Dynapac DTR100 Operating Instruction Download Page 5

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8.3 List of fuels and lubricants

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8.4 Running-in instructions

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8.4.1 General...................................................................................................................................... 83
8.4.2 After 25 operating hours............................................................................................................. 83

8.5 Maintenance Table

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8.6 Weekly

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8.6.1 Checking, cleaning the air filter.................................................................................................. 85
8.6.2 Draining the fuel tank sludge...................................................................................................... 87

8.7 Semi-annually

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8.8 Annually

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8.9 Every 2 years

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103

8.9.1 Changing hydraulic oil and hydraulic oil filter........................................................................... 103

8.10 As required

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105

Troubleshooting

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113

9.1 Preliminary remarks

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114

9.2 Starting the engine with the recoil starter

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115

9.3 Starting the engine with jump leads

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118

9.4 Engine malfunctions

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119

Disposal

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121

10.1 Final shut-down of machine

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122

Table of contents

DTR100

Summary of Contents for DTR100

Page 1: ...Operating Instruction Original Operating Instructions DTR100 Walk behind twin drum roller S N 861 924 75 1001 S N 861 924 76 1001 DL8 203 77 EN 06 2018 ...

Page 2: ...2 ...

Page 3: ...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 diesel fuel 24 3 4 3 Safety regulations and environmental protection regulations for handling oil 25 3 4 4 Safety regulations and environmental protection regulations for handling hydraulic oil 26 3 4 5 Safety regulations and environmental prot...

Page 4: ...up 49 5 1 Notes on safety 50 5 2 Visual inspections and function tests 51 5 3 Checking the engine oil level 52 5 4 Checking the fuel level topping up fuel 53 5 5 Checking the hydraulic oil level 54 5 6 Checking the rubber buffers 55 5 7 Checking the water level topping up 56 6 Operation 57 6 1 Adjusting the steering rod 58 6 2 Starting the engine 59 6 3 Travel operation 62 6 4 Operation 64 6 4 1 P...

Page 5: ...lter element 94 8 8 3 Replacing the fuel filter 96 8 8 4 Replacing the V belt 98 8 8 5 Replacing the toothed belt 99 8 8 6 Replacing the air filter 101 8 9 Every 2 years 103 8 9 1 Changing hydraulic oil and hydraulic oil filter 103 8 10 As required 105 8 10 1 Cleaning the water spraying system 105 8 10 2 Adjusting the scrapers 107 8 10 3 Cleaning the machine 107 8 10 4 Cleaning the cooling fins an...

Page 6: ...Table of contents DTR100 6 ...

Page 7: ...1 Introduction Introduction DTR100 7 ...

Page 8: ...ing 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 77 Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment The machin...

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 Introduction Foreword DTR100 9 ...

Page 10: ...r here Engine type Engine number 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 plate Introduction Machine type plate and engine type plate DTR100 10 ...

Page 11: ...2 Technical data Technical data DTR100 11 ...

Page 12: ... 5 0 2910 114 6 3010 118 5 20 0 8 10 0 4 750 29 5 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 1040 2293 kg lbs Basic weight 1010 2227 kg lbs Mean axle load CECE 520 1146 kg lbs Average static linear load CECE 6 9 39 kg cm pli Dimensions Technical data DTR100 12 ...

Page 13: ...r Yanmar Type L100 Cooling Air Number of cylinders 1 Rated power ISO 3046 6 2 8 3 kW hp Rated speed 3100 min 1 Drive system hydrostatic Driven drums front rear Brakes Service brake hydrostatic Parking brake mechanical Exciter system Vibrating drum front rear Drive system mechanical Frequency 55 3300 Hz vpm Amplitude 0 50 0 020 mm in Centrifugal force 22 8992 kN lbf Technical data DTR100 13 ...

Page 14: ...ng conditions 2 1 1 Noise data LpA 89 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 and EN 500 2 1 2 Vibration data Vector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 3 6 m s2 on crushed roc...

Page 15: ...3 Concerning your safety Concerning your safety DTR100 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 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 regulations...

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 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 bein...

Page 18: ...tended use This machine must only be used for n Soil compaction n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders n Compaction of bituminous material road surface layers Intended use also includes compliance with the specified oper ating maintenance and repair measures 3 1 5 Improper use Dangers may arise with the machine if it is used other than for its inten...

Page 19: ... steering rod as a seat when working Lifting tackle must be removed before starting 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 prohibited to use other lifting and lashing points e g guide handle steering rod Concerning your safety Basic prerequisites DTR1...

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 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 g...

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 DTR100 21 ...

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 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 acc...

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 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 informat...

Page 24: ...l 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 spilled diesel fuel with an oil binding agent ENVIRONMENT Diesel fuel is an environmentally hazardous substance Always keep diesel fuel in proper containers Immediately bind spilled diesel fuel with an oi...

Page 25: ...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 Dis...

Page 26: ...ontact 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 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 ...

Page 27: ...l 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 open fire is prohibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery Wear your personal protective equipment pro t...

Page 28: ...tact 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 lubrication grease in proper con tainers Collect excess lubrication grease and dispose of it according to regulations Dispose of cloths soiled with lubrication grease according to regulations B SYM 0210 ...

Page 29: ... tackle only in the prescribed direction of load application Lifting tackle must not be damaged by machine 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 qualified person Use only lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded Fasten the lifting gear...

Page 30: ...red 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 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 functiona...

Page 31: ... that could adversely affect the stability of the machine 3 7 3 Driving up and down slopes Do not drive on gradients or slopes exceeding the maximum gra deability of the machine Ä Chapter 2 Technical data on page 11 Drive extremely carefully on gradients and always directly up or down the slope The steering rod must always point uphill The operator must always stand above the machine Soil conditio...

Page 32: ...ine 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 against unauthorized use Mark machines which could be in the way with a clearly visible sign Concerning your safety Operation DTR100 32 ...

Page 33: ...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 DTR100 33 ...

Page 34: ...3 9 Emergency procedures In events of emergency e g in case of a cable fire disconnect the battery from the vehicle s electric system Concerning your safety Emergency procedures DTR100 34 ...

Page 35: ...ating temperature danger of scalding Any hydraulic oil must be collected and disposed of in an environ mentally friendly way Always collect and dispose of hydraulic oils separately Do not start the engine after draining off the hydraulic oil Once all work is completed with the system still depressurized check all connections and fittings for leaks Hydraulic hoses must be visually inspected at regu...

Page 36: ...y tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery The connection cables of the battery must not touch or rub against machine parts 3 10 5 Cleaning work Do not perform cleaning work while the motor is running Allow the engine to cool down before starting cleaning work Do not use gasoline or other easily inflammable substances for cle...

Page 37: ...a warning sign Only operate the machine after it has been repaired Repairs must only be performed by an expert qualified person When replacing safety relevant components only original spare parts must be used Concerning your safety Repair DTR100 37 ...

Page 38: ...aged and illegible stickers or signage immediately Water Hydraulic Oil MAX MAX 1 2 MINUTEN MIN 1 2 MINUTEN MIN 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 START OPERATION STOP Diesel Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No B 924 0020 Fig 10 Concerning your safety Signage DTR100 38 ...

Page 39: ...Follow operating instructions Information sticker Guaranteed sound capacity level Information sticker Lashing point Information sticker Lifting point Fig 11 Fig 12 Fig 13 Fig 14 Concerning your safety Signage DTR100 39 ...

Page 40: ...ater Information sticker Filler opening for hydraulic oil Information sticker Ultra low sulphur fuel Operation sticker Travel lever B DEC 0218 Water Fig 15 B DEC 0214 Hydraulic Oil Fig 16 Fig 17 Fig 18 Concerning your safety Signage DTR100 40 ...

Page 41: ...ration lever Operation sticker Throttle lever Operation sticker Fig 19 B DEC 0267 Fig 20 B DEC 0269 Fig 21 MAX MAX 1 2 MINUTEN MIN 1 2 MINUTEN MIN 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 START OPERATION STOP B DEC 0277 Fig 22 Concerning your safety Signage DTR100 41 ...

Page 42: ...pe plate example B DEC 0268 Fig 23 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 24 Concerning your safety Signage DTR100 42 ...

Page 43: ...4 Indicators and control elements Indicators and control elements DTR100 43 ...

Page 44: ...l 4 1 2 Throttle lever Position STOP Engine off Position MIN Idle speed Position MAX Maximum speed 4 1 3 Vibration lever Position Rear Vibration off Position Front Vibration on B 834 0232 Fig 25 STOP B 834 0235 Fig 26 B 834 0233 Fig 27 Indicators and control elements Machine DTR100 44 ...

Page 45: ...Switch the ignition off Ignition key can be removed Position I II Ignition on The warning buzzer sounds Position III Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed with a re start lock The ignition key must first be turned back to posi tion 0 before a new starting attempt can be made B 834 0234 F...

Page 46: ...ystem Position 0 Water spraying system off Turn anticlockwise Water spraying system on infinite adjustment of the spraying quan tity up to MAX position MAX B 100 0011 Fig 31 Indicators and control elements Machine DTR100 46 ...

Page 47: ...p Engine has no compression Only for starting with recoil starter and maintenance NOTICE Danger of engine damage Opening the decompression lever while the engine is running leads to engine damage Never use the decompression lever for stop ping the engine 4 2 3 Recoil starter B 100 0015 Fig 32 B 100 0002 Fig 33 B 100 0035 Fig 34 Indicators and control elements Engine DTR100 47 ...

Page 48: ...Indicators and control elements Engine DTR100 48 ...

Page 49: ...5 Checks prior to start up Checks prior to start up DTR100 49 ...

Page 50: ...ls 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 Chapter 6 6 Parking the machine in secured condition ...

Page 51: ...d hydraulic lines for condition and leaks 2 Check fuel tank and fuel lines for condition and leaks 3 Check the bolted connections are tight and secure 4 Check the machine for contamination and damage Checks prior to start up Visual inspections and function tests DTR100 51 ...

Page 52: ...stick 2 Screw the dipstick out wipe it off with a lint free clean cloth and screw it back in to the end stop 3 Unscrew the dipstick again ð The oil level must be between the MIN and MAX marks 4 NOTICE Danger of engine damage Do not fill in too much engine oil If the oil level is too low top up engine oil to the MAX mark 5 Screw the oil dipstick in B SYM 1068 Fig 35 MIN MAX B 100 0003 Fig 36 Checks...

Page 53: ...on Ä Chapter 8 2 2 Fuel on page 79 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 If necessary fill in fuel through a funnel with screen filter Only fill in fuel up to the red mark on the screen filter inside the tank 4 Close the cap B SYM 1069 Fig 37 Diesel B 100 0004 Fig 38...

Page 54: ...ge 80 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Unscrew the cap with the dipstick and pull it out 3 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it until it bottoms 4 Pull the dipstick out again ð The oil level must be between the MIN and MAX marks 5 If the oil level is too low top up hydrauli...

Page 55: ...between the frame and engine car rier for tight fit cracks and tear offs 2 Check all rubber buffers between the engine and engine car rier for tight fit cracks and tear offs 3 Replace damaged rubber buffers immediately B SYM 1073 Fig 41 B 100 0036 Fig 42 B 100 0037 Fig 43 Checks prior to start up Checking the rubber buffers DTR100 55 ...

Page 56: ...ions in case of frost Ä Chapter 8 10 5 Measures if there is a risk of frost on page 109 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 water supply in the water tank 3 If necessary fill in clean water 4 Close the cap Water B 100 0005 Fig 44 Checks prior to start up Checking the water level topping up...

Page 57: ...6 Operation Operation DTR100 57 ...

Page 58: ...ng rod 1 Loosen the screws on both sides of the steering rod and fold down the steering rod 2 Set the steering rod to the required height and tighten the screws B 100 0012 Fig 45 Operation Adjusting the steering rod DTR100 58 ...

Page 59: ...adequate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Operate the machine only with a correctly adjusted steering rod Protective equipment n Working clothes n Safety shoes n Hearing protection 1 Shift the vibration lever to Rear position 2 Set the throttle lever to position MIN B 834 0241 Fig 4...

Page 60: ...s uninterrupted or max 3 times for 10 seconds Then allow the starter to cool down to ambient temperature If the engine has not started after these attempts determine the cause Turn the ignition key through position II to position III ð The starter cranks the engine The warning buzzer stops B 100 0013 Fig 48 B ELE 0070 Fig 49 B ELE 0072 Fig 50 Operation Starting the engine DTR100 60 ...

Page 61: ...ed with a re start lock The ignition key must first be turned back to position 0 before a new starting attempt can be made NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load Operation Starting the engine DTR100 61 ...

Page 62: ...rake lever turn it to position rear and lock it in place ð The parking brake is released 2 Set the throttle lever to MAX position 3 Shift the travel lever forward ð The machine drives forward with a speed which corre sponds to the travel lever position B 100 0020 Fig 51 B 834 0245 Fig 52 Driving forward B 834 0246 Fig 53 Operation Travel operation DTR100 62 ...

Page 63: ...ne drives backwards with a speed which corre sponds to the travel lever position 5 Steer the machine by pushing from the side or pulling the steering rod handles 6 Release the travel lever ð Travel lever moves to neutral position Machine stops Driving backwards B 834 0247 Fig 54 Steering the machine Stopping the machine B 834 0248 Fig 55 Operation Travel operation DTR100 63 ...

Page 64: ...c power If necessary stop compacting with vibration NOTICE Components may get damaged Do not activate the vibration on hard frozen concrete ground Vibration at standstill causes transverse marks n Switch the vibration on only after shifting the travel lever in the desired travel direction n Switch the vibration off before stopping the machine 6 4 2 Working with vibration 1 Set the throttle lever t...

Page 65: ...standstill 3 Shift the vibration lever to Front position ð Vibration is switched on 4 CAUTION Danger of injury caused by the crushing of body parts When reversing steer the machine from the side using the steering handle Pull the travel lever back ð The machine drives backwards with a speed which corre sponds to the travel lever position Vibration during forward travel B 834 0254 Fig 57 B 834 0242...

Page 66: ...h the machine at standstill 5 Shift the vibration lever to Front position ð Vibration is switched on 6 Shift the vibration lever to Rear position ð Vibration is switched off after a short time B 834 0242 Fig 60 Switching the vibration off B 834 0241 Fig 61 Operation Operation DTR100 66 ...

Page 67: ...praying system on or off with the lever Position 0 Water spraying system off Turn anticlockwise Water spraying system on infinite adjustment of the spraying quantity up to MAX position MAX B 100 0011 Fig 62 Operation Water spraying system DTR100 67 ...

Page 68: ...e speed 4 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 Set the throttle lever to position STOP ð The engine is shut down The warning buzzer sounds 5 Turn the ignition key to position 0 and pull it out B 834 0248 Fig 63 B 834 0244 Fig 64 STOP B 834 0243 Fig 65 B ELE 0069 Fig 66 Operation Parking the machine in ...

Page 69: ...to position S 7 Pull out the parking brake lever turn it to position front and lock it in place ð The parking brake is applied B 100 0014 Fig 67 B 100 0021 Fig 68 Operation Parking the machine in secured condition DTR100 69 ...

Page 70: ...Operation Parking the machine in secured condition DTR100 70 ...

Page 71: ...7 Loading transporting the machine Loading transporting the machine DTR100 71 ...

Page 72: ...ting person should not be inside the travel range of the machine Use only transport vehicles with a sufficient load bearing capacity for the weight to be loaded Ä Chapter 2 Technical data on page 11 Protective equipment n Working clothes n Protective gloves 1 DANGER Danger to life caused by the machine slip ping or turning over Make sure that no persons are in the danger zone Drive the machine car...

Page 73: ...ection Lifting tackle must not be damaged by machine parts Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Fold up the steering rod into transport position and lock it 2 Fasten four ratchet straps to the marked lashing points 3 Lash the machine securely to the transport vehicle B 100 0017 Fig 69 B 100 0016 Fig 70 Loading transporting the machine Lashing the machine to t...

Page 74: ...lashing points Use lifting and lashing gear only in the prescribed direction of load application Lifting tackle must 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 Safety shoes n Protective gloves 1 Fasten the lifting tackle to the intended lifting points 2 D...

Page 75: ...g brake 2 DANGER Danger to life caused by the machine slip ping or turning over Make sure that no persons are in the danger zone Drive the machine carefully off the transport vehicle Loading transporting the machine After transport DTR100 75 ...

Page 76: ...Loading transporting the machine After transport DTR100 76 ...

Page 77: ...8 Maintenance Maintenance DTR100 77 ...

Page 78: ...your 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 accidentally started during maintenance work Thoroughly clean machine and engine before starting maintenance work Do not leave any tools or other objects that could cause damage in or on the machi...

Page 79: ...t and fuel residues 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 2 1 3 Oil change intervals Annually or every 250 operating hours When changing to a higher alloyed oil quality after a longer period of operation it is recommended to perform the first oil ch...

Page 80: ...in modern Common Rail injection sys tems Zinc and lead coatings in 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 depositing in the injection system 8 2 3 Hydraulic oil 8 2 3 1 Mineral oil based hydraulic oil The hydraulic system is operated with hydrau...

Page 81: ...nsult the lubrication oil service of the oil manufacturer or our customer service for details NOTICE Danger of damage to the hydraulic system After the changeover check the hydraulic oil fil ters increasingly for contamination Have regular oil analyses performed regarding the water content and mineral oil Replace the hydraulic oil filter at the latest after 500 operating hours 8 2 4 Lubrication gr...

Page 82: ...Winter diesel fuel 5 5 l 1 5 gal us Specification Ä Chapter 8 2 2 Fuel on page 79 Hydraulic system Hydraulic oil ISO HV 32 Specification Ä Chapter 8 2 3 1 Mineral oil based hydraulic oil on page 80 13 0 l 3 4 gal us or ester based biodegradable hydraulic oil Specification Ä Chapter 8 2 3 2 Bio degradable hydraulic oil on page 80 Water tank Water 60 l 15 8 gal us Gears High pressure grease lithium ...

Page 83: ...ust if necessary Ä Chapter 8 8 1 Checking adjusting the valve clearance on page 93 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exhaust and other attachment parts 5 Retighten the bolted connections on the machine 6 Check tension of V belt tighten if necessary Ä Chapter 8 7 2 Servicing the V belt on page 89 7 Check tension of toothed belt tighten if necessary ...

Page 84: ...lter element 94 8 8 3 Replacing the fuel filter 96 8 8 4 Replacing the V belt 98 8 8 5 Replacing the toothed belt 99 8 8 6 Replacing the air filter 101 Every 2 years 8 9 1 Changing hydraulic oil and hydraulic oil filter 103 As required 8 10 1 Cleaning the water spraying system 105 8 10 2 Adjusting the scrapers 107 8 10 3 Cleaning the machine 107 8 10 4 Cleaning the cooling fins and the cooling air...

Page 85: ... filter Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Allow the engine to cool down 3 Release both snap bows 1 and take off the cover 2 4 Clean the cover and dust discharge valve 5 Pull out the air filter with a slight turning motion NOTICE Danger of engine damage Prevent dir...

Page 86: ...oving the gun up and down inside the element until it is free of dust 9 Examine the air filter with a torch for cracks and holes in the paper bellows 10 Replace the air filter if it is damaged 11 Slide the air filter carefully into the housing NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage cor rectly 12 Reinstall the co...

Page 87: ... 6 Parking the machine in secured condition on page 68 2 Clean the area around the filling port and remove the cap 3 Use a suitable vessel to collect running out fuel 4 Unscrew the drain plug and drain off fuel 5 Screw the drain plug back on tightly Ensure leak tightness 6 Dispose of collected fuel in line with environmental regula tions B SYM 1075 Fig 79 Diesel B 100 0004 Fig 80 B 100 0030 Fig 81...

Page 88: ...machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Unscrew fastening screws and fold the cover forward 3 Remove the bracket 1 of the battery 4 Remove the battery 3 5 Check the condition of the vibration insulation mats 2 replace if necessary 6 Clean the outside of the battery 7 Clean the battery poles and terminals and grease them with pole grease Vaseline 8 On serv...

Page 89: ...8 2 Allow the engine to cool down 3 Unscrew the screws and take off the cover 4 Check condition and tension of V belt 1 ð Compression measurement 10 15 mm 0 4 0 6 in 5 Replace the V belt if damaged Ä Chapter 8 8 4 Replacing the V belt on page 98 6 If necessary retighten the V belt B SYM 1079 Fig 85 B 100 0032 Fig 86 Checking the V belt 1 B 834 0251 Fig 87 Maintenance Semi annually DTR100 89 ...

Page 90: ...he fastening screws 11 Fasten the cover with screws 8 7 3 Servicing the toothed belt Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Unscrew the screws and take off the cover Retightening the V belt 1 B 834 0252 Fig 88 B SYM 1111 Fig 89 B 100 0033 Fig 90 Maintenance Semi annually...

Page 91: ...elt 6 Loosen the fastening screws 1 7 Use a suitable tool e g spring balance with a tensile force of 90 to 120 N 66 to 88 5 lbs to pull the coupling upwards until the required compression measurement is reached 8 Tighten the fastening screws 9 Fasten the cover with screws Checking the toothed belt B 834 0272 Fig 91 Retightening the toothed belt 90 120 N 66 89 lbs 1 1 B 834 0273 Fig 92 Maintenance ...

Page 92: ...ety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Unscrew the screws and take off the cover 3 Remove old grease and apply new grease to all gears 4 Fasten the cover with screws 5 Dispose of grease in line with environmental regulations B SYM 1112 Fig 93 B 100 0033 Fig 94 Grease Fett Graisse Grassa B 834 0274 Fig 95 Maintenan...

Page 93: ...2 Let the engine cool down to ambient temperature 3 Check the position of the decompression lever if necessary move it to the initial position 4 Remove the valve cover with the seal Valve clearance Intake valve 0 15 mm 0 006 in Exhaust valve 0 15 mm 0 006 in 1 Turn the engine using a recoil starter until first the exhaust valve and then the intake valve are opened and closed again 2 Then turn the ...

Page 94: ... new seal and tighten the screws evenly 2 After a short test run check the valve cover for leaks 8 8 2 Changing engine oil and oil filter element NOTICE Danger of engine damage Change the oil only with the engine at oper ating temperature Use only oil of the permitted specification Ä Chapter 8 2 1 Engine oil on page 79 Filling quantity Ä Chapter 8 3 List of fuels and lubricants on page 82 2 3 1 B ...

Page 95: ...in plug and collect any oil running out 5 Clean the drain plug and screw it back in with a new seal ring tightening torque 20 Nm 15 ft lbf 6 Clean the area around the cover 1 7 Unscrew the screw 4 and pull the oil filter element 2 out 8 Replace the oil filter element 9 Clean the sealing face on the engine 10 Check the seal ring 3 on the cover for damage replace if necessary 11 Slightly lubricate t...

Page 96: ...e Ensure strict cleanliness Thoroughly clean the area around the fuel tank beforehand Never operate the engine after having removed the fuel filter Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Clean the area around the filling port and remove the cap 3 Use a suitable vessel to...

Page 97: ...w seal 11 Clean and insert screen filter 12 Fasten the fuel valve with new seal 13 Screw the drain plug back in Ensure leak tightness 14 Fill the fuel tank Ä Chapter 5 4 Checking the fuel level top ping up fuel on page 53 15 Close the cap 16 After a short test run check fuel filter fuel valve and fuel lines for leaks 17 Dispose of fuel and fuel filters in line with environmental reg ulations B 100...

Page 98: ... Push the engine carrier back until the V belt 1 is relieved 7 Take the V belt off and replace it 8 Install the new V belt 9 Insert the prybars on the opposite side between the rubber buffer and the frame 10 Push the engine carrier forward until the required compres sion measurement is reached ð Compression measurement 10 15 mm 0 4 0 6 in 11 Tighten the fastening screws 1 12 Fasten the cover with ...

Page 99: ...e in secured condition on page 68 2 Unscrew the screws and take off the cover 3 Loosen the fastening screws 1 and push the coupling down 4 Remove and replace the toothed belt 2 5 Mark the position of the exciter shafts 1 with a downward arrow B 100 0033 Fig 111 Replacing the toothed belt 1 1 2 B 834 0275 Fig 112 1 1 B 834 0276 Fig 113 Maintenance Annually DTR100 99 ...

Page 100: ...ensile force of 90 120 N 66 89 lbs to pull the coupling upwards until the required compression measurement is reached ð Compression measurement 10 15 mm 0 4 0 6 in 9 Tighten the fastening screws 1 10 Fasten the cover with screws 2 1 B 834 0277 Fig 114 Tensioning the toothed belt 90 120 N 66 89 lbs 1 1 B 834 0273 Fig 115 Maintenance Annually DTR100 100 ...

Page 101: ...snap bows 1 and take off the cover 2 4 Pull out the air filter 5 Pull out the air filter with a slight turning motion 6 Clean the cover and dust discharge valve 7 NOTICE Danger of engine damage Prevent dirt from getting into the air intake opening Do not clean the air filter housing with compressed air Clean the filter housing and sealing surfaces with a clean lint free cloth 8 Clean the inside of...

Page 102: ...carefully into the housing NOTICE Danger of engine damage The dust discharge valve must point vertically downwards Make sure that the cover locks engage cor rectly 11 Reinstall the cover Fig 118 Maintenance Annually DTR100 102 ...

Page 103: ...Protective gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Clean the area around the filler opening and remove the cap 3 Clean the area around the drain plug WARNING Danger of burning on hot components Wear your personal protective equipment pro tective gloves protective clothing Avoid touching hot components 4 Unscrew the drain plug and collect...

Page 104: ...il of the permitted specifi cation Ä Chapter 8 2 3 1 Mineral oil based hydraulic oil on page 80 11 Fill in new hydraulic oil 12 Check the hydraulic oil level with the dipstick top up if neces sary ð The oil level must be between the MIN and MAX marks 13 After a test run check for leaks 14 Dispose of the hydraulic oil and hydraulic oil filter in line with environmental regulations Replacing the hyd...

Page 105: ...tive gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Remove the cover of the filler opening 3 Unscrew the screws and take off the cover 4 Remove the cover of the drain bore Water B 100 0005 Fig 123 B 100 0034 Fig 124 B 834 0266 Fig 125 Maintenance As required DTR100 105 ...

Page 106: ...10 Fill the water tank with clean water to flush contaminants out of the lines Do not fill the water tank completely Only use as much water as necessary to clean the lines 11 Switch the water spraying system on to flush contaminants out of the lines 12 Flush both spray tubes well when cleaning 13 Insert the spray tubes slide on the water lines and insert the split pins 14 Fill the water tank with ...

Page 107: ...rews again 8 10 3 Cleaning the machine Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 68 2 Allow the engine to cool down for at least 30 minutes 3 NOTICE Electric components can be damaged by water entering into the system Do not guide the water jet directly into the openings of th...

Page 108: ... Parking the machine in secured condition on page 68 2 Allow the engine to cool down 3 Remove dried dirt with a suitable 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 working clothes goggles Blow out the cooling fins and cooling air intake openings with ...

Page 109: ...ting down If the machine is shut down for a longer period of time e g winter season the following work must be carried out 1 Clean the machine thoroughly 2 Clean the water separator 3 Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank 4 Change engine oil and oil filter if the oil change had been car ried out more than 300 operating hours ago 5 Change the...

Page 110: ...ly charged 12 3 V dis charged to 50 3 Recharge the battery immediately after an open circuit voltage of 12 25 V or less is reached Do not perform boost charging ð The open circuit voltage of the battery occurs approx 10 hours after the last charging process or one hour after the last discharge 4 Switch off the charging current before removing the charging clamps 5 After each charging process allow...

Page 111: ...6 Check the oil levels 7 Clean the machine thoroughly Maintenance As required DTR100 111 ...

Page 112: ...Maintenance As required DTR100 112 ...

Page 113: ...9 Troubleshooting Troubleshooting DTR100 113 ...

Page 114: ...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 the trouble shooting chart you should contact our customer service department Troubleshooting Preliminary remarks DTR100 114 ...

Page 115: ...y exhaust gases Do not inhale exhaust gases Avoid operation in closed or partly closed rooms or ensure adequate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Working clothes n Hearing protection n Safety shoes 1 Shift the vibration lever to Rear position B 834 0241 Fig 131...

Page 116: ... to position I 5 Lightly pull the rope with the starter handle until resistance can be felt compression pressure 6 Guide the starter handle back to initial position B 834 0244 Fig 132 B 100 0013 Fig 133 B ELE 0070 Fig 134 Fig 135 Troubleshooting Starting the engine with the recoil starter DTR100 116 ...

Page 117: ...ed the decompression lever automatically moves back to the initial position Bottom position 9 Manually guide the starter handle back to initial position 10 If the engine does not start during the first attempt repeat the starting process ð Always open the decompression lever when repeating the starting procedure NOTICE Danger of engine damage Warm up engine for a short while before starting work D...

Page 118: ...tery to the plus pole of the starter battery using the first jump lead 3 Next connect the second jump lead to the minus pole of the energizing external battery and then to the minus pole of the starter battery 4 Start the engine Ä Chapter 6 2 Starting the engine on page 59 5 After starting disconnect the minus poles first and the plus poles after 6 Assemble the battery box cover Fig 139 Troublesho...

Page 119: ...her cables not connected correctly Check Battery defective or not charged Check the battery charge or replace if necessary Starter defective Replace the starter Engine stops Fuel tank empty Check the fuel level top up if necessary Fuel filter clogged Replacing the fuel filter Tank ventilation blocked Ensure sufficient ventilation of the tank Air in the fuel system Check the fuel system for air ent...

Page 120: ...aminated Clean the air filter replace 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 Troubleshooting Engine malfunctions DTR100 120 ...

Page 121: ...10 Disposal Disposal DTR100 121 ...

Page 122: ...ubricants 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 Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries and dispose of in compliance with legal regulations 2 Empty the fuel tank 3 Drain off engine oil 4 Drain o...

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Dynapac DTR100, Operating Instruction

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