Dynapac DTR75 Operating Instruction Download Page 115

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9.4 Engine malfunctions

Fault

Possible cause

Remedy

The engine is hard

to start or does not

start at all

Fuel tank empty

Check the fuel level, top up if necessary

Fuel filter clogged

Check the fuel filter, replace if necessary

Fuel lines leaking

Check the fuel lines

The fuel shut-off valve has triggered auto-

matically

Check the engine oil level, top up if nec-

essary.

Check the fuel level, top up if necessary.

If necessary, check other causes for trig-

gering.

Bleed the fuel system by means of the

ventilation lever on the fuel shut-off valve.

Incorrect valve clearance

Check the valve clearance, adjust if nec-

essary

Wear on cylinder or piston rings

Have it checked by qualified expert per-

sonnel

Injection nozzle out of order

Have it checked by qualified expert per-

sonnel

Engine does not

start or starts poorly

at low temperatures

Fuel filter clogged by paraffin separation

Replace the fuel filter, use winter fuel

Engine oil with wrong SAE viscosity class Change the engine oil

Insufficiently charged battery

Check the battery, charge if necessary

Engine ignites, but

does not run

Fuel filter clogged

Check the fuel filter, replace if necessary

The starter does

not switch on or the

engine does not

crank.

Main fuse broken

Replace main fuse

Battery or other 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 entry.

The fuel shut-off valve has triggered auto-

matically

Check the engine oil level, top up if nec-

essary.

Check the fuel level, top up if necessary.

If necessary, check other causes for trig-

gering.

Bleed the fuel system by means of the

ventilation lever on the fuel shut-off valve.

Troubleshooting – Engine malfunctions

DTR75

115

Summary of Contents for DTR75

Page 1: ...Operating Instruction Original Operating Instructions DTR75 Double vibratory roller S N 861 924 72 1001 DL8 203 57 EN 04 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: ...r 47 4 2 2 Crank handle 47 5 Checks prior to start 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 ...

Page 5: ...lve clearance 90 8 9 2 Changing engine oil and oil filter element 92 8 9 3 Replacing the fuel filter 93 8 9 4 Replacing the V belt 95 8 9 5 Replacing the toothed belt 95 8 9 6 Replacing the air filter 97 8 9 7 Cleaning the crank handle guide 97 8 9 8 Checking the hydraulic lines 98 8 10 Every 2 years 99 8 10 1 Changing hydraulic oil and hydraulic oil filter 99 8 11 As required 101 8 11 1 Cleaning ...

Page 6: ...10 Disposal 117 10 1 Final shut down of machine 118 Table of contents DTR75 6 ...

Page 7: ...1 Introduction Introduction DTR75 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 75 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 DTR75 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 plate example Introduction Machine type plate and engine type plate DTR75 10 ...

Page 11: ...2 Technical data Technical data DTR75 11 ...

Page 12: ...110 4 3 2200 86 6 2320 91 3 20 0 8 8 0 3 650 25 6 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 757 1669 kg lbs Basic weight 727 1603 kg lbs Mean axle load CECE 379 836 kg lbs Average static linear load CECE 5 8 33 kg cm pli Dimensions Technical data DTR75 12 ...

Page 13: ...rer Hatz Type 1D42 Cooling Air Number of cylinders 1 Rated power ISO 3046 6 2 8 3 kW hp Rated speed 2800 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 45 0 018 mm in Centrifugal force 22 4946 kN lbf Technical data DTR75 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 DTR75 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: ...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: ...e 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 DTR...

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 DTR75 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: ...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: ...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: ...contact 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: ...ll 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 ...

Page 28: ...ntact 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: ...g 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 gea...

Page 30: ...ired 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 function...

Page 31: ...k 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 conditi...

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 DTR75 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 DTR75 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 DTR75 34 ...

Page 35: ...rating 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 reg...

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 DTR75 37 ...

Page 38: ...y with their meaning Replace damaged and illegible stickers or signage immediately Water Hydraulic Oil Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection Made in Germany B 924 0013 Fig 10 Concerning your safety Signage DTR75 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 DTR75 39 ...

Page 40: ...ter Information sticker Filler opening for hydraulic oil Operation sticker Starting process Operation sticker Travel lever B DEC 0218 Water Fig 15 B DEC 0214 Hydraulic Oil Fig 16 B DEC 0266 Fig 17 Fig 18 Concerning your safety Signage DTR75 40 ...

Page 41: ... sticker Throttle lever Operation sticker Vibration lever Operation sticker Throttle lever Maintenance sticker Fig 19 B DEC 0267 Fig 20 B DEC 0269 Fig 21 B DEC 0268 Fig 22 Concerning your safety Signage DTR75 41 ...

Page 42: ...e 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 23 Concerning your safety Signage DTR75 42 ...

Page 43: ...4 Indicators and control elements Indicators and control elements DTR75 43 ...

Page 44: ...el 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 24 STOP B 834 0235 Fig 25 B 834 0233 Fig 26 Indicators and control elements Machine DTR75 44 ...

Page 45: ...arter switch Position 0 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 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 Fig 27 ...

Page 46: ...ng bolt 4 1 8 Height adjustment 4 1 9 Water spraying system Position I Water spraying system off Position II Water spraying system on B 834 0236 Fig 30 B 834 0240 Fig 31 Fig 32 Indicators and control elements Machine DTR75 46 ...

Page 47: ...ment and mainte nance 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 2 Crank handle Start the engine with the crank handle only if the battery is defective empty or missing Optional equipment B 834 0187 Fig 33 Fig 34 Indicators and control elements Engine DTR75 47 ...

Page 48: ...Indicators and control elements Engine DTR75 48 ...

Page 49: ...5 Checks prior to start up Checks prior to start up DTR75 49 ...

Page 50: ...gulations 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 on page 67 2 Open and secur...

Page 51: ...nd 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 DTR75 51 ...

Page 52: ...ound the oil dipstick 2 Pull the dipstick out wipe it off with a lint free clean cloth and reinsert it to the end stop 3 Pull the dipstick out 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 Push the dipstick in Fig 35 Checks prior to start up Checking the...

Page 53: ...tive 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 4 Close the cap If the fuel tank has been completely emptied or when filling the fuel tank for the first time the fuel system must be bled before starting Ä Chapter 8 11 5 B...

Page 54: ...oil on page 79 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...

Page 55: ...eck all rubber buffers 1 between the frame and engine carrier for tight fit cracks and tear offs 2 Check all rubber buffers 2 between the engine and engine carrier for tight fit cracks and tear offs 3 Replace damaged rubber buffers immediately Fig 38 Checks prior to start up Checking the rubber buffers DTR75 55 ...

Page 56: ...tions in case of frost Ä Chapter 8 11 6 Measures if there is a risk of frost on page 105 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 834 0238 Fig 39 Checks prior to start up Checking the water level topping u...

Page 57: ...6 Operation Operation DTR75 57 ...

Page 58: ...d 1 Release the steering rod locking bolt and fold down the steering rod 2 Adjust the steering rod with the height adjustment to the required height B 834 0239 Fig 40 B 834 0240 Fig 41 Operation Adjusting the steering rod DTR75 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 ...

Page 60: ...the cause Turn the ignition key to position II ð The starter cranks the engine 5 As soon as the engine is running turn the ignition key to position I The starter switch is designed 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...

Page 61: ...arking brake lever turn it to the left 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 Fig 46 B 834 0245 Fig 47 Driving forward B 834 0246 Fig 48 Operation Travel operation DTR75 61 ...

Page 62: ...ine 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 49 Steering the machine Stopping the machine B 834 0248 Fig 50 Operation Travel operation DTR75 62 ...

Page 63: ...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 64: ...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 52 B 834 0242...

Page 65: ...th 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 55 Switching the vibration off B 834 0241 Fig 56 Operation Operation DTR75 65 ...

Page 66: ...6 5 Water spraying system 1 For switching on turn the lever to position II 2 For switching off turn the lever to position I Fig 57 Operation Water spraying system DTR75 66 ...

Page 67: ...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 58 B 834 0244 Fig 59 STOP B 834 0243 Fig 60 B ELE 0080 Fig 61 Operation Parking the machine in ...

Page 68: ...6 Pull out the parking brake lever turn it to the right and lock it in place ð The parking brake is applied Fig 62 Operation Parking the machine in secured condition DTR75 68 ...

Page 69: ...7 Loading transporting the machine Loading transporting the machine DTR75 69 ...

Page 70: ...cting 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 ca...

Page 71: ...ied loading direction 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 834 0256 Fig 63 B 834 0255 Fig 64 Loading transporting the machine Lashing t...

Page 72: ...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 73: ...ng 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 DTR75 73 ...

Page 74: ...Loading transporting the machine After transport DTR75 74 ...

Page 75: ...8 Maintenance Maintenance DTR75 75 ...

Page 76: ...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 77: ... and maintenance doors as well as securing certain components After this work close all maintenance flaps and doors again and return all components to their operating condition 8 2 1 Opening the protection hood 1 Unscrew the fastening screws left and right and fold the pro tection hood forward B 834 0249 Fig 66 Maintenance Preparations concluding work DTR75 77 ...

Page 78: ... 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 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 change of the higher quali...

Page 79: ...c 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 3 3 Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 32 ISO with a kinematic viscosity of 32 mm2 s at 40 C 1...

Page 80: ... us SAE 15W 40 SAE 10W 30 SAE 30 SAE 10W Fuel Diesel Winter diesel fuel 5 0 l 1 3 gal us Specification Ä Chapter 8 3 2 Fuel on page 78 Hydraulic system Hydraulic oil ISO HV 32 Specification Ä Chapter 8 3 3 Mineral oil based hydraulic oil on page 79 13 5 l 3 6 gal us Water tank Water 60 l 15 8 gal us Gears High pressure grease lithium saponified as required Maintenance List of fuels and lubricants ...

Page 81: ...just if necessary Ä Chapter 8 9 1 Checking adjusting the valve clearance on page 90 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 8 2 Servicing the V belt on page 87 7 Check tension of toothed belt tighten if necessary...

Page 82: ... 9 4 Replacing the V belt 95 8 9 5 Replacing the toothed belt 95 8 9 6 Replacing the air filter 97 8 9 7 Cleaning the crank handle guide 97 8 9 8 Checking the hydraulic lines 98 Every 2 years 8 10 1 Changing hydraulic oil and hydraulic oil filter 99 As required 8 11 1 Cleaning the water spraying system 101 8 11 2 Adjusting the scrapers 102 8 11 3 Cleaning the machine 103 8 11 4 Cleaning the coolin...

Page 83: ... using a torch Do not continue to use a damaged air filter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 67 2 Allow the engine to cool down 3 Remove the cap 1 4 Pull out the air filter 5 Clean the cover 6 NOTICE Danger of eng...

Page 84: ...cks and holes 9 Replace the air filter if it is damaged 10 Slide the air filter 2 carefully into the filter housing 11 Check the sealing face 3 on the cover 12 NOTICE Danger of engine damage Ensure correct fit of cover and seal Close the cap 1 8 7 2 Checking cleaning the water separator The service intervals for the water separator depend on the water content in the fuel and can therefore not be d...

Page 85: ...drain plug 3 Loosen the drain plug and collect running out fluid 4 Drain the fuel off until there is no water left If the fuel tank has been completely emptied bleed the fuel system before starting Ä Chapter 8 11 5 Bleeding the fuel system on page 104 5 Turn the drain plug tightly back in Ensure leak tightness 6 Dispose of collected fluid in an environmentally friendly way Fig 71 Maintenance Weekl...

Page 86: ... Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 67 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 battery poles and pole clamps and grease them with pole grease Vaseline 8...

Page 87: ...If necessary retighten the V belt 6 Loosen four fastening screws 1 on both sides 7 Insert two prybars between the rubber buffer and the frame 8 Push the engine carrier forward until the required compres sion measurement is reached 9 Tighten the fastening screws 8 8 3 Servicing the toothed belt Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Cha...

Page 88: ... compression measurement is reached 8 Tighten the fastening screws 9 Attach the cover 8 8 4 Greasing the gears NOTICE Inadequate lubrication will cause damage to components Use only grease of the permitted specification Ä Chapter 8 3 4 Lubrication grease on page 79 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine ...

Page 89: ...ove old grease and apply new grease to all gears 4 Attach the cover 5 Dispose of grease in line with environmental regulations Grease Fett Graisse Grassa B 834 0274 Fig 78 Maintenance Semi annually DTR75 89 ...

Page 90: ...he engine cool down Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 67 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 Preparations Fig 79 Fig 80 Mainte...

Page 91: ...eck the valve clearance on the exhaust valve adjust if necessary 1 Loosen screw 3 on the rocker arm 2 Adjust the screw 2 until the feeler gauge 1 can be inserted and pulled out with a barely noticeable resistance after the hexagon nut 3 has been tightened 1 Install the valve cover with a new seal and tighten the screws evenly 2 After a short test run check the valve cover for leaks Checking the va...

Page 92: ... machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 67 2 Clean the area around the dipstick and pull the dipstick out 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 any oil running out 5 Clea...

Page 93: ... top up oil if necessary 16 Check oil filter and drain plug for leaks 17 Dispose of oil and oil filter insert in an environmentally friendly way 8 9 3 Replacing the fuel filter NOTICE Danger of engine damage 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 Safet...

Page 94: ... flow direction of the new fuel filter 10 Insert the fuel filter with the fuel lines into the hose clamps 11 Screw the hose clamps to the holding fixtures 12 Open the fuel lines 13 If necessary fill up the fuel tank and bleed the fuel system before starting Ä Chapter 8 11 5 Bleeding the fuel system on page 104 14 After a short test run check fuel filter and fuel lines for leaks 15 Dispose of fuel ...

Page 95: ...ll the new V belt 8 Insert the prybars on the opposite side between the rubber buffer and the frame 9 Push the engine carrier forward until the required compres sion measurement is reached ð Compression measurement 10 25 mm 0 59 0 98 in 10 Tighten the fastening screws 1 11 Check the V belt tension again after 25 operating hours tighten if necessary 8 9 5 Replacing the toothed belt Protective equip...

Page 96: ...t 1 8 Use a suitable tool e g spring balance with a tensile force of 90 120 N 66 89 lbs to pull the coupling upwards until the required compression measurement is reached ð Compression measurement 10 25 mm 0 59 0 98 in 9 Tighten the fastening screws 1 10 Attach the cover Replacing the toothed belt 1 1 2 B 834 0275 Fig 92 1 1 B 834 0276 Fig 93 2 1 B 834 0277 Fig 94 Tensioning the toothed belt 90 12...

Page 97: ...ge Prevent dirt from getting into the air intake opening Do not clean the air filter housing with compressed air Clean the filter housing with a clean lint free cloth 7 Replace the air filter 8 Slide the air filter 2 carefully into the filter housing 9 Check the sealing face 3 on the cover 10 NOTICE Danger of engine damage Ensure correct fit of cover and seal Close the cap 1 8 9 7 Cleaning the cra...

Page 98: ... shows deformation in pressurized and depres surized condition which do not comply with the genuine shape of the hydraulic hose e g layer separation forma tion of blisters crushed spots buckling n leaks on hose socket or fitting n the hydraulic hose has separated from the fitting n fittings are damaged or deformed whereby the function and strength of the hose fitting connection is impaired n the f...

Page 99: ...1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 67 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 any oil running o...

Page 100: ... oil of the permitted specifi cation Ä Chapter 8 3 3 Mineral oil based hydraulic oil on page 79 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 101: ...tive gloves 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 67 2 Remove the cover of the filler opening 3 Remove the cover of the drain bore 4 Pull out the split pins on the spray tubes Water B 834 0238 Fig 103 B 834 0266 Fig 104 B 834 0267 Fig 105 Maintenance As required DTR75 101 ...

Page 102: ...e lines 10 Switch the water spraying system on to flush contaminants out of the lines 11 Flush both spray tubes well when cleaning 12 Insert the spray tubes slide on the water lines and insert the split pins 13 Fill the water tank with clean water and close the cap 8 11 2 Adjusting the scrapers Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Check the condition of the f...

Page 103: ...he system Do not guide the water jet directly into the openings of the safety crank handle into the air filter or onto electrical equipment Clean the machine from the outside and inside with a water jet 4 Warm up the engine for a while to avoid corrosion 8 11 4 Cleaning the cooling fins and the cooling air intake openings How dirty the cooling fins and cooling air intake openings are depends very ...

Page 104: ...ically interrupts the engine s fuel supply if the oil pressure is too low This makes it necessary to bleed the fuel system in the following situations n After an engine shut down due to an empty fuel tank n After filling the fuel tank for the first time n After using the crank handle without starting e g when tem peratures are low n After several unsuccessful starting attempts n After replacing th...

Page 105: ...ose the cap 8 11 7 Measures prior to extended shut down period 8 11 7 1 Measures before shutting 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 f...

Page 106: ...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 107: ...6 Check the oil levels 7 Clean the machine thoroughly Maintenance As required DTR75 107 ...

Page 108: ...Maintenance As required DTR75 108 ...

Page 109: ...9 Troubleshooting Troubleshooting DTR75 109 ...

Page 110: ...nce 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 DTR75 110 ...

Page 111: ...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 Safety shoes n Protective gloves n Hearing protection 1 Shift the vibration lever to Rear position B 834 02...

Page 112: ...ion I 5 Remove the crank handle from the holding fixture 6 Insert the crank handle 7 Stand in the correct position parallel to the machine 8 Grip the crank handle with both hands as shown 9 Turn the crank handle with both hands slowly in the direction of the arrow until it engages B 834 0244 Fig 112 B 834 0215 Fig 113 Fig 114 Fig 115 Troubleshooting Emergency starting with crank handle DTR75 112 ...

Page 113: ...ighest speed must be reached 11 As soon as the engine starts pull out the crank handle 12 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 Do not operate the engine immediately under full load 13 Hook the c...

Page 114: ...ttery 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 117 Troublesh...

Page 115: ...uel filter use winter fuel Engine oil with wrong SAE viscosity class Change the engine oil Insufficiently charged battery Check the battery charge if necessary Engine ignites but does not run Fuel filter clogged Check the fuel filter replace if necessary The starter does not switch on or the engine does not crank Main fuse broken Replace main fuse Battery or other cables not connected correctly Ch...

Page 116: ...aust smoke Air filter contaminated Clean the air filter replace if necessary Incorrect valve clearance Check the valve clearance adjust if nec essary Injection nozzle out of order Have it checked by qualified expert per sonnel Engine overheats Engine oil level too high Check the engine oil level drain off engine oil if necessary Air filter contaminated Clean the air filter replace if necessary Lac...

Page 117: ...10 Disposal Disposal DTR75 117 ...

Page 118: ...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 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 ...

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