9 2 Cleaning the machine 93 8 9 3 Cleaning the water spraying system 94 8 9 4 Servicing the V belt...

Page 6: ...Table of contents DFP8 6...

Page 7: ...1 Introduction Introduction DFP8 7...

Page 8: ...g 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: ...t 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 Introduc...

Page 10: ...Engine type Engine number Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerl nder Str 93 D 26203 Wardenburg 1 2 B 924 0001 Fig 1 Machine type...

Page 11: ...2 Technical data Technical data DFP8 11...

Page 12: ...14 2 Dimensions in millimetre Dimensions in inch Weights Operating weight CECE 83 183 kg lbs Basic weight 82 181 kg lbs Water spraying system optional equipment 7 15 4 kg lbs Transport wheels optiona...

Page 13: ...ed power SAE J 1349 2 6 3 5 kW hp Rated speed 3600 min 1 Drive system mechanical Exciter system Frequency 90 5400 Hz vpm Centrifugal force 10 2250 kN lbf amplitude 1 00 0 039 mm in Water sprinkling sy...

Page 14: ...ed 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 4 4 m s2 on crushed rock determined acc...

Page 15: ...3 Concerning your safety Concerning your safety DFP8 15...

Page 16: ...s 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 a...

Page 17: ...actices 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...

Page 18: ...use This 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 compaction of hard shoulders Int...

Page 19: ...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 the f...

Page 20: ...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 cons...

Page 21: ...operate 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: ...t 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 th...

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 limitati...

Page 24: ...Health hazard caused by contact with gasoline Wear your personal protective outfit protective gloves protective clothing Do not inhale any fuel fumes Do not swallow gasoline Avoid contact with gasoli...

Page 25: ...with fuel sta bilizer Wear your personal protective outfit protective gloves protective clothing Do not inhale any fuel stabilizer fumes Do not swallow fuel stabilizer Avoid contact with fuel stabiliz...

Page 26: ...caused 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 Immediat...

Page 27: ...ine 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 lift...

Page 28: ...other faults the machine must not be operated until these deficiencies have been corrected Do not operate the machine with defective indicators and control elements 3 6 2 Spark protection The spark p...

Page 29: ...Avoid operation in closed or partly closed rooms or ensure ade quate ventilation when working in trenches Concerning your safety Start up procedure DFP8 29...

Page 30: ...ual noises and development of smoke Perform trouble shooting and have the fault corrected Always keep a safe distance to excavation pit borders embank ments and edges Refrain from any work that could...

Page 31: ...and heat sources Apply measures against electrostatic charging Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep dirt and water away from the f...

Page 32: ...ters and other oil contaminated materials in a sepa rate specially marked container and dispose of environmentally 3 9 3 Cleaning work Do not perform cleaning work while the motor is running Allow the...

Page 33: ...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 34: ...Germany I 0 STOP OPERATION I 0 START before taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio weekly w chentlich hebdomadairement cada semana twice an...

Page 35: ...ction sticker Wear ear defenders Information sticker Guaranteed sound capacity level Fig 7 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that ar...

Page 36: ...nformation sticker Lifting point Information sticker Filler opening for petrol Information sticker Filler opening for water Fig 11 Fig 12 B DEC 0216 Gasoline Benzin Fig 13 B DEC 0218 Water Fig 14 Conc...

Page 37: ...ervicio weekly w chentlich hebdomadairement cada semana twice annual halbj hrlich tous les 6 mois cada 6 meses annual j hrlich annuellement anualmente BENZIN GASOLINE B DEC 0276 Fig 16 Made by Designa...

Page 38: ...3 12 Safety components 1 2 B 834 0293 Fig 18 1 Heat protection cover 2 Belt guard Concerning your safety Safety components DFP8 38...

Page 39: ...4 Indicators and control elements Indicators and control elements DFP8 39...

Page 40: ...Overview Fig 19 1 Start switch 2 Throttle lever 3 Choke lever 4 Recoil starter 5 Fuel valve 4 1 2 Starter switch Position OFF Ignition off Position ON Ignition on Fig 20 Indicators and control element...

Page 41: ...on MIN Idle speed Position MAX Maximum speed 4 1 4 Choke lever Position Left Choke closed Position Right Choke open 4 1 5 Recoil starter B HON 0041 Fig 21 B HON 0042 Fig 22 Fig 23 Indicators and contr...

Page 42: ...4 1 6 Fuel valve Position Left Fuel valve closed Position Right Fuel valve open B HON 0043 Fig 24 Indicators and control elements Engine DFP8 42...

Page 43: ...aying system 4 2 1 Shut off valve Position 0 Water spraying system off turn anticlockwise Water spraying system on infinite adjustment of the spraying quan tity up to MAX position Fig 25 Fig 26 Indica...

Page 44: ...4 3 Transport wheels Fig 27 1 Locking of guide handle 2 Locking of transport wheels Indicators and control elements Transport wheels DFP8 44...

Page 45: ...5 Checks prior to start up Checks prior to start up DFP8 45...

Page 46: ...fixed settings 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 dl...

Page 47: ...lines for condition and leaks 2 Check bolted connections for tight fit 3 Check machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check starter rope for chafing Checks p...

Page 48: ...pstick and wipe it clean with a lint free clean cloth 3 Insert the dipstick into the oil filler socket do not screw it in but pull it out again to check the oil level The oil level must be between the...

Page 49: ...ion or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Chapter 8 2 2 Fuel on page 71 Protective equipment n Working clothes n S...

Page 50: ...lothes n Safety shoes n Protective gloves 1 Check the rubber buffer pairs left and right for tight fit cracks and tear offs Replace damaged rubber buffers immediately B SYM 1073 Fig 32 B 834 0081 Fig...

Page 51: ...loves 1 Clean the area around the filling port 2 Remove the cap 1 and check the water supply in the water tank 3 If necessary fill in clean water 4 Close the cap Alternatively the water tank can also...

Page 52: ...Checks prior to start up Checking the water level topping up DFP8 52...

Page 53: ...6 Operation Operation DFP8 53...

Page 54: ...ng screws Insert the fastening screws from the inside so that the guide handle can be folded down completely 2 Force the guide handle apart and plug it onto the holding fix tures 3 Lock and secure the...

Page 55: ...g on hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components WARNING Loss of hearing caused by too high noise bur dens Wear your per...

Page 56: ...empera tures are high the choke must remain open to prevent the engine from stalling Close the choke 5 Set the throttle lever to MIN position 6 Turn the starter switch to ON position B HON 0035 Fig 38...

Page 57: ...ith power 10 Manually guide the starter handle back to initial position 11 If the engine does not start during the first attempt repeat the starting process 12 Open the choke bit by bit when the engin...

Page 58: ...starter is frequently operated with the choke closed the engine will draw in too much fuel and is unable to start Chapter 9 3 What to do if the engine has flooded on page 105 Operation Starting the e...

Page 59: ...ng on hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components WARNING Loss of hearing caused by too high noise bur dens Wear your pe...

Page 60: ...he machine by means of the guide handle 4 For short work interruptions you should always return the throttle lever to MIN position idle speed Vibration is switched off Fig 46 Fig 47 Operation Operatio...

Page 61: ...ystem must be switched on and off by the shut off valve Position 0 Water spraying system off turn anticlockwise Water spraying system on infinite adjustment of the spraying quantity up to MAX position...

Page 62: ...aring protection n Working clothes n Protective gloves n Safety shoes 1 Park the machine on level and firm ground 2 Set the throttle lever to MIN position idle speed 3 NOTICE Danger of engine damage D...

Page 63: ...4 Close the fuel valve completely 5 Secure the machine against unauthorised use B HON 0036 Fig 51 Operation Parking the machine in secured condition DFP8 63...

Page 64: ...Operation Parking the machine in secured condition DFP8 64...

Page 65: ...7 Loading transporting the machine Loading transporting the machine DFP8 65...

Page 66: ...not be damaged by machine components When lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide ropes Protective equipment n Working clothes n Protective g...

Page 67: ...lication Lifting tackle must not be damaged by machine components Protective equipment n Protective gloves 1 Fold down the guide handle 2 Pull at least two suitable lashing belts crosswise across the...

Page 68: ...guide handle with the locking bolts 1 3 Unlock the locking bolt 2 and fold down the transport wheels 4 Push the machine up by the guide handle and fold the trans port wheels under the base plate The m...

Page 69: ...8 Maintenance Maintenance DFP8 69...

Page 70: ...equipment Do not touch hot components Park the machine on horizontal level firm ground Perform maintenance work only with the engine shut down and the spark plug connector disconnected Make sure that...

Page 71: ...ne oil espe cially under low ambient temperatures SAE 10W 30 is recommended for general use You may alternatively use 15W 40 except under low tempera tures 8 2 1 3 Oil change intervals Oil change inte...

Page 72: ...Please follow the instructions of the manufacturer concerning the correct mixing ratio and shelf life Mixing in fuel stabilizer does not regenerate old fuel 8 2 3 Oil for exciter shaft housing Use on...

Page 73: ...al us SAE 30 Fuel Gasoline unleaded Specification Chapter 8 2 2 Fuel on page 71 2 0 l 0 5 gal us Fuel stabilizer Specification Chapter 8 2 2 2 Fuel stabil izer on page 72 DL 009 940 20 as required Exc...

Page 74: ...e engine oil Chapter 8 7 1 Changing the engine oil on page 79 2 Check engine and machine for leaks 3 Retighten the fastening screws on air filter exhaust and other attachments 4 Retighten the bolted c...

Page 75: ...fuel strainer 84 8 8 5 Replacing the air filter 87 8 8 6 Replacing the starter rope 88 8 8 7 Changing the oil in the exciter housing 90 As required 8 9 1 Cleaning the cooling fins and the cooling air...

Page 76: ...torch Do not continue to use 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 machin...

Page 77: ...by moving the gun up and down inside the element until it is free of dust 9 In case of excessive dirt replace the paper element 10 Clean the foam element 5 in warm soapy water rinse it and let it dry...

Page 78: ...seal 5 16 Insert the filter element 4 correctly and tighten it with the wing nut 3 17 Tighten the cover 2 with the wing nut 1 18 Dispose of the filter element if replaced in an environmen tally frien...

Page 79: ...ot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Clean the area around oil dipstick 1 and drain plug 3 3 Unscrew the oil dipsti...

Page 80: ...around the spark plug 4 Unscrew the spark plug using a 13 16 inch spark plug spanner 5 Check the electrode gap of the new spark plug with a feeler gauge if necessary adjust the gap Nominal value 0 7...

Page 81: ...seal 3 5 Set the piston to the top dead centre position of the compres sion stroke For this purpose align the alignment mark 2 on the starter disc to the top bore 1 Valve clearance Intake valve IN 0...

Page 82: ...ening screws 1 evenly 3 After a short test run check the engine for leaks 8 8 3 Replacing the V belt Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely...

Page 83: ...8 Check tension of V belt tighten if necessary Compression measurement approx 5 mm 0 2 in 9 Assemble the V belt guard 1 with fastening screws 2 10 Check the V belt tension again after 25 operating hou...

Page 84: ...5 Park the machine safely Chapter 6 5 Parking the machine in secured condition on page 62 6 If frequency incorrect n Check the engine speed n Check the V belt n If necessary contact our customer servi...

Page 85: ...filter 1 5 Clean filter bowl and filter in a non inflammable solvent dry them thoroughly afterwards 6 Open the fuel valve and collect running out fuel 7 Close the fuel valve B HON 0036 Fig 77 1 2 3 B...

Page 86: ...tank 12 Loosen the hose clamp 1 and pull off the fuel hose 13 Unscrew the fuel strainer 3 with the seal 2 14 Clean the fuel strainer check the condition of the screen replace if necessary 15 Turn the...

Page 87: ...ved the air filter Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 5 Parking the machine in secured condition on page 62 2 Allow the engin...

Page 88: ...t 3 10 Tighten the cover 2 with the wing nut 1 11 Dispose of the old filter element in an environmentally friendly way 8 8 6 Replacing the starter rope Protective equipment n Working clothes n Protect...

Page 89: ...il 2 to the housing 5 with a cable strap 1 7 Untie the knots of the starter rope at both ends and remove the old starter rope 8 Thread in the new starter rope 3 and fix it with knots on both ends 9 CA...

Page 90: ...es n Safety shoes n Protective gloves 1 Drive the machine onto horizontal level firm ground 2 Park the machine safely Chapter 6 5 Parking the machine in secured condition on page 62 3 Tilt the machine...

Page 91: ...housing Observe the filling quantity Chapter 8 3 List of fuels and lubricants on page 73 9 Fill in oil 10 Stand the machine horizontally and check the oil level The oil level must reach the bottom ed...

Page 92: ...king clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Chapter 6 5 Parking the machine in secured condition on page 62 2 Allow the engine to cool down 3 Remove dried...

Page 93: ...rosion 3 Look for the cause of oily contamination and have any leaks sealed by our customer service 8 9 2 Cleaning the machine NOTICE Danger of engine damage caused by reduced cooling Immediately seal...

Page 94: ...r tank with clean water and close the cap 8 9 4 Servicing the V belt Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 5 Parking the machine...

Page 95: ...ng clothes n Protective gloves Special tool n 13 16 inch spark plug spanner 1 Park the machine in secured condition Chapter 6 5 Parking the machine in secured condition on page 62 2 Allow the engine t...

Page 96: ...g surface of the used spark plug is in contact tighten for another 1 8 to 1 4 turn with the spark plug spanner NOTICE Danger of engine damage caused by a loose spark plug Always screw the spark plug i...

Page 97: ...the machine for approx 6 to 12 months 1 Park the machine safely Chapter 6 5 Parking the machine in secured condition on page 62 2 Allow the engine to cool down for at least 30 minutes 3 Clean the mac...

Page 98: ...ith the recoil starter to dis tribute the oil in the cylinder 4 Screw the spark plug back in 5 Slowly pull the starter rope until resistance can be felt and the alignment mark 2 on the starter disc is...

Page 99: ...prohibited Keep away from heat sources sparks and other sources of ignition Do not spill any gasoline 1 Check the oil levels 2 If the fuel was drained off before shutting down you must now fill in fu...

Page 100: ...Maintenance As required DFP8 100...

Page 101: ...9 Troubleshooting Troubleshooting DFP8 101...

Page 102: ...ce 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 t...

Page 103: ...e recoil starter Spring broken Replace the recoil starter Starter rope of recoil starter does not return to initial position Recoil starter dirty Clean the recoil starter Insufficient pre tension of t...

Page 104: ...change the fuel Engine oil level too low Check the engine oil level correct if nec essary Engine runs with high speed but no vibration Centrifugal clutch defective Have checked by qualified expert per...

Page 105: ...ion Do not spill any gasoline Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles Special tool n 13 16 inch spark plug spanner 1 Allow the engine to cool down 2...

Page 106: ...if necessary adjust the gap Nominal value 0 7 0 8 mm 0 028 0 032 in 12 Screw the used spark plug carefully in by hand and once the sealing surface of the used spark plug is in contact tighten it for a...

Page 107: ...10 Disposal Disposal DFP8 107...

Page 108: ...is prohibited Keep gasoline away from heat sources sparks and other sources of ignition Do not spill any gasoline Components that previously contained gaso line must not be cut with a cutting torch W...

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