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Fayat DYNAPAC DRP40DX, Operating Instructions Manual

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8.5  Running-in instructions

8.5.1  General

The following maintenance work must be performed when running

in new machines or overhauled engines.

8.5.2  After 25 operating hours

1.

Change the engine oil.

2.

Check the valve clearance, adjust if necessary

 

Ä

 Chapter

8.9.2 „Checking, adjusting the valve clearance“ on page 77

.

3.

Check engine and machine for leaks.

4.

Retighten the fastening screws on air filter, exhaust and other

attachments.

5.

Retighten the bolted connections on the machine.

6.

Check the V-belt

 

Ä

 Chapter 8.11.3 „Servicing the V-

belt“ on page 93

.

7.

Check the oil level in the exciter shaft housing

 

Ä

 Chapter

8.11.4 „Checking the oil level in the exciter

housing“ on page 94

.

Maintenance – Running-in instructions

 

DRP40DX

 

69

Summary of Contents for DYNAPAC DRP40DX

Page 1: ...Operating Instruction Original Operating Instructions DRP40DX Reversible vibratory plate S N 101 924 55 1001 DL8 203 71 EN 04 2018 ...

Page 2: ...2 ...

Page 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 protection regula...

Page 4: ...notes 62 8 2 Preparations concluding work 63 8 2 1 Opening closing the protection hood 63 8 3 Fuels and lubricants 65 8 3 1 Engine oil 65 8 3 2 Fuel 65 8 3 3 Oil for exciter shaft housing 66 8 3 4 Mineral oil based hydraulic oil 66 8 4 List of fuels and lubricants 68 8 5 Running in instructions 69 8 5 1 General 69 8 5 2 After 25 operating hours 69 8 6 Maintenance Table 70 8 7 Weekly 71 8 7 1 Check...

Page 5: ...he cooling air intake openings 92 8 11 3 Servicing the V belt 93 8 11 4 Checking the oil level in the exciter housing 94 8 11 5 Measures prior to extended shut down period 94 9 Troubleshooting 97 9 1 Preliminary remarks 98 9 2 Starting the engine with the recoil starter 99 9 3 Starting the engine with jump leads 101 9 4 Fuse assignment 102 9 5 Engine malfunctions 103 9 6 Malfunctions during operat...

Page 6: ...Table of contents DRP40DX 6 ...

Page 7: ...1 Introduction Introduction DRP40DX 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 61 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 DRP40DX 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 DRP40DX 10 ...

Page 11: ...2 Technical data Technical data DRP40DX 11 ...

Page 12: ... 31 1 980 38 6 1350 53 1 1700 66 9 900 35 4 450 17 7 550 21 7 750 29 5 Weights Operating weight CECE W 390 860 kg lbs Operating weight CECE W1 405 893 kg lbs Operating weight CECE W2 420 926 kg lbs Basic weight 400 882 kg lbs Dimensions Technical data DRP40DX 12 ...

Page 13: ...orce 50 11241 kN lbf Amplitude 1 85 0 073 mm in Filling capacities Fuel diesel 5 0 1 3 l gal us 2 1 Noise and vibration data The following noise and vibration data were determined in accord ance with the following guidelines under equipment specific condi tions and by using harmonized standards n EU Machine Directive edition 2006 42 EU n Noise Emission Directive 2000 14 EU Noise Protection Direc t...

Page 14: ...d acc to ISO 3744 and EN 500 2 1 2 Vibration data Vector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 2 5 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertainty K 0 6 m s2 determined acc to EN 12096 Observe the daily vibration load work safety acc to 2002 44 EC Sound pressure level at the opera tor s stand Guarant...

Page 15: ...3 Concerning your safety Concerning your safety DRP40DX 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: ...ctices for safe and environment friendly disposal of fuels and lubricants as well as replacement parts 3 1 3 Personal protective equipment Depending on the work to be carried out personal protective 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 being...

Page 18: ...use This machine must only be used for n Compaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders Intended use also includes compliance with the specified oper ating maintenance and repair measures 3 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than the one i...

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

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 ge...

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 DRP40DX 21 ...

Page 22: ... be informed about the dangers that arise from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert qualified person as required for the conditions the 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 acce...

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: ... 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 oil...

Page 25: ...aused by contact with oil Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil 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 Disp...

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: ...ne components Secure the machine on the transport vehicle against rolling slip ping and turning over Loads must only be attached and hoisted by an expert capable person Use only lifting gear and lifting tackle with sufficient load bearing capacity for the weight to be loaded Fasten the lifting gear only at the specified lifting points Danger to the life of persons if they step or stand under a sus...

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: ...reversing steer the machine from the side using the steering handle Watch out for unusual noises and development of smoke Perform trouble shooting and have the fault corrected Always keep a safe distance to excavation pit borders embank ments and edges Refrain from any work that could adversely affect the stability of the machine 3 7 3 Parking the machine Park the machine on horizontal level firm ...

Page 32: ...the static charging than diesel fuel with a higher sulphur content Apply measures against electrostatic charging Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off 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 Refuell...

Page 33: ...ilters and other oil contaminated materials in a sepa rate specially marked container and dispose of environmentally 3 9 3 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material Do not use fuses with higher ampere ratings and do not bridge fuses When working on the battery smoking or ...

Page 34: ...3 9 5 After maintenance work Reassemble all guards and protections Concerning your safety Maintenance work DRP40DX 34 ...

Page 35: ... been repaired When replacing safety relevant components only original spare parts must be used Repairs must only be performed by an expert qualified person When performing welding work on the machine you should cover the fuel tank with insulating material Concerning your safety Repair DRP40DX 35 ...

Page 36: ...on Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection Made in Germany before taking into 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 if available falls...

Page 37: ...ger of injury due to defective starter rope n Before use check the starter rope for chafing n Do not use a defective starter rope Information sticker Lashing point Information sticker Lifting point Fig 10 Fig 11 Fig 12 Fig 13 Concerning your safety Signage DRP40DX 37 ...

Page 38: ...ion sticker Throttle lever Instruction sticker Wear ear protection brief operating instruc tions Fig 14 Fig 15 Fig 16 B 692 0202 START OPERATION STOP 1 2 3 1 2 3 1 2 3 4 4 4 008 327 46 MAX START STOP 1 2 MINUTEN MAX MIN 1 2 MINUTEN MIN 0 STOP Fig 17 Concerning your safety Signage DRP40DX 38 ...

Page 39: ...twice annual halbjährlich tous les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h DIESEL if available falls vorhanden si existant si está disponible B DEC 0274 Fig 18 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 19 Concerning your safety Signage DRP40DX ...

Page 40: ...Concerning your safety Signage DRP40DX 40 ...

Page 41: ...4 Indicators and control elements Indicators and control elements DRP40DX 41 ...

Page 42: ... 6 7 1 3 B 924 0016 Fig 20 1 Recoil starter 2 Operating hour meter 3 Starter switch 4 Handle 5 Throttle lever 6 Locking pawl lever 7 Steering rod height adjustment Indicators and control elements DRP40DX 42 ...

Page 43: ...5 Checks prior to start up Checks prior to start up DRP40DX 43 ...

Page 44: ...lations 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 4 Parking the machine in secured condition on page 55 2 Open and secure ...

Page 45: ... lines for condition and leaks 2 Check bolted connections for tight fit 3 Check machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check starter rope for chafing Checks prior to start up Visual inspections and function tests DRP40DX 45 ...

Page 46: ...il dipstick 2 Pull out the dipstick and wipe it clean with a lint free clean cloth 3 Insert the dipstick and pull it out again to check the oil level 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 oil to the MAX mark 5 Push the dipstick in B SYM 1068 Fig 21 B HAT 0003 Fig 22 Checks prior t...

Page 47: ...e only fuel of the permitted specification Ä Chapter 8 3 2 Fuel on page 65 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 4 Close the cap B SYM 1069 Fig 23 B 692 0019 Fig 24 Checks prior to start up Checking the fu...

Page 48: ...machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rubber buffers immediately B SYM 1073 Fig 25 B 834 0042 Fig 26 Checks prior to start up Checking the rubber buffers DRP40DX 48 ...

Page 49: ...6 Operation Operation DRP40DX 49 ...

Page 50: ... 1 Pull the locking pawl lever 2 and fold down the steering rod ð The steering rod can swing freely 2 Adjust the steering rod with the height adjustment 1 to the required height Fig 27 Operation Folding down the steering rod DRP40DX 50 ...

Page 51: ...losed 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 Working clothes n Safety shoes 1 Set the throttle lever to position MIN 2 Set the handle to position 0 B 692 0023 Fig 28 B 692 0241 Fig 29 Operation Starting ...

Page 52: ...ninterrupted 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 NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine i...

Page 53: ...old on to a running machine Always keep an eye on a running machine Protective equipment n Hearing protection n Working clothes n Safety shoes 1 Make sure that nobody is in the danger zone 2 NOTICE The centrifugal clutch may be damaged Operate the machine only with full throttle Set the throttle lever to MAX position 3 Shift the handle forwards ð The machines vibrates forward with a speed which co...

Page 54: ...rruptions you should always return the throttle lever to MIN position idle speed ð Vibration is switched off 7 For short work interruptions you should always park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 1 Keep shifting the throttle lever between MIN and MAX positions At the same time use the steering rod to pull the machine right and left ...

Page 55: ...ger 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 4 Turn the ignition key to position 0 and pull it out ð The warning buzzer stops Fig 38 Fig 39 Fig 40 Operation Parking the machine in secured condition DRP40DX 55 ...

Page 56: ...Operation Parking the machine in secured condition DRP40DX 56 ...

Page 57: ...7 Loading transporting the machine Loading transporting the machine DRP40DX 57 ...

Page 58: ...e specified loading direction Lifting tackle must not be damaged by machine parts When lifting the machine make sure the load does not move in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine t...

Page 59: ... eye 1 6 DANGER Danger to life caused by suspended loads Do not step or stand under suspended loads Lift the machine carefully and set down again at the intended location 1 B 692 0246 Fig 42 Loading transporting the machine Loading the machine DRP40DX 59 ...

Page 60: ... only in the specified loading direction Lifting tackle must not be damaged by machine parts Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Pull the lashing belts crosswise over the marked lashing point 1 2 Lash the machine securely to the transport vehicle as shown 1 B 692 0064 Fig 43 1 B 692 0244 Fig 44 Loading transporting the machine Lashing the machine to the tran...

Page 61: ...8 Maintenance Maintenance DRP40DX 61 ...

Page 62: ...our 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 machin...

Page 63: ... condition 8 2 1 Opening closing the protection hood 8 2 1 1 Opening the protection hood Protective equipment n Working clothes n Protective gloves 1 Remove the rear screws 2 on both sides of the machine 2 Put the screws 2 and the matching washers to the side 3 Loosen the front screws 1 on both sides 4 Fold the protection hood forward 5 Secure the protection hood against accidental closing For thi...

Page 64: ...screws and their washers Protective equipment n Working clothes n Protective gloves 1 Loosen the screw 1 on both sides 2 Close the protection hood 3 Tighten the screw 1 on both sides 4 Screw in screws 2 and washers on both sides and tighten them 1 B 692 0204 Fig 47 B 692 0205 1 2 Fig 48 Maintenance Preparations concluding work DRP40DX 64 ...

Page 65: ...versely 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 quality ...

Page 66: ...s 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 Oil for exciter shaft housing Use only engine oils according to the following specifications n API CI 4 or higher quality Avoid mixing engine oils NOTICE Compon...

Page 67: ...The viscosity index must be at least 150 observe information of manufacturer Maintenance Fuels and lubricants DRP40DX 67 ...

Page 68: ...age 65 1 5 l 0 4 gal 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 65 Exciter shaft housing as engine oil 0 4 l 0 11 gal us Steering rod Hydraulic oil ISO HV 32 Specification Ä Chapter 8 3 4 Mineral oil based hydraulic oil on page 66 0 4 l 0 11 gal us Maintenance List of fuels and lubricants DRP40DX 68 ...

Page 69: ... 9 2 Checking adjusting the valve clearance on page 77 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exhaust and other attachments 5 Retighten the bolted connections on the machine 6 Check the V belt Ä Chapter 8 11 3 Servicing the V belt on page 93 7 Check the oil level in the exciter shaft housing Ä Chapter 8 11 4 Checking the oil level in the exciter housing...

Page 70: ...fuel filter 81 8 9 5 Replacing the air filter 82 8 9 6 Changing the oil in the exciter housing 83 8 9 7 Checking the hydraulic oil level 85 8 9 8 Replacing the starter rope 87 8 9 9 Lubricating the machine 89 Every 2 years every 500 operating hours 8 10 1 Changing the hydraulic oil 90 As required 8 11 1 Cleaning the machine 92 8 11 2 Cleaning the cooling fins and the cooling air intake openings 92...

Page 71: ...se a damaged air filter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool down 3 Remove the cap 3 4 Unscrew the knurled nut 2 and pull out the air filter 1 5 Clean the cover 6 NOTICE Danger of engin...

Page 72: ...r filter if it is damaged 10 Insert the air filter 1 carefully into the filter housing and fasten it with the knurled nut 2 11 NOTICE Danger of engine damage Ensure correct fit of air filter cover and seal Close the cap 3 8 7 2 Checking and cleaning the water separator The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisel...

Page 73: ...ition on page 55 2 Place the transparent container under the drain plug 3 Loosen the drain plug and collect escaping fluid 4 Drain the fuel off until there is no water left 5 Screw the drain plug tightly back in Ensure leak tightness 6 Dispose of collected fluid in line with environmental regula tions B HAT 0005 Fig 55 Maintenance Weekly DRP40DX 73 ...

Page 74: ... n Safety goggles 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Remove the bracket 1 of the battery 3 Remove the battery 3 and the vibration damping mats 2 4 5 6 4 Check the condition of the vibration insulation mats replace if necessary 5 Clean the outside of the battery 6 Clean battery poles and pole clamps and grease them with pole grease Vaseline...

Page 75: ... secured condition on page 55 2 Allow the engine to cool down 3 Unscrew the V belt guard 1 4 Unscrew the guard 1 5 Unscrew the V belt pulley 1 6 Replace the V belt 3 7 If necessary reassemble the spacers 2 that may have been removed 8 Fasten the V belt pulley tightening torque 35 Nm 26 ft lbf Fig 58 B 692 0206 1 Fig 59 2 B 692 0207 1 3 Fig 60 Maintenance Annually every 250 operating hours DRP40DX ...

Page 76: ... tightening torque 15 Nm 11 ft lbf 11 Fasten the V belt guard 1 8 9 1 1 Checking the frequency of the base plate Keep feet and hands clear of the vibrating base plate CAUTION Danger of injury caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine Fig 61 B 692 0206 1 Fig 62 Fig 63 Maintenance Annually every 250 operating hours DRP40DX 76 ...

Page 77: ...cured condition on page 55 6 If frequency incorrect n Check the engine speed n Check the V belt n If necessary contact our customer service 8 9 2 Checking adjusting the valve clearance NOTICE Danger of engine damage We recommend to have this work carried out by trained personnel or our after sales service Before checking the valve clearance let the engine cool down Protective equipment n Working c...

Page 78: ...mm 0 008 in 1 Crank the engine until the exhaust valve EX is fully open 2 Check the valve clearance on the intake valve IN with a feeler gauge 1 adjust if necessary 3 Crank the engine further until the intake valve is fully open 4 Check the valve clearance on the exhaust valve adjust if necessary Fig 64 Fig 65 Checking the valve clearance Fig 66 Maintenance Annually every 250 operating hours DRP40...

Page 79: ...r filter cover 2 4 After a short test run check the valve cover for leaks 8 9 3 Changing the engine oil and cleaning the oil filter 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 3 1 Engine oil on page 65 Filling quantity Ä Chapter 8 4 List of fuels and lubricants on page 68 Adjusting the valve cl...

Page 80: ... components Unscrew the drain plug 2 and collect any oil running out 6 Clean and screw in the drain plug 7 Assemble the drain hose with the hose clamp 8 Loosen the screw 1 for approx five turns and pull the oil filter 2 out of the housing 9 CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes goggles Use c...

Page 81: ...g for leaks 18 Dispose of oil in an environmentally friendly way 8 9 4 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 Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the m...

Page 82: ...art the engine after having removed the air filter Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool down 3 Remove the cap 3 4 Unscrew the knurled nut 2 and pull out the air filter 1 5 Clean the cover 6 NOTICE Danger of engine damage Prevent dirt from gettin...

Page 83: ... low ash engine oils for the exciter shaft housing Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine on level ground 2 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 3 Clean the area around the bleeding screw 1 and filling drain plug 2 4 Tilt the machine slightly towards the oil drain side and secure it properly ...

Page 84: ...ominal value Bottom edge of filling drain bore 10 Clean the bleed screw 1 and filling drain plug 2 and screw them in with a low strength sealing agent e g spare parts number DL 009 700 16 11 Dispose of oil in line with environmental regulations B 692 0014 Fig 79 2 1 B 692 0015 Fig 80 Maintenance Annually every 250 operating hours DRP40DX 84 ...

Page 85: ...he filler screw is horizontal 3 Unscrew the filler screw 4 Press the handle forward against the stop and secure it using suitable means 5 The oil level must reach the mark on the steering rod head if necessary fill in hydraulic oil Mark approx 40 mm 1 6 in below the filler opening NOTICE Components may get damaged Use only oil of the permitted specification Fig 81 Fig 82 Fig 83 Fill in hydraulic o...

Page 86: ...crew to collect leaking oil 8 Slacken the bleeding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Screw in the filler screw Fig 84 Fig 85 Fig 86 Concluding work Fig 87 Maintenance Annually every 250 operating hours DRP40DX 86 ...

Page 87: ...g screws 1 and disassemble the recoil starter 2 4 Pull the starter rope with the starter handle 1 out com pletely 5 Secure the coil 2 against winding up 6 Loosen the knot 3 in the starter rope and remove the old starter rope 7 Carefully turn the coil back until the recoil spring is relieved 8 Thread in the new starter rope and fix it with knots on both ends A 15 mm 0 6 in Fig 88 Fig 89 Fig 90 Main...

Page 88: ...he starter handle hitting against your body Do not let the starter handle hit back Slowly guide the starter handle back to initial position 11 Pull the starter handle to check the function and light move ment of the recoil starter 12 Assemble the recoil starter 2 with fastening screws 1 Fig 91 Fig 92 Fig 93 Maintenance Annually every 250 operating hours DRP40DX 88 ...

Page 89: ... 2 3 NOTICE Inadequate lubrication will cause damage to components Use only grease of the permitted specifi cation Spare parts number of lubrication grease DL 009 960 17 Grease the mechanical parts between the fork head 1 lever 2 and bolt 3 4 Fasten the cover 2 with four fastening screws tightening torque 10 Nm 7 5 ft lbf 2 1 B 692 0245 Fig 94 B 692 0186 2 1 Grease 3 Fig 95 2 1 B 692 0245 Fig 96 M...

Page 90: ...in secured condition on page 55 2 Adjust the steering rod with height adjustment so that the area with the filler screw is horizontal 3 Unscrew the filler screw 4 Press the handle forward against the stop and secure it using suitable means 5 Unscrew the bleeding screw and collect any oil running out 6 Screw in the bleeding screw Fig 97 Fig 98 Fig 99 Maintenance Every 2 years every 500 operating ho...

Page 91: ...in below the filler opening 8 Slacken the bleeding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Screw in the filler screw 12 Dispose of oil in an environmentally friendly way Fig 100 Fig 101 Fig 102 Fig 103 Maintenance Every 2 years every 500 operating hours DRP40DX 91 ...

Page 92: ... the cooling fins and the cooling air intake openings How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions clean daily if necessary Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to co...

Page 93: ...e machine in secured condition on page 55 2 Allow the engine to cool down 3 Unscrew the V belt guard 1 4 Check condition and tension of V belt ð Compression measurement 10 25 mm 0 59 0 98 in 5 The V belt cannot be re tightened Replace the V belt if it is damaged or if the compression measurement is exceeded Ä Chapter 8 9 1 Replacing the V belt on page 75 6 Fasten the V belt guard 1 Fig 106 Fig 107...

Page 94: ...alue Bottom edge of filling drain bore 7 Clean the bleed screw and filling drain plug and screw them in with a low strength sealing agent e g spare parts number DL 009 700 16 8 11 5 Measures prior to extended shut down period 8 11 5 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 th...

Page 95: ...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 96: ...6 Check the oil levels 7 Clean the machine thoroughly Maintenance As required DRP40DX 96 ...

Page 97: ...9 Troubleshooting Troubleshooting DRP40DX 97 ...

Page 98: ...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 DRP40DX 98 ...

Page 99: ... by 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 Set the throttle lever to position MIN B 692 0023 Fig 110 T...

Page 100: ...TICE The starter rope may tear off Do not pull the starter rope all the way against the end stop Pull the starter handle quickly and with power 6 Manually guide the starter handle back to initial position 7 If the engine does not start during the first attempt repeat the starting process NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine ...

Page 101: ...le of the external battery to the plus pole of the starter battery using the first jump lead 4 Next connect the second jump lead to the minus pole of the energizing external battery and then to the minus pole of the starter battery 5 Start the engine Ä Chapter 6 2 Starting the engine on page 51 6 After starting disconnect the minus poles first and the plus poles after 7 Install the bracket of the ...

Page 102: ...t WARNING Danger of injury by fire in the machine Do not use fuses with higher ampere ratings and do not bridge fuses Pos Amperage Designation 1 25 A Fuse 1 B 924 0017 Fig 115 Troubleshooting Fuse assignment DRP40DX 102 ...

Page 103: ...l starter does not return to initial position Recoil starter dirty Clean the recoil starter Insufficient pre tension of the spring Check the pre tension of the spring adjust if necessary Spring broken Replace the recoil starter 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 Fault in the elec...

Page 104: ...just the valve clearance Injection nozzle out of order Have checked by qualified expert per sonnel Engine overheats Engine oil level too high Check drain off if necessary Lack of cooling air Clean the cooling fins and the cooling air intake openings Check air guide plates and ducts for com pleteness and good sealing Engine runs with high speed but no vibration Centrifugal clutch defective Have che...

Page 105: ...shaft housing Protective equipment n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Press the handle forward against the end stop and hold it in this position 3 Carefully loosen the filler screw 1 ð The air makes a slight hissing sound when escaping 4 Wait until all air has escaped and then tighten the filler screw Rele...

Page 106: ...Troubleshooting Malfunctions during operation DRP40DX 106 ...

Page 107: ...10 Disposal Disposal DRP40DX 107 ...

Page 108: ...fety 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 engine oil from engine and exciter h...

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