Dynapac DRP45DX Page 35 Operating Instructions Manual Download

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3.10 Repair

Identify a defect machine with a 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.

When performing welding work on the machine you should cover

the fuel tank with insulating material.

Concerning your safety – Repair

DRP45DX

Summary of Contents for DRP45DX

Page 1: ...Operating Instruction Maintenance Instruction Original Operating Instructions DRP45DX Reversible plate S N 101 925 40 1001 DL8 206 39 EN 01 2022...

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: ...safety 50 5 2 Visual inspections and function tests 51 5 3 Daily maintenance 52 5 3 1 Checking the engine oil level 52 5 3 2 Checking the fuel level topping up fuel 53 5 3 3 Bleeding the fuel system 5...

Page 5: ...hecking the hydraulic oil level 95 8 9 8 Replacing the starter rope 97 8 9 9 Lubricating the machine 99 8 10 Every 2 years every 500 operating hours 100 8 10 1 Changing the hydraulic oil 100 8 11 As r...

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: ...ngine 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 typ...

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

Page 12: ...50 29 5 Dimensions with STONEGUARD special base plate for paving stones 800 31 5 990 39 1360 53 5 1735 68 3 970 38 2 680 26 8 Dimensions in millimetres Dimensions in inches Weights Operating weight W...

Page 13: ...t min Max gradeability depending on soil depending on weather 35 Drive Engine manufacturer Hatz Type 1B50E Cooling system Air Number of cylinders 1st Rated power ISO 3046 7 6 10 2 kW hp Rated speed 30...

Page 14: ...dB A determined acc to ISO 11201 and EN 500 WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection LWA 108 dB A determined acc to ISO 3744 an...

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: ...dicate practices 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 pr...

Page 18: ...gainst particulate pollutants Respiratory protection This protects the airways against substances or parti cles 3 1 4 Intended use This machine is intended for commercial use only The machine must onl...

Page 19: ...rting work Starting and operating the machine in explosive environments and in underground mining is prohibited The lifting and lashing points specified in these instructions must be used It is prohib...

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 104 It is not necessary to define a maximum storage period if the...

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: ...bj hrlich tous les 6 mois cada 6 meses annual 250 h j hrlich 250 h annuellement 250 h anualmente 250 h DIESEL ASTM D975 09a 1 D S15 2 D S15 API CJ 4 ACEA E9 E7 WARNING California Proposition 65 Warnin...

Page 37: ...e for chafing n Do not use a defective starter rope Warning sticker California Proposition 65 Information sticker Lashing point Fig 10 Fig 11 WARNING California Proposition 65 Warning This product con...

Page 38: ...sound capacity level Information sticker Ultra low sulphur fuel Information sticker Low ash engine oil Fig 14 Fig 15 Fig 16 Part No 4812161855 5 l 4812161856 20 l Dynapac Engine Oil 200 API CJ 4 ACEA...

Page 39: ...ver n Brief operating instructions n Instruction sticker Wear ear protection n Instruction sticker Observe operating instructions Fig 18 B DEC 0374 Fig 19 START OPERATION STOP 0 1 1 3 1 2 2 2 3 3 4 4...

Page 40: ...ana 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 ASTM D975 09a 1 D S15 2 D S15 API CJ 4 ACEA E9 E7 B DEC 0273 Fig 21 Ma...

Page 41: ...3 12 Safety Components 2 1 3 B 695 0036 Fig 23 1 Protection hood 2 Heat protection cover 3 Belt guard Concerning your safety Safety Components DRP45DX 41...

Page 42: ...Concerning your safety Safety Components DRP45DX 42...

Page 43: ...4 Indicators and control elements Indicators and control elements DRP45DX 43...

Page 44: ...Switch the ignition off Ignition key can be removed Position I Ignition on Position II Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine s...

Page 45: ...l light The engine control light reports malfunctions or necessary mainte nance by flashing at different intervals The flashing intervals occur only when the engine is at a standstill and after an ign...

Page 46: ...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 Indicator DCI on page 64 Opt...

Page 47: ...015 Fig 31 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 32 Indicators and control e...

Page 48: ...er 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 0096 Fig 33 B 695...

Page 49: ...5 Checks prior to start up Checks prior to start up DRP45DX 49...

Page 50: ...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 51: ...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 52: ...e area around the oil dipstick 2 Pull out the dipstick and wipe it clean with a lint free clean cloth 3 Insert the dipstick and pull it out again to check the oil level The oil level must be between t...

Page 53: ...fuel tank has been completely emptied or when filling the fuel tank for the first time the fuel system must be bled before starting Chapter 5 3 3 Bleeding the fuel system on page 53 5 3 3 Bleeding the...

Page 54: ...off audibly 4 Turn the ignition key to position 0 5 Repeat the procedure several times to completely bleed the fuel system The engine is ready for starting If the engine does not start after bleeding...

Page 55: ...k the machine safely Chapter 6 4 Parking the machine in secured condition on page 63 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rub...

Page 56: ...Checks prior to start up Daily maintenance DRP45DX 56...

Page 57: ...6 Operation Operation DRP45DX 57...

Page 58: ...ering rod down Do not click the locking pawl lever into posi tion again The steering rod must be able to swing freely 2 Use the height adjustment to set the steering rod to the required height B 695 0...

Page 59: ...gh noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection n Working clothes n Safety shoes 1 Folding down and adjusting the steering rod Chapte...

Page 60: ...ICE Components may get damaged Starting attempts should not exceed 30 seconds uninterrupted or max 3 times for 10 seconds Then allow the starter to cool down to ambient temperature If the engine has n...

Page 61: ...vibrating base plate CAUTION Danger of injury caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine Protective equipment n Hearing protect...

Page 62: ...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 63: ...ibration is shut down 3 NOTICE Danger of engine damage Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Turn the ignition key to position 0 The en...

Page 64: ...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 warnin...

Page 65: ...7 Loading transporting the machine Loading transporting the machine DRP45DX 65...

Page 66: ...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 67: ...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 68: ...Loading transporting the machine Lashing the machine to the transport vehicle DRP45DX 68...

Page 69: ...8 Maintenance Maintenance DRP45DX 69...

Page 70: ...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 71: ...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 72: ...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 73: ...ues This 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 3 1 3 O...

Page 74: ...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 75: ...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 76: ...2 Fuel on page 73 Exciter shaft housing SAE 10W 40 Specification Chapter 8 3 3 Oil for exciter shaft housing on page 74 Components may get damaged Do not use low ash engine oils for the exciter shaft...

Page 77: ...9 2 Checking adjusting the valve clearance on page 86 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exhaust and other attachments 5 Retighten the bolted connectio...

Page 78: ...86 8 9 3 Changing the engine oil and cleaning the oil filter 88 8 9 4 Replacing the fuel filter 91 8 9 5 Replacing the air filter 92 8 9 6 Changing the oil in the exciter housing 93 8 9 7 Checking th...

Page 79: ...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 80: ...y 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 1...

Page 81: ...Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page 63 2 Place the transparent container under the drain plug 3 L...

Page 82: ...n Safety goggles 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page 63 2 Remove the bracket 1 of the battery 3 Remove the battery 3 and the vibration damping mats...

Page 83: ...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 84: ...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 85: ...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 59 3 Run the machine at maximum...

Page 86: ...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 87: ...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 88: ...8 3 1 Engine oil on page 73 Filling quantity Chapter 8 4 List of fuels and lubricants on page 76 Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the m...

Page 89: ...n 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 aro...

Page 90: ...th both ends 14 Tighten the screw 15 Fill in fresh engine oil up to the bottom edge of the filling opening 16 After a short test run check the oil level on the dipstick if nec essary top up to the top...

Page 91: ...y Chapter 6 4 Parking the machine in secured condition on page 63 2 Clean the area around the cap and then remove it 3 Pull the fuel filter out of the tank using the string 4 Pull the fuel line 3 off...

Page 92: ...gine damage Do not start the engine after having removed the air filter Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Chapter 6 4 Parking the machi...

Page 93: ...ngine oils for the exciter shaft housing Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Drive the machine onto horizontal level firm ground 2 Park the machine safely Chapt...

Page 94: ...on page 76 8 Fill in new oil 9 Stand the machine horizontally and check the oil level Nominal value Bottom edge of filling drain bore 10 Clean the bleed screw and filling drain plug and screw them in...

Page 95: ...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 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...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 t...

Page 102: ...ntake openings 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 Prot...

Page 103: ...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 i...

Page 104: ...lue 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 e...

Page 105: ...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 106: ...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 107: ...9 Troubleshooting Troubleshooting DRP45DX 107...

Page 108: ...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 109: ...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 protection Protective equipme...

Page 110: ...TION Danger of injury caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine NOTICE The starter rope may tear off Do not pull the starter r...

Page 111: ...oes not start during the first attempt repeat the starting process NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full...

Page 112: ...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 113: ...fuses with higher ampere ratings and do not bridge fuses Position Fuse Amperage Designation 1 F67 25 A Potential 30 2 F68 25 A Potential 30 ECU 3 F103 15 A Potential 15 4 F275 5 A DCI fuse optional eq...

Page 114: ...the fault has been rectified engine control light remains off Flashing code Fault Possible cause Remedy 1 x short No engine oil pressure The engine is shut down Engine oil level too low Check the engi...

Page 115: ...short Ambient pressure sensor error internal Have it checked by qualified expert personnel 6 x short Perform maintenance The amount of operating hours for maintenance has been reached Check the operat...

Page 116: ...ngine does not crank Fuse defective Check the fuse replace if necessary Battery or other cables not connected correctly Check Starter defective Replace the starter Starter switch defective Have it che...

Page 117: ...heck the engine control light and perform trou bleshooting Have checked by qualified expert per sonnel Engine does not crank when oper ating the recoil starter Recoil starter defective Replace the rec...

Page 118: ...Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on page 63 2 Press the handle forward against the end stop and hold i...

Page 119: ...connection 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...

Page 120: ...Troubleshooting DCI faults DRP45DX 120...

Page 121: ...10 Disposal Disposal DRP45DX 121...

Page 122: ...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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