Dynapac DTR75D Operating Instruction Download Page 87

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8.4 Running-in instructions

8.4.1 General

The following maintenance work must be performed when running

in new machines or overhauled engines.

8.4.2 After 25 operating hours

Change the engine oil

Chapter 8.8.1 ‘Changing engine oil

and oil filter element’ on page 93

Check engine and machine for leaks.

Retighten the fastening screws on air filter, exhaust and other

attachments.

Retighten the bolted connections on the machine.

Maintenance – Running-in instructions

DTR75D

Summary of Contents for DTR75D

Page 1: ...Operating Instruction Maintenance Instruction Original Operating Instructions DTR75D Walk behind twin drum roller S N 961 924 79 1001 DL8 207 13 EN 05 2021 ...

Page 2: ...uding 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 to the State of California to cause cancer and birth defects or other reproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the ou...

Page 3: ...ns to the machine 22 3 3 4 Damage defects misuse of safety devices 22 3 4 Handling fuels and lubricants 23 3 4 1 Preliminary remarks 23 3 4 2 Safety regulations and environmental protection regulations for handling 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 hydra...

Page 4: ... 48 4 3 Engine 49 4 3 1 Recoil starter 49 5 Checks prior to start up 51 5 1 Notes on safety 52 5 2 Visual inspections and function tests 53 5 3 Daily maintenance 54 5 3 1 Checking the engine oil level 54 5 3 2 Checking the fuel level topping up fuel 55 5 3 3 Checking the hydraulic oil level 56 5 3 4 Checking the reversing protection 58 5 3 5 Checking the rubber buffers 59 5 3 6 Checking the water ...

Page 5: ...oil filter element 93 8 8 2 Replacing the fuel filter 95 8 8 3 Changing the oil in the exciter housing 96 8 8 4 Replacing the air filter 96 8 8 5 Checking the hydraulic lines 98 8 9 Every 2 years every 500 operating hours 100 8 9 1 Changing hydraulic oil and hydraulic oil filter 100 8 10 As required 103 8 10 1 Cleaning the water spraying system 103 8 10 2 Cleaning the scrapers 104 8 10 3 Checking ...

Page 6: ...10 Disposal 119 10 1 Final shut down of machine 120 Table of contents DTR75D 6 ...

Page 7: ...1 Introduction Introduction DTR75D 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 Maintenance on page 81 Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment The machine...

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 DTR75D 9 ...

Page 10: ...mber 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 MADE IN ITALY Model rpm s n Spec 1 2 B KOH 0001 Fig 2 Engine type plate example Introduction Machine type plate and engine type plate DTR75D 10 ...

Page 11: ...2 Technical data Technical data DTR75D 11 ...

Page 12: ... 1700 67 155 6 1 2030 80 2130 84 35 1 4 8 0 3 650 25 6 Dimensions in millimetres Dimensions in inches Weights Operating weight 740 1631 kg lbs Basic weight 710 1565 kg lbs Average axle load 370 816 kg lbs Average static linear load 5 7 31 9 kg cm pli Dimensions Technical data DTR75D 12 ...

Page 13: ...ooling system Air Number of cylinders 1 Rated power ISO 3046 6 3 8 4 kW hp Rated speed 3000 min 1 Drive system hydrostatic Driven drums front rear Brakes Service brake hydrostatic Parking brake hydro mechanical Exciter system Drive system hydrostatic Frequency 63 3780 Hz vpm Amplitude high 0 5 0 019 mm in Amplitude low 0 25 0 009 mm in Centrifugal force high 25 5620 kN lbf Centrifugal force low 13...

Page 14: ...ng conditions 2 1 1 Noise data LpA 87 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 9 m s2 on crushed roc...

Page 15: ...3 Concerning your safety Concerning your safety DTR75D 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: ...ndicate 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 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 ag...

Page 18: ...nst substances or parti cles 3 1 4 Intended use This machine is intended for commercial use only The 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 I...

Page 19: ...plosive 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 3 1 6 Estimated service life of the machine If the following general conditions are met the service life of the machine is usually in the range of several thousand operating ho...

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 DTR75D 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: ... 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 29: ...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 30: ...ving 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 conditions and weather influences impair the gradeability of the machine We...

Page 31: ...ne on horizontal level firm ground Before leaving the machine n Shut down the engine n secure the machine against unauthorised use Mark machines which could be in the way with a clearly visible sign Concerning your safety Work mode DTR75D 31 ...

Page 32: ...ition and heat sources Apply measures against electrostatic charging Do not spill any fuel Collect leaking 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 cover if necessary replace immediately Concerning your safety Refuelling DTR75D 32 ...

Page 33: ...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 DTR75D 33 ...

Page 34: ...alves Drain the hydraulic oil at operating 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 hos...

Page 35: ...arts 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 cleaning 3 10 6 Measures for longer shut down periods If the machine is taken out of operation for a longer period of time various conditions must be met and maintenance work must be carried out ...

Page 36: ...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 DTR75D 36 ...

Page 37: ...o operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio weekly wöchentlich hebdomadairement cada semana twice annual halbjährlich tous les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h DIESEL Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Made in Germany Ammerländer Str 93 D 26203 Wardenbur...

Page 38: ...ticker Hot surface Information sticker Filler opening for hydraulic oil Instruction sticker Wear ear defenders Information sticker Guaranteed sound capacity level Fig 10 Hydraulic Oil B DEC 0354 Fig 11 Fig 12 Fig 13 Concerning your safety Signage DTR75D 38 ...

Page 39: ... Disconnecting the battery Information sticker Lashing point Information sticker Lifting point Information sticker fuses B DEC 0219 Fig 14 Fig 15 Fig 16 F103 F153 B DEC 0380 Fig 17 Concerning your safety Signage DTR75D 39 ...

Page 40: ...tion sticker Vibration lever n Brief operating instructions n Instruction sticker Observe operating instructions B DEC 0359 Fig 18 Fig 19 B DEC 0246 Fig 20 S T A R T S T O P W O R K 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 B DEC 0381 Fig 21 Concerning your safety Signage DTR75D 40 ...

Page 41: ...h hebdomadairement cada semana twice annual halbjährlich tous les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h DIESEL B DEC 0372 Fig 22 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 DTR75D 41 ...

Page 42: ...Concerning your safety Signage DTR75D 42 ...

Page 43: ...4 Indicators and control elements Indicators and control elements DTR75D 43 ...

Page 44: ...ting hour meter 3 Starter switch 4 1 1 Water spraying system Position 0 Water spraying system off Turn anticlockwise Water spraying system on infinite adjustment of the spraying quan tity up to MAX position B 016 0006 Fig 25 Indicators and control elements Machine DTR75D 44 ...

Page 45: ...itch 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 4 1 4 Warning buzzer for engine oil pressure sounds When starting up n Starter switch is in position I ignition on Must stop after the engine has started During operation n Low engine oil pressure detected n Shut down the engine n Check the engine oil level n If...

Page 46: ...rod locking bolt 2 Travel lever 3 Throttle lever 4 Reversing protection 5 Cleaning rod 6 Vibration lever 7 Locking pawl lever 8 Steering rod height adjustment 4 2 1 Steering rod locking bolt B 016 0005 Fig 30 Indicators and control elements Steering rod DTR75D 46 ...

Page 47: ...on STOP Engine off Position MIN Idle speed Position MAX Maximum speed 4 2 4 Reversing protection actuated Machine stops Travel lever is disengaged No travel movement possible release Reverse travel and forward travel pos sible B 834 0318 Fig 31 B 834 0320 Fig 32 B 834 0321 Fig 33 Indicators and control elements Steering rod DTR75D 47 ...

Page 48: ... 4 2 6 Locking pawl lever Position Bottom Steering rod swings freely Normal operation Position Top Steering rod is locked in position Temporary operation with fixed steering rod e g for work on uneven terrain 4 2 7 Height adjustment B 834 0322 Fig 34 B 016 0013 Fig 35 B 016 0007 Fig 36 Indicators and control elements Steering rod DTR75D 48 ...

Page 49: ...4 3 Engine 4 3 1 Recoil starter B 016 0064 Fig 37 Indicators and control elements Engine DTR75D 49 ...

Page 50: ...Indicators and control elements Engine DTR75D 50 ...

Page 51: ...5 Checks prior to start up Checks prior to start up DTR75D 51 ...

Page 52: ...xed settings WARNING Health hazard caused by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started 1 Park the machine safely Ä Chapt...

Page 53: ...tank and hydraulic lines and check for leaks 2 Check the condition of the fuel tank and fuel lines and for 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 DTR75D 53 ...

Page 54: ...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 overfill with engine oil If the oil level is too low top up engine oil to the MAX mark 5 Insert the dipstick B SYM 1068 Fig 38 MIN MAX B LOM 0010 Fig 39 B LO...

Page 55: ...ilter Use only fuel of the permitted specification Ä Chapter 8 2 2 Fuel on page 84 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 with fuel through a funnel with screen filter 4 Close the cap B SYM 1069 Fig 41 Diesel B LOM 0005 Fig 42 Checks prior to start u...

Page 56: ...only oil of the permitted specification Ä Chapter 8 2 4 Hydraulic oil on page 85 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Check the oil level in the inspection glass Normal level approx 1 2 height of inspection glass Minimum level approx 1 3 height of inspection glass 2 Unscrew the covering plate to refill 3 Clean the area around the filling port B SYM 1071 Fig 4...

Page 57: ...4 Unscrew the cap and fill in oil through a funnel with screen filter 5 Retighten the cap and covering plate HV 32 B 016 0022 Fig 46 Checks prior to start up Daily maintenance DTR75D 57 ...

Page 58: ...es backwards with a speed which corre sponds to the travel lever position 3 Push in the reversing protection and check the proper func tion ð Make sure the machine brakes until it comes to a stand still The travel lever must disengage 4 If this does not work correctly shut down the machine and notify our Customer Service department 5 Only operate the machine again after it has been repaired 6 Shif...

Page 59: ...ety shoes n Protective gloves 1 Check the rubber buffers left and right for tight fit cracks and tear offs ð Replace damaged rubber buffers immediately 2 Check the rubber buffers on the steering rod for tight fit cracks and tear offs ð Replace damaged rubber buffers immediately B 834 0326 Fig 51 B SYM 1073 Fig 52 B 016 0023 Fig 53 B 834 0327 Fig 54 Checks prior to start up Daily maintenance DTR75D...

Page 60: ...maintenance instructions in case of frost Ä Chapter 8 10 6 Measures if there is a risk of frost on page 106 Protective equipment n Working clothes n Safety shoes 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 016 0025 Fig 55 Checks prior to start up Daily maintenance DTR75D 60 ...

Page 61: ...6 Operation Operation DTR75D 61 ...

Page 62: ...g rod with the height adjustment to the required height Click the locking pawl lever into position only for temporary operation with fixed steering rod e g for work on uneven terrain 4 Turn the locking pawl lever to position Top and click it into position ð The steering rod is locked in position Folding down and adjusting the steering rod B 834 0336 Fig 56 B 016 0007 Fig 57 Locking the steering ro...

Page 63: ...5 Turn the locking pawl lever to position Bottom ð The steering rod can swing freely B 016 0028 Fig 59 Operation Folding down and adjusting the steering rod DTR75D 63 ...

Page 64: ...ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection 1 Folding down and adjusting the steering rod Ä Chapter 6 1 Folding down and adjusting the steering rod on page 62 2 Set the throttle lever to MIN position 3 Shift the travel lever to neutral position B 016 0...

Page 65: ...on key to position II ð The starter cranks the engine The warning buzzer must stop 7 If the warning buzzer does not stop after the engine has started n Shut down the engine n Check the engine oil level top up if necessary n If necessary contact our Customer Service 8 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 ignitio...

Page 66: ...rm for approx 1 to 2 minutes in idle speed 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 DTR75D 66 ...

Page 67: ...t your hands do not hit against solid objects CAUTION Danger of injury caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine 1 Set the throttle lever to position MAX 2 Shift the travel lever forward ð The machine drives forward with a speed which corre sponds to the travel lever position B 016 0030 Fig 65 Driving forward B 834 0323 Fig ...

Page 68: ...to the travel lever position 4 Move the travel lever quickly alternating between forward and reverse 5 At the same time steer the machine by pushing from the side or pulling the steering rod handles 6 Shift the travel lever to neutral position ð The machine decelerates to a standstill Driving backwards B 834 0324 Fig 67 steer the machine B 834 0333 Fig 68 Stopping the machine B 834 0325 Fig 69 Ope...

Page 69: ...ctivate 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 Move the machine forward or back NOTICE Vibration at standstill causes transverse marks Do not switch on vibration wit...

Page 70: ...er a short time 5 For short work interruptions you should always return the throttle lever to MIN position idle speed 6 For short work interruptions you should always park the machine in secured condition Ä Chapter 6 6 Parking the machine in secured condition on page 72 B 834 0330 Fig 71 B 834 0328 Fig 72 B 016 0032 Fig 73 Operation Work mode DTR75D 70 ...

Page 71: ...1 For switching on turn the lever out of position 0 The spraying quantity can be infinitely adjusted until MAX position 2 For switching off turn the lever to position 0 B 016 0006 Fig 74 Operation Switching the water spraying system on off DTR75D 71 ...

Page 72: ...CE 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 ð The warning buzzer stops B 834 0325 Fig 75 B 016 0032 Fig 76 B 016 0033 Fig 77 B ELE 0080 Fig 78 Operation Parking the mac...

Page 73: ...ine and an obstacle during reverse travel If reversing protection is activated the machine brakes to a stand still The travel lever is disengaged by the reversing protection the machine cannot be moved forward or backward Prerequisites n Reversing protection has been triggered n The machine is at a standstill n The travel lever is disengaged 1 Step aside from the machine slightly lift the steering...

Page 74: ...is engaged again 5 If the travel lever does not engage in neutral position pull out the reversing protection if necessary 6 Shift the travel lever forward 7 Move the machine forward away from the obstacle B 016 0032 Fig 81 B 834 0325 Fig 82 B 834 0326 Fig 83 B 834 0323 Fig 84 Operation Emergency procedures DTR75D 74 ...

Page 75: ...7 Loading transporting the machine Loading transporting the machine DTR75D 75 ...

Page 76: ...nsport 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 Safety shoes 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 carefully onto the transport vehicle 2 Park the machine safely Ä ...

Page 77: ...tackle 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 Fasten four ratchet straps to the marked lashing points 2 Lash the machine securely to the transport vehicle B 834 0337 Fig 86 Loading transporting the machine Lashing the machine to the transport vehicle DTR75D 77 ...

Page 78: ...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 point 2 DA...

Page 79: ...en onto or down from the transport vehicle The instructing person should not be inside the travel range of the machine 1 Folding down and adjusting the steering rod Ä Chapter 6 1 Folding down and adjusting the steering rod on page 62 2 Start the engine Ä Chapter 6 2 Starting the engine on page 64 3 DANGER Danger to life caused by the machine slip ping or turning over Make sure that no persons are ...

Page 80: ...Loading transporting the machine After transportation DTR75D 80 ...

Page 81: ...8 Maintenance Maintenance DTR75D 81 ...

Page 82: ...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 83: ...his 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 Mineral oil base Semi synthetic base Synthetic base 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 recommen...

Page 84: ...for Arctic climates NOTICE Danger of engine damage The admixture of petroleum and the addition of flow enhancing additives fuel additives is not permitted 8 2 2 3 Storage Even traces of zinc lead and copper can cause deposits in the injection nozzles especially in modern Common Rail injection sys tems Zinc and lead coatings in refuelling systems and fuel lines are not permitted Copper containing m...

Page 85: ...iodegradable hydraulic oil Panolin HLP Synth 46 or Plantohyd 46 S meets all the requirements of a mineral oil based hydraulic oil according to DIN 51524 In hydraulic systems filled with biodegradable 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 t...

Page 86: ... page 84 Exciter shaft housing SAE 10W 40 Specification Ä Chapter 8 2 3 Oil for exciter shaft housing on page 84 Components may get damaged Do not use low ash engine oils for the exciter shaft housing 0 25 l 0 07 gal us SAE 15W 40 SAE 10W 30 Hydraulic system Hydraulic oil ISO HV 32 Specification Ä Chapter 8 2 4 Hydraulic oil on page 85 24 l 6 3 gal us or ester based biodegradable hydraulic oil Spe...

Page 87: ...ines 8 4 2 After 25 operating hours 1 Change the engine oil Ä Chapter 8 8 1 Changing engine oil and oil filter element on page 93 2 Check engine and machine for leaks 3 Retighten the fastening screws on air filter exhaust and other attachments 4 Retighten the bolted connections on the machine Maintenance Running in instructions DTR75D 87 ...

Page 88: ...anging engine oil and oil filter element 93 8 8 2 Replacing the fuel filter 95 8 8 3 Changing the oil in the exciter housing 96 8 8 4 Replacing the air filter 96 8 8 5 Checking the hydraulic lines 98 Every 2 years every 500 operating hours 8 9 1 Changing hydraulic oil and hydraulic oil filter 100 As required 8 10 1 Cleaning the water spraying system 103 8 10 2 Cleaning the scrapers 104 8 10 3 Chec...

Page 89: ...ent is covered with a sooty deposit Do not use gasoline or hot fluids to clean the filter element After cleaning the air filter must be inspected for damage 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 Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 6 Parking the ...

Page 90: ...nger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes goggles Blow the air filter out with dry compressed air max 5 bar 73 psi from inside to outside by moving 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 10 Replace the air filter if it is ...

Page 91: ... initially every day 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 72 2 Place the transparent container under the drain plug 3 Loosen the drain plug and drain the fluid until pure diesel fuel starts to run out 4 Collect the escaping fluid 5 Screw the drain plug back on tightly Ensur...

Page 92: ...es n Safety goggles 1 Park the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 72 2 Remove the holding fixture 1 of the battery 3 Remove the battery 2 and the vibration damping mat 3 4 Check the condition of the vibration damping mat replace if necessary 5 Clean the outside of the battery 6 Clean the battery poles and terminals and grease them with pole grease Vaselin...

Page 93: ...e machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 72 2 Clean the area around the filling port 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 out 5 Clean ...

Page 94: ...l and tighten it 12 Fill in fresh engine oil up to the bottom edge of the filling opening 13 After a short test run check the oil level on the dipstick top up oil if necessary 14 Close the cap 15 Check filter cover and drain plug for leaks 16 Dispose of the oil and oil filter in an environmentally friendly way B LOM 0007 Fig 101 Filling in engine oil B LOM 0009 Fig 102 MIN MAX B LOM 0010 Fig 103 C...

Page 95: ...an the area around the fuel filter 5 Loosen the hose clamps on the three fuel lines and discon nect the fuel lines 6 Remove the screw open the bracket and take off the fuel filter 7 Replace the fuel filter Observe the installation direction arrow when assembling the new fuel filter 8 Insert the new fuel filter and fasten the bracket with the screw 9 Attach the fuel lines and fasten them with hose ...

Page 96: ...screw 1 and drain plug 2 4 Unscrew the filler screw 5 Unscrew the drain plug and collect any oil running out 6 Clean the drain plug and screw it in with a low strength sealing agent e g spare parts number DL 009 700 16 7 Fill in new oil ð Filling quantity Ä Chapter 8 3 List of fuels and lubri cants on page 86 8 Clean the filler screw and screw it in with a low strength sealing agent e g spare part...

Page 97: ...on Ä Chapter 6 6 Parking the machine in secured condition on page 72 2 Allow the engine to cool down 3 Remove the cap 4 Check the pre filter in the cover for dirt or blockage clean if necessary 5 Unscrew the wing nut and remove the air filter Fig 108 Fig 109 Fig 110 Maintenance Annually DTR75D 97 ...

Page 98: ...ydraulic hoses must be immediately replaced if n the outer layer is damaged down to the inlay e g chafing cuts cracks n embrittlement of the outer layer or formation of cracks in the hose material n the hose 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 bucklin...

Page 99: ...3 Replace damaged hydraulic hoses immediately fasten these properly and avoid chafing 4 Only operate the machine after it has been repaired Maintenance Annually DTR75D 99 ...

Page 100: ...ark the machine safely Ä Chapter 6 6 Parking the machine in secured condition on page 72 2 Remove the covering plate 3 Clean the area around the filler opening and remove the cap 4 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 5 Unscrew the drain plug and ...

Page 101: ... cover 14 Remove the suction filter 4 and replace it 15 Attach the cover with a new seal 3 and fasten the screws 16 Tighten the screws crosswise in the correct sequence 1 10 tightening torque 15 Nm 11 ft lbf 17 Then retighten the screws in the same sequence tightening torque 35 Nm 26 ft lbf Replacing the hydraulic oil filter B 834 0312 Fig 114 Replacing the suction filter 1 2 3 4 B 834 0217 Fig 11...

Page 102: ...ction glass top up if necessary ð Nominal value Middle of inspection glass 20 Retighten the cap and covering plate 21 Check the connections on the hydraulic oil tank and the hydraulic oil filter for leaks 22 Dispose of the hydraulic oil and hydraulic oil filter in line with environmental regulations Filling up hydraulic oil HV 32 B 016 0022 Fig 117 Concluding work Maintenance Every 2 years every 5...

Page 103: ...e 72 2 Open the water tank cover 3 Open the lever and drain off all water 4 Unscrew the two spray tubes and pull them out of the frame 5 Flush the water tank out with a strong water jet 6 Flush spray tubes and water lines 7 Insert the spray tubes and screw them tight 8 Fill the water tank with clean water and close the cap Water B 016 0025 Fig 118 B 016 0043 Fig 119 B 834 0334 Fig 120 Maintenance ...

Page 104: ... Clean the scraper with the cleaning rod 4 Insert the cleaning rod again and fasten it 8 10 3 Checking adjusting the scrapers Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Check the condition of the front and rear scrapers as well as both middle scrapers regarding settings and condition read just them if necessary B 016 0045 Fig 121 B 016 0046 Fig 122 B 016 0048 Fig 1...

Page 105: ... 6 Parking the machine in secured condition on page 72 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 wit...

Page 106: ...ooling air openings of the recoil starter into the air filter the exhaust outlet the battery or other 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 10 6 Measures if there is a risk of frost Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 6 Park...

Page 107: ... 5 Clean the water separator 6 Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank 7 Change engine oil and oil filter 8 Change the fuel filter 9 Protect the cooled down engine against dust and moisture 8 10 7 2 Battery service during prolonged machine downtimes WARNING Danger of injury caused by exploding gas mix ture Remove the plugs before starting to r...

Page 108: ...arge 4 Switch off the charging current before removing the charging clamps 5 After each charging process allow the battery to rest for one hour before taking it into service 6 For standstill periods of more than one month you should always disconnect the battery Do not forget to perform reg ular open circuit voltage measurements 8 10 7 3 Measures before restarting 1 Replace the fuel filter 2 Repla...

Page 109: ...9 Troubleshooting Troubleshooting DTR75D 109 ...

Page 110: ...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 DTR75D 110 ...

Page 111: ...e 3 First connect the plus pole 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 minus pole of the starter battery 5 Start the engine Ä Chapter 6 2 Starting the engine on page 64 6 After starting disconnect the minus poles first and the plus poles after ...

Page 112: ...ion 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 Hearing protection n Safety shoes n Protective gloves 1 Folding down and adjusting the steering rod Ä Chapter 6 1 Folding down and adjusting the steering rod on page 62 2 ...

Page 113: ...the ignition key to position I 6 Pull the rope by the starter handle until resistance can be felt 7 Guide the starter handle back to initial position B 834 0325 Fig 133 B 834 0328 Fig 134 B ELE 0081 Fig 135 B GEN 0083 Fig 136 Troubleshooting Starting the engine with the recoil starter DTR75D 113 ...

Page 114: ...dle quickly and with power 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 11 Run the engine warm for approx 1 to 2 minutes in idle speed NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load B GEN 0084 Fig 137 Troubl...

Page 115: ...se Amperage Designation F153 10 A Fuse for potential 15 F103 10 A Fuse for potential 15 9 4 2 Main fuse Fuse Amperage Designation F00 30 A Main fuse F103 F153 B 834 0345 Fig 138 B 016 0057 Fig 139 Troubleshooting Fuse assignment DTR75D 115 ...

Page 116: ...es 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 Ensu...

Page 117: ...sary Lack of cooling air Clean the cooling fins and the cooling air intake openings Check air guide plates and ducts for com pleteness and good sealing Engine runs with high speed but no vibration Hydraulic pump defective Have it checked by qualified expert per sonnel Clutch between engine and hydraulic pump defective Have it replaced by qualified expert per sonnel Engine runs with high speed but ...

Page 118: ...Troubleshooting Engine malfunctions DTR75D 118 ...

Page 119: ...10 Disposal Disposal DTR75D 119 ...

Page 120: ...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 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 2 Empty the fuel tank 3 Drain engine oil from engine and ex...

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