Dynapac DFP12D Operating Instruction Download Page 94

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Fault

Possible cause

Remedy

Injection nozzle does not work correctly

Have it checked by qualified expert per-

sonnel

Engine overheats

Engine oil level too high

Check, drain off if necessary

Lack of cooling air

Clean the cooling fins and the cooling air

intake openings.

Check air guide plates and ducts for com-

pleteness and good sealing.

Engine runs with

high speed, but no

vibration

Centrifugal clutch defective

Have it checked by qualified expert per-

sonnel

V-belt torn

Replacing the V-belt

Troubleshooting – Engine malfunctions

DFP12D

Summary of Contents for DFP12D

Page 1: ...Operating Instruction Original Operating Instructions DFP12D Forward plate S N 101 924 26 1001 DL8 203 75 EN 06 2018...

Page 2: ...2...

Page 3: ...egular 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...

Page 4: ...ling system on off 57 6 5 Parking the machine in secured condition 58 7 Loading transporting the machine 59 7 1 Loading the machine 60 7 2 Lashing the machine to the transport vehicle 61 7 3 Transport...

Page 5: ...creen 85 8 8 As required 87 8 8 1 Cleaning the cooling fins and the cooling air intake openings 87 8 8 2 Cleaning the machine 87 8 8 3 Cleaning the water spraying system 88 8 8 4 Measures prior to ext...

Page 6: ...Table of contents DFP12D 6...

Page 7: ...1 Introduction Introduction DFP12D 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: ...Engine type 1 Engine number 2 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 ty...

Page 11: ...2 Technical data Technical data DFP12D 11...

Page 12: ...42 7 542 21 3 500 19 7 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 122 269 kg lbs Basic weight 123 271 kg lbs Water spraying system optional equipment 10 22 kg lbs Tran...

Page 13: ...power ISO 3046 3 1 4 2 kW hp Rated speed 3000 min 1 Drive system mechanical Exciter system Frequency 92 5520 Hz vpm Centrifugal force 25 5620 kN lbf Amplitude 1 75 0 069 mm in Water sprinkling system...

Page 14: ...d 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 3 m s2 on crushed rock determined acc...

Page 15: ...3 Concerning your safety Concerning your safety DFP12D 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: ...ctices 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 e...

Page 18: ...se 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 Inte...

Page 19: ...to stand on the machine while working Lifting tackle must be removed before starting work Starting and operating the machine in explosive environments and in underground mining is prohibited The lifti...

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 const...

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 spill...

Page 25: ...aused 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 Immediate...

Page 26: ...ne 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 lifti...

Page 27: ...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 28: ...al 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 a...

Page 29: ...he static charging than diesel fuel with a higher sulphur content Apply measures against electrostatic charging Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off...

Page 30: ...danger of scalding Wipe off spilled oil catch running out oil and dispose of environ mentally When working on the air filter no dirt should fall into the air duct Do not work on the hot exhaust dange...

Page 31: ...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 32: ...heir meaning Replace damaged and illegible stickers or signage immediately X 008 338 08 008 338 21 START OPERATION STOP Water Made by Designation Type Nominal Power Operating Mass Year of Construction...

Page 33: ...sticker Follow operating instructions Warning sticker Starter rope Instruction sticker Wear ear defenders Information sticker Lifting point Fig 7 Fig 8 Fig 9 Fig 10 Concerning your safety Signage DFP...

Page 34: ...Information sticker Guaranteed sound capacity level Information sticker Filler opening for water Information sticker Shut down pin throttle lever Fig 11 Fig 12 B DEC 0218 Water Fig 13 Fig 14 Concerni...

Page 35: ...Brief operating instructions Fig 15 Concerning your safety Signage DFP12D 35...

Page 36: ...e type plate example Fig 16 Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerl nder Str 93 D 26203 Wardenburg B 924 0002 Fig 17 Concerning your...

Page 37: ...4 Indicators and control elements Indicators and control elements DFP12D 37...

Page 38: ...Throttle lever Position MIN Idle speed position Position MAX Full load position 4 1 2 Shut down pin press Shut down the engine 4 1 3 Recoil starter Fig 18 Fig 19 Fig 20 Indicators and control elements...

Page 39: ...2 1 Rotary button for water sprinkling system Position 0 Water sprinkling system off turn anticlockwise Water sprinkling system on infinite adjustment of the sprinkling quantity up to position MAX 1 2...

Page 40: ...4 3 Transport wheels Fig 23 1 Locking of guide handle 2 Locking of transport wheels Optional equipment Indicators and control elements Transport wheels DFP12D 40...

Page 41: ...4 3 1 Transport wheels with steering bow in middle position Fig 24 1 Locking of guide handle 2 Locking of transport wheels Indicators and control elements Transport wheels DFP12D 41...

Page 42: ...Indicators and control elements Transport wheels DFP12D 42...

Page 43: ...5 Checks prior to start up Checks prior to start up DFP12D 43...

Page 44: ...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 Chapter 3 4 Han dli...

Page 45: ...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 pr...

Page 46: ...stick 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 the MIN and MAX mark...

Page 47: ...lter Use only fuel of the permitted specification Chapter 8 2 2 Fuel on page 67 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Rem...

Page 48: ...s n Protective gloves 1 Check the rubber buffer pairs left and right for tight fit cracks and tear offs Have damaged rubber buffers replaced by authorised service personnel immediately B SYM 1073 Fig...

Page 49: ...ontaminated water can block the bore holes Fill only with clean water 3 If necessary fill in clean water 4 Close the cap Alternatively the water tank can also be removed and transported for filling 1...

Page 50: ...Checks prior to start up Checking the water level topping up DFP12D 50...

Page 51: ...6 Operation Operation DFP12D 51...

Page 52: ...ment n Working clothes n Safety shoes n Protective gloves 1 Force the guide handle apart and plug it onto the brackets 2 Lock and secure the guide handle on both sides with clip pins B 230 0064 Fig 33...

Page 53: ...nents 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 personal protecti...

Page 54: ...starter handle back to initial position 8 If the engine does not start during the first attempt repeat the starting process NOTICE Danger of engine damage Warm up engine for a short while before start...

Page 55: ...eration WARNING Danger of burning on hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components Protective equipment n Hearing protecti...

Page 56: ...N idle speed for short work breaks Vibration is switched off 5 For short work interruptions you should always park the machine in secured condition Chapter 6 5 Parking the machine in secured condition...

Page 57: ...inkling system on or off with the rotary button Position 0 Water sprinkling system off turn anticlockwise Water sprinkling system on infinite adjustment of the sprinkling quantity up to position MAX F...

Page 58: ...machine on level and firm ground 2 Set the throttle lever to position MIN idle speed NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle fo...

Page 59: ...7 Loading transporting the machine Loading transporting the machine DFP12D 59...

Page 60: ...s When lifting the machine make sure the load does not move in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n Working clothes n Safety shoes n Protective...

Page 61: ...tackle must not be damaged by machine parts Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Fasten the lashing tackle to the marked lashing point 2 Lash the machine securel...

Page 62: ...le with the locking bolts 1 3 Unlock the locking bolts 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 machine ca...

Page 63: ...58 2 Lock the guide handle with the hook 1 3 Unlock the locking bolts 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...

Page 64: ...Loading transporting the machine Transport wheels DFP12D 64...

Page 65: ...8 Maintenance Maintenance DFP12D 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: ...adversely 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 2 1 3 Oil change...

Page 68: ...traces of zinc lead and copper can cause deposits in the injection nozzles especially in modern Common Rail injection sys tems Zinc and lead coatings in refuelling systems and fuel lines are not permi...

Page 69: ...W 30 SAE 30 SAE 10W Fuel Diesel Winter diesel fuel 3 0 l 0 8 gal us Specification Chapter 8 2 2 Fuel on page 67 Exciter shaft housing SAE 10W 40 Specification Chapter 8 2 3 Oil for exciter shaft housi...

Page 70: ...il 2 Check the valve clearance adjust if necessary Chapter 8 7 2 Checking adjusting the valve clearance on page 77 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter e...

Page 71: ...7 3 Replacing the air filter 79 8 7 4 Replacing the V belt 80 8 7 5 Replacing the fuel filter 82 8 7 6 Replacing the starter rope 83 8 7 7 Changing the oil in the exciter housing 85 8 7 8 Cleaning the...

Page 72: ...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 5 Parki...

Page 73: ...filter if it is damaged 10 Insert the air filter 1 carefully into the filter housing and fasten it with the knurled nut 2 11 NOTICE Danger of engine damage Ensure correct fit of air filter cover and...

Page 74: ...tion on page 58 2 Place the transparent container under the drain plug 3 Loosen the drain plug and collect escaping fluid 4 Drain the fuel off until there is no water left 5 Screw the drain plug tight...

Page 75: ...ng 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 58 2 Clean the area around oil dipstick 1 and drain...

Page 76: ...compressed air to blow the oil filter out from the inside to the outside 8 Check the seal ring 2 for damage change if necessary 9 Slightly oil the seal rings 1 and 2 10 Insert the oil filter 2 into th...

Page 77: ...e damage We recommend to have this work carried out by trained personnel or our after sales service Before checking the valve clearance let the engine cool down Protective equipment n Working clothes...

Page 78: ...ith a feeler gauge 1 adjust if necessary 3 Crank the engine further until the intake valve is fully open 4 Check the valve clearance on the exhaust valve adjust if necessary 1 Loosen screw 3 on the ro...

Page 79: ...r leaks 8 7 3 Replacing the air filter NOTICE Danger of engine damage Do not start the engine after having removed the air filter Protective equipment n Working clothes n Protective gloves 1 Park the...

Page 80: ...er 1 carefully into the filter housing and fasten it with the knurled nut 2 9 NOTICE Danger of engine damage Ensure correct fit of air filter cover and seal Close the cap 3 8 7 4 Replacing the V belt...

Page 81: ...Check tension of V belt tighten if necessary Compression measurement 5 10 mm 0 2 0 4 in 9 Assemble the V belt guard 1 with fastening screws 2 10 Check the V belt tension again after 25 operating hour...

Page 82: ...hnical data on page 11 5 Park the machine safely Chapter 6 5 Parking the machine in secured condition on page 58 6 If frequency incorrect n Check the engine speed n Check the V belt n If necessary con...

Page 83: ...the starter rope Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Chapter 6 5 Parking the machine in secured condition on page 58 2 Allow the engine...

Page 84: ...in the coil 10 CAUTION Danger of injury caused by the 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 t...

Page 85: ...side and sup port it safely 4 Unscrew the oil drain plug 1 and collect running out oil 5 Stand the machine upright NOTICE Components may get damaged Do not use low ash engine oils for the exciter shaf...

Page 86: ...rom the screen insert with an appropriate wire brush 8 Check the screen insert for damage replace if necessary 9 Reassemble the screen insert and the fastening strap 10 Tighten the fastening nut for a...

Page 87: ...le brush from all cooling fins and cooling air intake openings 4 CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective worki...

Page 88: ...Flush the water tank with a strong water jet until all dirt has run out 4 Fill the water tank with clean water and close the cap 8 8 4 Measures prior to extended shut down period 8 8 4 1 Measures befo...

Page 89: ...the air filter 3 Change the engine oil and clean the oil filter 4 Check cables hoses and lines for cracks and leaks 5 Start the engine and run it for 15 to 30 minutes with idle speed 6 Check the oil l...

Page 90: ...Maintenance As required DFP12D 90...

Page 91: ...9 Troubleshooting Troubleshooting DFP12D 91...

Page 92: ...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 93: ...e starter rope does not return to the initial position Recoil starter dirty Clean the recoil starter Insufficient pretension of the spring Check the pretension of the spring adjust if necessary Spring...

Page 94: ...ain off if necessary Lack of cooling air Clean the cooling fins and the cooling air intake openings Check air guide plates and ducts for com pleteness and good sealing Engine runs with high speed but...

Page 95: ...10 Disposal Disposal DFP12D 95...

Page 96: ...ING 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 and lubri...

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