Fayat Dynapac DR7X, Operating Instruction

Page 1: ...Operating Instruction Original Operating Instructions DR7X Rammer S N 101 924 05 1001 S N 101 924 06 1001 DL8 203 46 EN 06 2018 ...

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Page 3: ...erations 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 oil 24 3 4 3 Safety regulations and environmental protection regulations for handling gasoline 25 3 4 4 Safety regulations and environmental protection regulations for handling fu...

Page 4: ...and safety notes 62 8 2 Fuels and lubricants 63 8 2 1 Engine oil 63 8 2 2 Fuel 63 8 2 3 Gear oil SAE 75W 90 64 8 3 List of fuels and lubricants 65 8 4 Running in instructions 66 8 4 1 General 66 8 4 2 After 25 operating hours 66 8 5 Maintenance Table 67 8 6 Weekly 68 8 6 1 Checking cleaning the air filter 68 8 7 Monthly 71 8 7 1 Checking the tamper foot 71 8 8 Semi annually 73 8 8 1 Changing the e...

Page 5: ...g up refitting 97 9 1 Changing the tamper foot plate 98 10 Troubleshooting 99 10 1 Preliminary remarks 100 10 2 Engine faults 101 10 3 What to do if the engine has flooded 103 11 Disposal 107 11 1 Final shut down of machine 108 Table of contents DR7X 5 ...

Page 6: ...Table of contents DR7X 6 ...

Page 7: ...1 Introduction Introduction DR7X 7 ...

Page 8: ...ting 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 61 Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment The machi...

Page 9: ...ot 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 DR7X 9 ...

Page 10: ...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 and engine number Introduction Machine type plate and engine type plate DR7X 10 ...

Page 11: ...2 Technical data Technical data DR7X 11 ...

Page 12: ... 2 280 11 0 Dimensions in millimetres Dimensions in inch Weights Basic weight 67 148 kg lbs Operating weight CECE 68 150 kg lbs Travel characteristics Max working speed 20 66 m min ft min Max area output depending on soil 336 3616 m2 h ft2 h Dimensions Technical data DR7X 12 ...

Page 13: ...and vibration data were determined in accord ance with the following guidelines under equipment specific condi tions and by using harmonized standards n EU Machine Directive edition 2006 42 EU n Noise Emission Directive 2000 14 EU Noise Protection Direc tive 2003 10 EU n Vibration Protection Directive 2002 44 EU During operation these values may vary because of the prevailing operating conditions ...

Page 14: ...ector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 5 5 m s2 on crushed rock determined acc to EN 500 ISO 5349 Associated uncertainty K 0 8 m s2 determined acc to EN 12096 Observe the daily vibration load work safety acc to 2002 44 EC Guaranteed sound power level Hand arm vibration Technical data Noise and vibration data DR7X 14 ...

Page 15: ...3 Concerning your safety Concerning your safety DR7X 15 ...

Page 16: ...ns 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 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 regulation...

Page 17: ...ractices 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 bei...

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 Intended use also includes compliance with the specified oper ating maintenance and repair measures 3 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than the one ...

Page 19: ...on n Ramming of poles n Vibrating of paving blocks It is not permitted to stand on the machine while working starting and operation of the machine in explosive environments and in underground mining is prohibited Concerning your safety Basic prerequisites DR7X 19 ...

Page 20: ...f 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 ...

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 therefore only be performed by trained specialists Concerning your safety Definition of responsible persons DR7X 21 ...

Page 22: ...st 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 machine is working under but at least once every year 3 3 3 Modifications and alterations to the machine Unauthorized changes to the machine are prohibited for safety rea sons Original parts and ac...

Page 23: ...n 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 limitation and monitoring of exposure personal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n informa...

Page 24: ... 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 Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally hazardous substance Always keep oil in proper containers Immediately bind spilled oil with an oil binding agent Di...

Page 25: ...G 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 gasoline ENVIRONMENT Gasoline is an environmentally hazardous sub stance Always keep gasoline in proper containers Immediately bind spilled gasoline with an oil binding agent and dispose of in accordance w...

Page 26: ... 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 stabilizer ENVIRONMENT Fuel stabilizer is an environmentally hazardous substance Immediately bind spilled fuel stabilizer with an oil binding agent and dispose of according to regulations Dispose of fuel sta...

Page 27: ...hine 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 lifting tackle with sufficient load bearing capacity for the weight to be loaded Fasten the lifting gear only at the specified lifting points Danger to the life of persons if they step or stand under a s...

Page 28: ... 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 with defective indicators and control elements 3 6 2 Starting the engine Do not use any starting aids like start pilot or ether The machine must not be operated with damaged missing or non functional safety installations Bef...

Page 29: ...ly be the steering bow Guide the machine so hat your hands do not hit against solid objects Watch out for unusual noises and development of smoke Perform trouble shooting and have the fault corrected 3 7 3 Parking the machine Park the machine on horizontal level firm ground Before leaving the machine n Shut down the engine n Secure the machine against accidental tipping over n Secure the machine a...

Page 30: ... 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 fuel A leaking fuel tank can cause an explosion Ensure tight fit of the fuel tank cover if necessary replace immediately Concerning your safety Refuelling DR7X 30 ...

Page 31: ...filter no dirt should fall into the air duct Do not work on the hot exhaust danger of burning Store used filters and other oil contaminated materials in a sepa rate specially marked container and dispose of environmentally 3 9 3 Working on the tamper foot Drain the tamper foot oil at operating temperature danger of scalding Wipe off spilled oil catch running out oil and dispose of environ mentally...

Page 32: ... warning sign Only operate the machine after it has been repaired When replacing safety relevant components only original spare parts must be used Repairs must only be performed by an expert qualified person Concerning your safety Repair DR7X 32 ...

Page 33: ... 1 2 6 2 3 4 1 2 1 5 Low Oil Level No Start Max 0 3 l 18 3 in 3 3 6 Sec 1 2 MINUTEN MIN MAX 3600 4200 min 1 2 MINUTEN MIN MAX MAX 3850 4200 min 1 MIN 1850 2000 min 1 1 OFF ON OFF ON Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerländer Str 93 D 26203 Wardenburg B 924 0006 Fig 6 Concerning your safety Signage DR7X 33 ...

Page 34: ...ker Do not inhale exhaust gases Do not operate inside closed areas Warning sign Fire hazard Fill up with fuel only when engine is stopped and has cooled down Instruction sticker Wear ear defenders Fig 7 Fig 8 Fig 9 Fig 10 Concerning your safety Signage DR7X 34 ...

Page 35: ...ticker Lifting point Information sticker Lashing point Information sticker Guaranteed sound capacity level Information sticker pre tensioned spring Fig 11 Fig 12 Fig 13 Fig 14 Concerning your safety Signage DR7X 35 ...

Page 36: ...uctions Machine type plate example Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerländer Str 93 D 26203 Wardenburg B 924 0002 Fig 16 Concerning your safety Signage DR7X 36 ...

Page 37: ...4 Indicators and control elements Indicators and control elements DR7X 37 ...

Page 38: ... 1 3 RUN B 924 0007 Fig 17 1 Engine oil level warning light 2 Engine stop switch 3 Operating hour meter engine rpm meter 4 Throttle lever 5 Recoil starter 6 Choke lever Indicators and control elements DR7X 38 ...

Page 39: ...5 Checks prior to start up Checks prior to start up DR7X 39 ...

Page 40: ...ixed 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 Ä Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started 1 Park the machine safely Ä Chap...

Page 41: ...d 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 prior to start up Visual inspections and function tests DR7X 41 ...

Page 42: ...ot is in horizontal posi tion 2 Clean the area around the oil dipstick 1 3 Unscrew the dipstick and wipe it clean with a lint free clean cloth 4 Insert the dipstick into the oil filler socket do not screw it in but pull it out again to check the oil level 5 NOTICE Danger of engine damage Do not overfill the engine The oil level must always be between the MIN and MAX marks If the oil level is too l...

Page 43: ...refuelling process Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel through a screen filter Use only fuel of the permitted specification Ä Chapter 8 2 2 Fuel on page 63 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Remove the cap and check the filling level visually 3 Fill in fuel t...

Page 44: ... Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rubber buffers immediately B 924 0023 Fig 20 Checks prior to start up Checking the rubber buffers DR7X 44 ...

Page 45: ...6 Operation Operation DR7X 45 ...

Page 46: ...guide handle position 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Disassemble the fastening screws and washers on both sides 3 Set the steering bow to the desired height 4 Assemble the fastening screws and washers on both sides Fig 21 Operation Adjusting the guide handle DR7X 46 ...

Page 47: ...r ensure adequate ventilation 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 Safety shoes The engine does not start if the oil level is too low The engine oil level warning lamp flashes when operating the recoil starter 1 Set the engine stop switch to position ON F...

Page 48: ...ose the choke Always close the choke to start a cold and warm engine 4 Pull the rope by the starter handle until resistance can be felt 5 Guide the starter handle back to initial position Fig 24 Fig 25 Fig 26 Operation Starting the engine DR7X 48 ...

Page 49: ...l position 8 If the engine does not start during the first attempt repeat the starting process 9 Open the choke 3 to 6 seconds after the engine has started running 10 Set the throttle lever to position MIN and let the engine run at idle speed to warm up for 1 to 2 minutes NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately unde...

Page 50: ...starter is frequently operated with the choke closed the engine will draw in too much fuel and is unable to start Ä Chapter 10 3 What to do if the engine has flooded on page 103 Operation Starting the engine DR7X 50 ...

Page 51: ... of the tamper foot plate Always hold on to a running machine Always keep an eye on a running machine WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection The layer thickness of the material to be com pacted should not be higher than is possible for the machine to cope with Protective equipment n Working clothes n Safety shoes n Protectiv...

Page 52: ...and or inclination of the machine NOTICE The centrifugal clutch may be damaged Do not work with engine speeds which are below the working range 4 If the display LOW appears increase the engine speed 5 Adapt the marching speed by applying load to the guide handle A No load slowly forward B Heavy load fast forward 6 Always shift the throttle lever to position MIN for short work breaks B 541 0011 I F...

Page 53: ...e for about two minutes 2 Set the engine stop switch to position OFF ð The engine is shut down 3 Park the machine so that it cannot turn over 4 Pull the rope by the starter handle until resistance can be felt Guide the starter handle back to initial position ð This procedure protects against moisture deposits inside the engine Fig 35 Fig 36 Fig 37 Operation Parking the machine in secured condition...

Page 54: ...0 seconds after starting the engine Display Description Engine speed in the working range Engine speed below the working range Display LOW alternately displayed with the engine speed to increase the engine speed Operating hours Hour meter Maintenance display in together with the remaining period in hours until the next maintenance Set maintenance intervals n after the first 25 operating hours n th...

Page 55: ...indicator or the hour meter is displayed 3 Press the function key for three seconds ð The maintenance indicator is reset to 100 hours The hour meter is reset to zero hours Resetting the maintenance indi cator hour meter Fig 39 Operation Operating hour meter engine rpm meter DR7X 55 ...

Page 56: ...Operation Operating hour meter engine rpm meter DR7X 56 ...

Page 57: ...7 Loading transporting the machine Loading transporting the machine DR7X 57 ...

Page 58: ...ake sure the load does not move in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n Protective gloves n Safety shoes 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Make sure that no fuel will be spilled from the tank during transport n Close the fuel tank tightly n Consider the filling quantity in the tank ...

Page 59: ...hot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Lay the machine on the rollers B 541 0017 Fig 41 Loading transporting the machine Loading the machine DR7X 59 ...

Page 60: ...Protective equipment n Working clothes n Protective gloves n Safety shoes WARNING Danger of burning on hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components 1 Lean the tamper foot against the side wall of the transport vehicle 2 Fasten the machine on the transport vehicle with at least two suitable lashing belts B 541 0019 Fig 4...

Page 61: ...8 Maintenance Maintenance DR7X 61 ...

Page 62: ...h hot components Park the machine on horizontal level firm ground Secure the machine against accidental tipping over Perform maintenance work only with the engine shut down and the spark plug connector disconnected Make sure that the engine cannot be accidentally started during maintenance work Thoroughly clean machine and engine before starting maintenance work Do not leave any tools or other obj...

Page 63: ...ine 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 interval semi annually or every 100 operating hours 8 2 2 Fuel 8 2 2 1 Fuel quality Use unleaded gasoline with a research octane number of 91 or higher or octane number 86 or higher Use unleaded standard...

Page 64: ...l The fuel stabilizer has a limited shelf life 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 Gear oil SAE 75W 90 Use a fully synthetic gear oil in accordance with SAE 75W 90 API GL5 with a kinematic viscosity of at least 16 mm2 s at 100 C 212 F Maintenance Fuels and lubricants DR7X ...

Page 65: ... Engine oil on page 63 0 3 l 0 08 gal us SAE 30 Fuel Gasoline unleaded Specification Ä Chapter 8 2 2 Fuel on page 63 3 l 0 8 gal us Fuel stabilizer Specification Ä Chapter 8 2 2 2 Fuel stabil izer on page 64 DL 009 940 20 as required Rammer foot SAE 75W 90 API GL 5 Specification Ä Chapter 8 2 3 Gear oil SAE 75W 90 on page 64 1 l 0 26 gal us Maintenance List of fuels and lubricants DR7X 65 ...

Page 66: ...ill drop to the normal level after approx 100 to 250 operating hours 8 4 2 After 25 operating hours 1 Change the engine oil Ä Chapter 8 8 1 Changing the engine oil on page 73 2 Check the idle speed and the max speed of the engine adjust if necessary Ä Chapter 8 9 6 Checking adjusting the engine speed on page 87 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exh...

Page 67: ...sting the valve clearance 74 8 9 2 Replacing the spark plug 79 8 9 3 Replacing the fuel filter 80 8 9 4 Cleaning the fuel screen 83 8 9 5 Replacing the air filter 85 8 9 6 Checking adjusting the engine speed 87 8 9 7 Replacing the starter rope 90 8 9 8 Changing the oil in the rammer foot 92 As required 8 10 1 Cleaning the machine 94 8 10 2 Checking cleaning the spark plug 94 Maintenance Maintenanc...

Page 68: ...on on page 53 2 Allow the engine to cool down 3 Disassemble the cover 1 and air filter 2 4 Clean the cover 5 CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes goggles Blow the air filter out with dry compressed air max 6 bar 87 psi from inside to outside by moving the gun up and down inside the element ...

Page 69: ...ger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes goggles Blow the air filter out from inside to outside with dry com pressed air max 2 bar 29 psi until all dust has been removed 15 Check seals and air filter for damage 16 Replace the air filter if it is damaged B 924 0008 Fig 47 1 3 2 B 541 0072 Fig 48 1 2 B 541 ...

Page 70: ...le the cover 3 with fastening screws 1 tightening torque 3 Nm 2 ft lbf 19 Connect the air hose 1 with the hose clamp 2 to the cover 3 20 Assemble the left engine guard 1 2 B 541 0097 3 Nm Fig 51 1 3 2 B 541 0072 Fig 52 B 924 0008 Fig 53 Maintenance Weekly DR7X 70 ...

Page 71: ...hat the tamper foot is in horizontal posi tion 3 Allow the machine to cool down 4 Clean the sight glass 5 Check the oil level 6 The oil must be visible between the middle and the upper edge of the oil level inspection glass if necessary top up oil up to the bottom edge of the filling opening The upper edge of the inspection glass equals the bottom edge of the oil filling bore 7 Check concertina wa...

Page 72: ...ighten 4 screws 1 on the tamper foot plate tightening torque 60 70 Nm 44 52 ft lbf 10 Retighten 5 screws 1 on the tamper foot plate tightening torque 15 Nm 11 ft lbf Fig 56 Fig 57 Maintenance Monthly DR7X 72 ...

Page 73: ...per foot is in horizontal posi tion 3 WARNING Danger of burning on hot 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 4 Unscrew the oil dipstick 5 Unscrew the drain plug and collect any oil running out 6 Clean the oil drain plug and screw it back in with a new seal ring 2 7...

Page 74: ...ngine cool down Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Let the engine cool down to ambient temperature 3 Pull the air feed hose 1 and the hose clamp 2 off the cover 3 4 Disassemble the cover 1 and air filter 2 Preparations 1 3 2 B 541 0072 Fig 60 2 1 B 541 0073 Fig 61 Ma...

Page 75: ...o not tear off any hoses or cables Remove the guide handle and secure it to the housing with a fastening screw Tighten the fastening screw hand tight 7 Disassemble the recoil starter Fig 62 Fig 63 Fig 64 1 Pipe clamp 2 Screw M6x18 3 Screw M6x14 4 Screw M6x18 Maintenance Annually DR7X 75 ...

Page 76: ...he cylinder head cover 2 NOTICE Components may get damaged Do not apply force to remove the cylinder head cover Insert a screwdriver into the recess and lever the cylinder head cover carefully off 3 Check the cylinder head cover for damage 4 Replace a damaged or bent cylinder head cover Fig 65 Checking adjusting the valve clear ance Fig 66 Fig 67 Maintenance Annually DR7X 76 ...

Page 77: ...ew 1 and loosen the locking nut 3 9 Turn the valve adjustment screw in or out as required 10 Retighten the locking nut tightening torque 8 Nm 6 ft lbf 11 Clean the sealing faces on cylinder head cover and cylinder block 12 Apply a bead of liquid sealant approx 1 5 to 2 0 mm 0 06 to 0 08 in in diameter to the inner side of the cylinder head cover Liquid sealant Three Bond 1207B or similar 13 Attach...

Page 78: ...he fastening screws for the recoil starter by mistake Assemble the recoil starter 3 Attach the guide handle and tighten the right hand fastening screws hand tight Concluding work Fig 72 Fig 73 1 Pipe clamp 2 Fastening screw M6x18 3 Fastening screw M6x14 4 Fastening screw M6x18 Fig 74 Maintenance Annually DR7X 78 ...

Page 79: ... cover 1 7 Wait another 20 minutes before starting the engine 8 After a short test run check the engine for leaks 8 9 2 Replacing the spark plug NOTICE Danger of engine damage Do not use spark plugs with incorrect heat value Recommended spark plugs NGK CR5HSB DENSO U16FSR UB 1 3 2 B 541 0072 Fig 75 Fig 76 2 1 B 541 0073 Fig 77 Maintenance Annually DR7X 79 ...

Page 80: ...Nominal value 0 6 0 7 mm 0 024 0 028 in 7 Carefully screw in the spark plug by hand 8 Once the sealing surface of the new spark plug is in contact tighten for another 1 2 turn with the spark plug spanner 8 9 3 Replacing the fuel filter DANGER Danger to life caused by explosive gas air mixes Do not allow gasoline to come into contact with hot components Smoking and open fire is prohibited Keep away...

Page 81: ...ble the left engine guard 5 Loosen the hose clamps 1 and 4 and pull the fuel hoses off the fuel filter 2 6 Loosen fastening screw 3 7 Take off the old fuel filter B 541 0066 Fig 79 B 924 0008 Fig 80 Disassembling the fuel filter 1 4 3 2 B 541 0100 Fig 81 Maintenance Annually DR7X 81 ...

Page 82: ...ition ON until the fuel filter is filled with fuel 12 Close the fuel valve engine stop switch in position OFF 13 Connect the upper fuel hose to the fuel filter with the hose clamp 1 14 Assemble the left engine guard 15 Dispose of fuel and fuel filters in line with environmental reg ulations Assembling the fuel filter and filling it with fuel 4 3 2 B 541 0101 Fig 82 1 B 541 0102 Fig 83 Concluding w...

Page 83: ...rks and other sources of ignition Do not spill any gasoline Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Loosen hose clamp 1 and pull the fuel hoses off the fuel valve 2 3 Open the fuel valve engine stop switch in position ON and catch runni9ng out fuel Fig 85 Fig 86 Maintenanc...

Page 84: ...e seal 1 6 Clean the screen and check for damage 7 Replace the fuel valve if damaged 8 Assemble the fuel valve with a new seal 9 Assemble the engine stop switch 1 with screws 2 10 Connect the fuel hose with the hose clamp 1 to the fuel valve 2 Fig 87 Fig 88 Fig 89 Fig 90 Maintenance Annually DR7X 84 ...

Page 85: ...he air filter Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Allow the engine to cool down 3 Disassemble the cover 1 and air filter 2 4 Clean the cover 5 Replace the air filter 6 Insert the air filter and reassemble the cover Fig 91 2 1 B 541 0073 Fig 92 Maintenance Annually DR7...

Page 86: ... and air filter 2 11 Wipe the inside of the air filter housing with a clean cloth 12 Replace the air filter 13 Slide the air filter 2 carefully into the housing 14 Assemble the cover with fastening screws 1 tightening torque 3 Nm 2 ft lbf B 924 0008 Fig 93 1 3 2 B 541 0072 Fig 94 1 2 B 541 0081 Fig 95 1 2 B 541 0097 3 Nm Fig 96 Maintenance Annually DR7X 86 ...

Page 87: ...ng the engine oil level on page 42 Protective equipment n Hearing protection n Safety shoes CAUTION Danger of injury caused by uncontrolled machine movement Keep your feet clear of the tamper foot plate Always hold on to a running machine Always keep an eye on a running machine WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection 1 3 2 B ...

Page 88: ...at can be compacted 3 Set the throttle lever to position MIN 4 After approx 30 to 40 seconds read the idle speed from the engine rpm meter 5 Set the throttle lever to MAX position 6 After approx 30 to 40 seconds read the max speed from the engine rpm meter 7 If necessary adjust the idle speed or maximum speed as required Fig 99 Fig 100 Fig 101 Maintenance Annually DR7X 88 ...

Page 89: ...ng on hot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Adjust the idle speed using the stop screw 2 on the throttle lever 4 Adjust the maximum speed via the stop screw 1 5 Secure the stop screws with counter nuts Adjust the throttle cable if this should be necessary 6 Assemble the left engine guard B 924 0008 Fig 102 1 2 B 5...

Page 90: ...3 Disassembling the recoil starter 4 Pull the starter rope with the starter handle out completely 5 If the starter rope has been torn or the coil has recoiled com pletely n Before assembling the rope turn the coil 2 5 revolutions in anti clockwise direction and align the rope openings in coil and housing 5 to one another A Fig 105 1 Pipe clamp 2 Screw M6x18 3 Screw M6x14 4 Screw M6x18 Fig 106 Fig ...

Page 91: ...nst your body Do not let the starter handle hit back Remove the fixing of the coil and run the starter handle slowly back to initial position 10 Pull the starter handle to check the function and light move ment of the recoil starter 11 Clip in the spacer ring 2 on the recoil starter 1 12 NOTICE The recoil starter may get damaged Do not mix up the fastening screws for the recoil starter by mistake ...

Page 92: ...ot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 53 2 Clean the area around filler and drain plug 3 Unscrew the drain plug tilt the machine backward and collect running out oil 4 Stand the machine on its foot again and secure it against ...

Page 93: ...k in with a new seal ring 10 Check the oil level in the inspection glass correct if neces sary The upper edge of the inspection glass equals the bottom edge of the oil filling bore 11 Dispose of oil in line with environmental regulations B 541 0048 Fig 113 B 541 0049 Fig 114 Maintenance Annually DR7X 93 ...

Page 94: ...arking the machine in secured condition on page 53 2 Allow the engine to cool down NOTICE Components can be damaged by water entering into the system Do not guide the water jet directly into the air intake and the recoil starter 3 Clean the machine with a water jet 4 Warm up the engine for a while to avoid corrosion 8 10 2 Checking cleaning the spark plug NOTICE Danger of engine damage Do not use ...

Page 95: ...spark plug spanner 2 6 Check the condition of the spark plug clean if necessary 7 In case of excessive combustion residues or burned off elec trodes replace the spark plug Ä Chapter 8 9 2 Replacing the spark plug on page 79 8 Check the electrode gap of the spark plug with a feeler gauge if necessary adjust the gap ð Nominal value 0 6 0 7 mm 0 024 0 028 in 9 Carefully screw in the spark plug by han...

Page 96: ...Maintenance As required DR7X 96 ...

Page 97: ...9 Setting up refitting Setting up refitting DR7X 97 ...

Page 98: ...page 53 2 Allow the machine to cool down 3 Lay the machine carefully on the rollers 4 Unscrew the fastening screws 5 Take off the tamper foot plate and lay the tamper foot on the floor 6 Fasten the new tamper foot plate with the fastening screws tightening torque 60 bis 70 Nm 44 bis 52 ft lbf 7 Check the engine speed readjust if necessary Ä Chapter 8 9 6 Checking adjusting the engine speed on page...

Page 99: ...10 Troubleshooting Troubleshooting DR7X 99 ...

Page 100: ...ance 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 the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks DR7X 100 ...

Page 101: ...d expert per sonnel Engine does not crank when oper ating the recoil starter Recoil starter defective Replace the 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 the spring Check the pre tension of the spring adjust if necessary Spring broken Replace ...

Page 102: ...ed by qualified expert per sonnel Engine runs irregu larly Basic setting of governor arm de adjusted Have checked by qualified expert per sonnel Insufficient engine power Spark plug defective Check the spark plug replace if neces sary Incorrect valve clearance Check adjust if necessary Valve or valve seat worn or damaged Have checked by qualified expert per sonnel Cylinder piston or piston rings w...

Page 103: ... Wear your personal protective equipment ear protection Protective equipment n Hearing protection n Safety shoes 1 Set the engine stop switch to position OFF 2 Open the choke 3 Set the throttle lever to position MAX Fig 120 Fig 121 Fig 122 Troubleshooting What to do if the engine has flooded DR7X 103 ...

Page 104: ... a running machine Always keep an eye on a running machine Operate the recoil starter once again 7 If the engine does not start after 3 to 5 attempts close the choke and operate the recoil starter once again 8 If the engine still does not start after 3 to 5 attempts clean the spark plug Fig 123 Fig 124 Fig 125 Troubleshooting What to do if the engine has flooded DR7X 104 ...

Page 105: ...al protective equipment safety gloves protective working clothes goggles Dry the spark plug with a clean cloth or blow it dry with com pressed air 5 If necessary clean the spark plug with a wire brush 6 Screw the spark plug carefully in by hand and once the sealing surface of the used spark plug is in contact tighten for another 1 8 to 1 4 turn with the spark plug spanner 7 Plug the spark plug soc...

Page 106: ...Troubleshooting What to do if the engine has flooded DR7X 106 ...

Page 107: ...11 Disposal Disposal DR7X 107 ...

Page 108: ...e 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 WARNING Health hazard caused by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 Prote...

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