Dynapac DTR100 Operating Instruction
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Dynapac DTR100 Operating Instruction

Dynapac DTR100 Operating Instruction

Walk behind twin drum roller
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Operating Instruction
Original Operating Instructions
DTR100
Walk behind twin drum roller
S/N 861 924 75 1001> / S/N 861 924 76 1001>
DL8 203 77 EN
© 06/2018

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Summary of Contents for Dynapac DTR100

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

  • Page 3: Table Of Contents

    3.7 Operation............................. 31 3.7.1 Persons in the danger area......................31 3.7.2 Operation........................... 31 3.7.3 Driving up and down slopes....................... 31 3.7.4 Working with vibration........................ 31 3.7.5 Parking the machine........................32 3.8 Refuelling............................. 33 3.9 Emergency procedures......................34 3.10 Maintenance work........................35 DTR100...
  • Page 4 6.6 Parking the machine in secured condition................68 Loading / transporting the machine....................71 7.1 Loading the machine........................72 7.2 Lashing the machine to the transport vehicle................73 7.3 Loading by crane........................74 7.4 After transport..........................75 Maintenance............................77 8.1 Preliminary remarks and safety notes..................78 DTR100...
  • Page 5 8.10.6 Measures prior to extended shut-down period............... 109 Troubleshooting..........................113 9.1 Preliminary remarks........................114 9.2 Starting the engine with the recoil starter................115 9.3 Starting the engine with jump leads..................118 9.4 Engine malfunctions......................... 119 Disposal............................. 121 10.1 Final shut-down of machine....................122 DTR100...
  • Page 6 Table of contents DTR100...

  • Page 7: Introduction

    Introduction Introduction DTR100...

  • Page 8: Foreword

    For your own personal safety you should only use original parts from Dynapac. For your machine we offer service kits to make maintenance easier. In the course of technical development we reserve the right for technical modifications without prior notification.
  • Page 9 Introduction – Foreword The above notes do not 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. DTR100...

  • Page 10: Machine Type Plate And Engine Type Plate

    Type Serial number (2): Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany B-924-0001 Fig. 1: Machine type plate (example) Please enter here: Engine type: Engine number: Fig. 2: Engine type plate DTR100...

  • Page 11: Technical Data

    Technical data Technical data DTR100...
  • Page 12 (45.6) (5.0) (114.6) (118.5) (0.8) (0.4) (29.5) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) 1040 (2293) (lbs) Basic weight 1010 (2227) (lbs) Mean axle load (CECE) (1146) (lbs) Average static linear load (CECE) kg/cm (39) (pli) DTR100...
  • Page 13 Rated speed 3100 Drive system hydrostatic Driven drums front + rear Brakes Service brake hydrostatic Parking brake mechanical Exciter system Vibrating drum front + rear Drive system mechanical Frequency (3300) (vpm) Amplitude 0.50 (0,020) (in) Centrifugal force (8992) (lbf) DTR100...

  • Page 14: Noise And Vibration Data

    Total vibration value a = 3.6 m/s on crushed rock determined acc. to ISO 5349 and EN 500. Associated uncertainty K = 0.6 m/s , determined acc. to EN 12096. Observe the daily vibration load (work safety acc. to 2002/44/EC). DTR100...

  • Page 15: Concerning Your Safety

    Concerning your safety Concerning your safety DTR100...

  • Page 16: Basic Prerequisites

    WARNING! Danger to life or danger of severe injuries if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. DTR100...

  • Page 17: Personal Protective Equipment

    Safety shoes To protect against heavy falling parts and slipping on slippery ground. Protective gloves To protect the hands against excoriation, punctures or deep injuries, against irritating and caustic substances as well as against burns. DTR100...

  • Page 18: Intended Use

    3.1.5 Improper use Dangers may arise with the machine if it is used other than for its intended purpose. Any danger caused by improper use is the sole responsibility of the operating company or driver/operator, the manufacturer cannot be held liable. DTR100...
  • Page 19 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). DTR100...

  • Page 20: Definition Of Responsible Persons

    Observe your local laws and regulations. Rights, obligations and rules of conduct for driver or operator: The driver or operator must: be instructed about his rights and obligations, wear protective equipment as appropriate for the application, have read and understood the operating instructions, DTR100...
  • Page 21 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. DTR100...

  • Page 22: Basic Safety Regulations For Safe Operation

    Machines which are not safe to operate or in traffic must be imme- diately taken out of service and shall not be used, until these defi- ciencies have been properly rectified. Safety installations and switches must neither be removed nor must they be made ineffective. DTR100...

  • Page 23: Handling Fuels And Lubricants

    / personal protective equipment physical and chemical properties stability and reactivity toxicological data environmental data notes on waste disposal information on transport legislation other data DTR100...

  • Page 24: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    Diesel fuel is an environmentally hazardous substance! – Always keep diesel fuel in proper containers. – Immediately bind spilled diesel fuel with an oil- binding agent and dispose of properly. – Dispose of diesel fuel and fuel filters according to regulations. DTR100...

  • Page 25: Safety Regulations And Environmental Protection Regulations For Handling 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. – Dispose of oil and oil filter according to regula- tions. DTR100...

  • Page 26: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic 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. – Dispose of oil and oil filter according to regula- tions. DTR100...

  • Page 27: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    Do not wear jewellery (watch, bracelets, etc.) when working on the battery. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). ENVIRONMENT! Battery acid is an environmentally hazardous substance! – Dispose of battery and battery acid according to regulations. DTR100...

  • Page 28: Safety Regulations And Environmental Protection Regulations When Handling Lubrication Grease

    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. DTR100...

  • Page 29: Loading / Transporting The Machine

    Fasten the lifting gear only at the specified lifting points. Danger to the life of persons if they step or stand under a sus- pended load. When lifting the machine, avoid uncontrolled movements of the load. If necessary, hold the load with guide ropes. DTR100...

  • Page 30: Start-Up Procedure

    Do not inhale exhaust fumes, because they contain toxic sub- stances, which could cause damage to health, unconsciousness or even death. Avoid operation in closed or partly closed rooms, or ensure ade- quate ventilation when working in trenches. DTR100...

  • Page 31: Operation

    Greater danger of accident! B-834-0279 Fig. 9 3.7.4 Working with vibration When compacting with vibration you must always check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power). If necessary stop compacting with vibration. DTR100...

  • Page 32: Parking The Machine

    Park the machine on horizontal, level, firm ground. Before leaving the machine: Shut down the engine, Secure the machine against accidental tipping over, Secure the machine against unauthorized use. Mark machines, which could be in the way, with a clearly visible sign. DTR100...

  • Page 33: Refuelling

    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. DTR100...

  • Page 34: Emergency Procedures

    Concerning your safety – Emergency procedures 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. DTR100...

  • Page 35: Maintenance Work

    When working on the air filter no dirt should fall into the air duct. Do not work on the hot exhaust - danger of burning! Store used filters and other oil contaminated materials in a sepa- rate, specially marked container and dispose of environmentally. DTR100...

  • Page 36: Maintenance Work On Electric Components And Battery

    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 After maintenance work Reassemble all guards and protections. DTR100...

  • Page 37: Repair

    Repair Identify a defective machine with 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. DTR100...

  • Page 38: Signage

    Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or signage immediately. START 1-2 MINUTEN OPERATION STOP 1-2 MINUTEN Water Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No. Hydraulic Oil Diesel B-924-0020 Fig. 10 DTR100...
  • Page 39 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 11 Information sticker - Guaranteed sound capacity level Fig. 12 Information sticker - Lashing point Fig. 13 Information sticker - Lifting point Fig. 14 DTR100...
  • Page 40 Information sticker - Filler opening for water Water B-DEC-0218 Fig. 15 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 16 Information sticker - Ultra-low sulphur fuel Fig. 17 Operation sticker - Travel lever Fig. 18 DTR100...
  • Page 41 Concerning your safety – Signage Operation sticker - Throttle lever Fig. 19 Operation sticker - Vibration lever B-DEC-0267 Fig. 20 Operation sticker - Throttle lever B-DEC-0269 Fig. 21 Operation sticker START 1-2 MINUTEN OPERATION STOP 1-2 MINUTEN B-DEC-0277 Fig. 22 DTR100...
  • Page 42 Concerning your safety – Signage Maintenance sticker B-DEC-0268 Fig. 23 Machine type plate (example) Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No. Ammerländer Str. 93 D-26203 Wardenburg Made in Germany B-924-0002 Fig. 24 DTR100...

  • Page 43: Indicators And Control Elements

    Indicators and control elements Indicators and control elements DTR100...

  • Page 44: Machine

    Pull back Backward travel B-834-0232 Fig. 25 4.1.2 Throttle lever Position “STOP” Engine off STOP Position “MIN” Idle speed Position “MAX” Maximum speed B-834-0235 Fig. 26 4.1.3 Vibration lever Position “Rear” Vibration off Position “Front” Vibration on B-834-0233 Fig. 27 DTR100...

  • Page 45: Reversing Protection

    Turn the ignition key back to position “I” B-ELE-0069 when the engine starts Fig. 30 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. DTR100...

  • Page 46: Water Spraying System

    Indicators and control elements – Machine 4.1.7 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-100-0011 Fig. 31 DTR100...

  • Page 47: Engine

    NOTICE! B-100-0002 Danger of engine damage! Opening the decompression lever while the engine Fig. 33 is running leads to engine damage. – Never use the decompression lever for stop- ping the engine. 4.2.3 Recoil starter B-100-0035 Fig. 34 DTR100...
  • Page 48 Indicators and control elements – Engine DTR100...

  • Page 49: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up DTR100...

  • Page 50: Notes On Safety

    Before starting work on the machine make sure that the engine can not be started. Park the machine safely Ä Chapter 6.6 „Parking the machine in secured condition“ on page 68. Open and secure the protection hood. Close the protection hood again after work is completed. DTR100...

  • Page 51: Visual Inspections And Function Tests

    5.2 Visual inspections and function tests Check hydraulic oil tank and hydraulic lines for condition and leaks. Check fuel tank and fuel lines for condition and leaks. Check the bolted connections are tight and secure. Check the machine for contamination and damage. DTR100...

  • Page 52: Checking The Engine Oil Level

    ð The oil level must be between the “MIN” and “MAX” marks. NOTICE! B-100-0003 Danger of engine damage! Fig. 36 – Do not fill in too much engine oil. If the oil level is too low, top up engine oil to the “MAX” mark. Screw the oil dipstick in. DTR100...

  • Page 53: Checking The Fuel Level; Topping Up Fuel

    Remove the cap and check the filling level visually. If necessary, fill in fuel through a funnel with screen filter. Only fill in fuel up to the red mark on the screen filter inside the tank. Close the cap. B-100-0004 Fig. 38 DTR100...

  • Page 54: Checking The Hydraulic Oil Level

    Pull the dipstick out again. ð The oil level must be between the “MIN” and “MAX” marks. If the oil level is too low, top up hydraulic oil to the “MAX” mark. B-834-0237 Fasten the cap and dipstick again. Fig. 40 DTR100...

  • Page 55: Checking The Rubber Buffers

    Check all rubber buffers between the frame and engine car- rier for tight fit, cracks and tear-offs. B-100-0036 Fig. 42 Check all rubber buffers between the engine and engine car- rier for tight fit, cracks and tear-offs. Replace damaged rubber buffers immediately. B-100-0037 Fig. 43 DTR100...

  • Page 56: Checking The Water Level, Topping Up

    Protective equipment: Working clothes Safety shoes Protective gloves Clean the area around the filling port. Remove the cap and check the water supply in the water Water tank. If necessary, fill in clean water. Close the cap. B-100-0005 Fig. 44 DTR100...

  • Page 57: Operation

    Operation Operation DTR100...

  • Page 58: Adjusting The Steering Rod

    Operation – Adjusting the steering rod 6.1 Adjusting the steering rod Loosen the screws on both sides of the steering rod and fold down the steering rod. Set the steering rod to the required height and tighten the screws. B-100-0012 Fig. 45 DTR100...

  • Page 59: Starting The Engine

    Operate the machine only with a correctly adjusted steering rod. Protective equipment: Working clothes Safety shoes Hearing protection Shift the vibration lever to “Rear” position. B-834-0241 Fig. 46 Set the throttle lever to position “MIN”. B-834-0244 Fig. 47 DTR100...
  • Page 60 – If the engine has not started after these attempts, determine the cause. B-ELE-0072 Turn the ignition key through position “II” to position “III”. Fig. 50 ð The starter cranks the engine. The warning buzzer stops. DTR100...
  • Page 61 The ignition key must first be turned back to position “0” before a new starting attempt can be made. NOTICE! Danger of engine damage! – Warm up engine for a short while before starting work. Do not operate the engine immediately under full load. DTR100...

  • Page 62: Travel Operation

    B-100-0020 Fig. 51 Set the throttle lever to “MAX” position. B-834-0245 Fig. 52 Driving forward Shift the travel lever forward. ð The machine drives forward with a speed which corre- sponds to the travel lever position. B-834-0246 Fig. 53 DTR100...
  • Page 63 Fig. 54 Steering the machine Steer the machine by pushing from the side or pulling the steering rod handles. Stopping the machine Release the travel lever. ð Travel lever moves to neutral position. Machine stops. B-834-0248 Fig. 55 DTR100...

  • Page 64: Operation

    Vibration at standstill causes transverse marks: Switch the vibration on only after shifting the travel lever in the desired travel direction. Switch the vibration off before stopping the machine. 6.4.2 Working with vibration Set the throttle lever to “MAX” position. B-834-0245 Fig. 56 DTR100...
  • Page 65 – 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- B-834-0247 sponds to the travel lever position. Fig. 59 DTR100...
  • Page 66 Shift the vibration lever to “Front” position. ð Vibration is switched on. B-834-0242 Fig. 60 Switching the vibration off Shift the vibration lever to “Rear” position. ð Vibration is switched off after a short time. B-834-0241 Fig. 61 DTR100...

  • Page 67: Water Spraying System

    6.5 Water spraying system Switch the water spraying system on or off with the lever: Position “0” Water spraying system off Turn anticlockwise Water spraying system on infinite adjustment of the spraying quantity up to “MAX” position B-100-0011 Fig. 62 DTR100...

  • Page 68: Parking The Machine In Secured Condition

    Set the throttle lever to position “STOP”. ð The engine is shut down. B-834-0243 The warning buzzer sounds. Fig. 65 Turn the ignition key to position “0” and pull it out. B-ELE-0069 Fig. 66 DTR100...
  • Page 69 Operation – Parking the machine in secured condition Set the fuel valve to position "S". B-100-0014 Fig. 67 Pull out the parking brake lever, turn it to position “front” and lock it in place. ð The parking brake is applied. B-100-0021 Fig. 68 DTR100...
  • Page 70 Operation – Parking the machine in secured condition DTR100...

  • Page 71: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine DTR100...

  • Page 72: Loading The Machine

    – Make sure that no persons are in the danger zone. Drive the machine carefully onto the transport vehicle. Park the machine safely Ä Chapter 6.6 „Parking the machine in secured condition“ on page 68. DTR100...

  • Page 73: Lashing The Machine To The Transport Vehicle

    Working clothes Safety shoes Protective gloves Fold up the steering rod into transport position and lock it. B-100-0017 Fig. 69 Fasten four ratchet straps to the marked lashing points. Lash the machine securely to the transport vehicle. B-100-0016 Fig. 70 DTR100...

  • Page 74: Loading By Crane

    Fasten the lifting tackle to the intended lifting points. 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 B-100-0018 location. Fig. 71 DTR100...

  • Page 75: After Transport

    7.4 After transport Release the parking brake. 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. DTR100...
  • Page 76 Loading / transporting the machine – After transport DTR100...

  • Page 77: Maintenance

    Maintenance Maintenance DTR100...

  • Page 78: Preliminary Remarks And Safety Notes

    After maintenance work has been completed, dispose of fuels and lubricants, filters, sealing elements and cleaning cloths in an envi- ronmentally friendly way. After all maintenance work is completed reinstall all guards and safety installations. DTR100...

  • Page 79: Fuels And Lubricants

    25 operating hours. 8.2.2 Fuel 8.2.2.1 Fuel quality The following fuel specifications are permitted: EN 590 ASTM D975 Grade-No. 1-D and 2-D BS 2869 A1/A2 ISO 8217 DMX JIS K2204 Grade No. 2 KSM-2610 GB252 DTR100...

  • Page 80: Hydraulic Oil

    DIN 51524, part 3, or hydraulic oil type HV according to ISO 6743/4. The viscosity index must be at least 150 (observe information of manufacturer). 8.2.3.2 Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil. DTR100...

  • Page 81: Lubrication Grease

    – Replace the hydraulic oil filter at the latest after 500 operating hours. 8.2.4 Lubrication grease For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G. DTR100...

  • Page 82: List Of Fuels And Lubricants

    (3.4 gal us) hydraulic oil“ on page 80 or ester based biodegradable hydraulic oil Specification: Ä Chapter 8.2.3.2 „Bio-degradable hydraulic oil“ on page 80 Water tank Water 60 l (15.8 gal us) Gears High pressure grease (lithium saponified) as required DTR100...

  • Page 83: Running-In Instructions

    Retighten the bolted connections on the machine. Ä Chapter 8.7.2 Check tension of V-belt, tighten if necessary „Servicing the V-belt“ on page 89. Ä Chapter Check tension of toothed belt, tighten if necessary 8.7.3 „Servicing the toothed belt“ on page 90. DTR100...

  • Page 84: Maintenance Table

    Cleaning the water spraying system 8.10.2 Adjusting the scrapers 8.10.3 Cleaning the machine 8.10.4 Cleaning the cooling fins and the cooling air intake openings 8.10.5 Measures if there is a risk of frost 8.10.6 Measures prior to extended shut-down period DTR100...

  • Page 85: Weekly

    Prevent dirt from getting into the air intake opening. – Do not clean the air filter housing with com- pressed air. Thoroughly clean the filter housing and sealing faces. Fig. 75 Clean the inside of the drain pipe in the filter housing thor- oughly. DTR100...
  • Page 86 Fig. 77 Slide the air filter carefully into the housing. NOTICE! Danger of engine damage! – The dust discharge valve must point vertically downwards. – Make sure that the cover locks engage cor- rectly. Reinstall the cover. Fig. 78 DTR100...

  • Page 87: Draining The Fuel Tank Sludge

    Use a suitable vessel to collect running out fuel. B-100-0004 Fig. 80 Unscrew the drain plug and drain off fuel. Screw the drain plug back on tightly. Ensure leak tightness. Dispose of collected fuel in line with environmental regula- tions. B-100-0030 Fig. 81 DTR100...

  • Page 88: Semi-Annually

    (Vaseline). On serviceable batteries check the acid level, if necessary B-834-0259 top up to the filling mark with distilled water. Fig. 84 Install the battery. Install the bracket of the battery. Close the cover and tighten the fastening screws. DTR100...

  • Page 89: Servicing The V-Belt

    Check condition and tension of V-belt (1). ð Compression measurement: 10 - 15 mm (0.4 - 0.6 in). Ä Chapter 8.8.4 „Replacing Replace the V-belt if damaged the V-belt“ on page 98. If necessary, retighten the V-belt. B-834-0251 Fig. 87 DTR100...

  • Page 90: Servicing The Toothed Belt

    8.7.3 Servicing the toothed belt B-SYM-1111 Fig. 89 Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.6 „Parking the machine Park the machine safely in secured condition“ on page 68. Unscrew the screws and take off the cover. B-100-0033 Fig. 90 DTR100...
  • Page 91 Use a suitable tool (e.g. spring balance) with a tensile force 66 – 89 lbs of 90 to 120 N (66 to 88.5 lbs) to pull the coupling upwards until the required compression measurement is reached. Tighten the fastening screws. Fasten the cover with screws. B-834-0273 Fig. 92 DTR100...

  • Page 92: Greasing The Gears

    Unscrew the screws and take off the cover. B-100-0033 Fig. 94 Remove old grease and apply new grease to all gears. Fasten the cover with screws. Grease Fett Graisse Dispose of grease in line with environmental regulations. Grassa B-834-0274 Fig. 95 DTR100...

  • Page 93: Annually

    Turn the engine using a recoil starter until first the exhaust valve and then the intake valve are opened and closed again. Then turn the engine a bit more using a recoil starter until the compression resistance can be felt. DTR100...

  • Page 94: Changing Engine Oil And Oil Filter Element

    Change the oil only with the engine at oper- ating temperature. – Use only oil of the permitted specification Ä Chapter 8.2.1 „Engine oil“ on page 79. Ä Chapter 8.3 „List of fuels and – Filling quantity: lubricants“ on page 82 DTR100...
  • Page 95 Clean the sealing face on the engine. Check the seal ring (3) on the cover for damage, replace if necessary. Slightly lubricate the seal ring. Insert the cover with oil filter element and seal ring. B-100-0028 Fig. 102 Screw the cover back on tightly. DTR100...

  • Page 96: Replacing The Fuel Filter

    Ä Chapter 6.6 „Parking the machine Park the machine safely in secured condition“ on page 68. Clean the area around the filling port and remove the cap. Diesel Use a suitable vessel to collect running out fuel. B-100-0004 Fig. 104 DTR100...
  • Page 97 53. Close the cap. After a short test run check fuel filter, fuel valve and fuel lines for leaks. Dispose of fuel and fuel filters in line with environmental reg- B-100-0029 ulations. Fig. 107 DTR100...

  • Page 98: Replacing The V-Belt

    ð Compression measurement: 10 - 15 mm (0.4 - 0.6 in). Tighten the fastening screws (1). Fasten the cover with screws. Check the V-belt tension again after 25 operating hours, B-834-0252 tighten if necessary. Fig. 110 DTR100...

  • Page 99: Replacing The Toothed Belt

    Replacing the toothed belt Loosen the fastening screws (1) and push the coupling down. Remove and replace the toothed belt (2). B-834-0275 Fig. 112 Mark the position of the exciter shafts (1) with a downward arrow. B-834-0276 Fig. 113 DTR100...
  • Page 100 90 – 120 N (66 – 89 lbs) to pull the coupling upwards until 66 – 89 lbs the required compression measurement is reached. ð Compression measurement: 10 - 15 mm (0.4 - 0.6 in). Tighten the fastening screws (1). Fasten the cover with screws. B-834-0273 Fig. 115 DTR100...

  • Page 101: Replacing The Air Filter

    Do not clean the air filter housing with compressed air. Fig. 117 Clean the filter housing and sealing surfaces with a clean, lint-free cloth. Clean the inside of the drain pipe in the filter housing thor- oughly. Replace the air filter. DTR100...
  • Page 102 Maintenance – Annually Slide the air filter carefully into the housing. NOTICE! Danger of engine damage! – The dust discharge valve must point vertically downwards. – Make sure that the cover locks engage cor- rectly. Reinstall the cover. Fig. 118 DTR100...

  • Page 103: Every 2 Years

    Danger of burning on hot components! – Wear your personal protective equipment (pro- tective gloves, protective clothing). – Avoid touching hot components. Unscrew the drain plug and collect any oil running out. B-834-0263 Clean and screw in the drain plug. Fig. 120 DTR100...
  • Page 104 ð The oil level must be between the “MIN” and “MAX” marks. B-834-0265 Fig. 122 Concluding work After a test run, check for leaks. Dispose of the hydraulic oil and hydraulic oil filter in line with environmental regulations. DTR100...

  • Page 105: As Required

    Park the machine safely in secured condition“ on page 68. Remove the cover of the filler opening. Water B-100-0005 Fig. 123 Unscrew the screws and take off the cover. B-100-0034 Fig. 124 Remove the cover of the drain bore. B-834-0266 Fig. 125 DTR100...
  • Page 106 Switch the water spraying system on to flush contaminants out of the lines. Flush both spray tubes well when cleaning. Insert the spray tubes, slide on the water lines and insert the split pins. Fill the water tank with clean water and close the cap. DTR100...

  • Page 107: Adjusting The Scrapers

    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. Warm up the engine for a while to avoid corrosion. DTR100...

  • Page 108: Cleaning The Cooling Fins And The Cooling Air Intake Openings

    – Wear your personal protective equipment (safety gloves, protective working clothes, goggles). Blow out the cooling fins and cooling air intake openings with compressed air. In case of damp or oily contamination you should consult our customer service department. DTR100...

  • Page 109: Measures If There Is A Risk Of Frost

    Change engine oil and oil filter if the oil change had been car- ried out more than 300 operating hours ago. Change the fuel filter. After shutting down store the machine under cover in a dry and well ventilated room. Protect the cooled down engine against dust and moisture. DTR100...
  • Page 110 Replace the fuel filter. Replace the air filter. Change the engine oil and clean the oil filter. Check cables, hoses and lines for cracks and leaks. Start the engine and run it for 15 to 30 minutes with idle speed. DTR100...
  • Page 111 Maintenance – As required Check the oil levels. Clean the machine thoroughly. DTR100...
  • Page 112 Maintenance – As required DTR100...

  • Page 113: Troubleshooting

    Troubleshooting Troubleshooting DTR100...

  • Page 114: Preliminary Remarks

    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. DTR100...

  • Page 115: Starting The Engine With The Recoil Starter

    WARNING! Loss of hearing caused by too high noise bur- dens! – Wear your personal protective equipment (ear protection). Protective equipment: Working clothes Hearing protection Safety shoes Shift the vibration lever to “Rear” position. B-834-0241 Fig. 131 DTR100...
  • Page 116 Set the fuel valve to position "O". B-100-0013 Fig. 133 Turn the ignition key to position “I”. B-ELE-0070 Fig. 134 Lightly pull the rope with the starter handle, until resistance can be felt (compression pressure). Guide the starter handle back to initial position. Fig. 135 DTR100...
  • Page 117 ð Always open the decompression lever when repeating the starting procedure. B-100-0023 NOTICE! Fig. 138 Danger of engine damage! – Warm up engine for a short while before starting work. Do not operate the engine immediately under full load. DTR100...

  • Page 118: Starting The Engine With Jump Leads

    Ä Chapter 6.2 „Starting the Start the engine engine“ on page 59. After starting disconnect the minus poles first and the plus poles after. Assemble the battery box cover. Fig. 139 DTR100...

  • Page 119: Engine Malfunctions

    Check the valve clearance, adjust if nec- black exhaust essary smoke 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 DTR100...
  • Page 120 Possible cause Remedy Air filter contaminated Clean the air filter, replace if necessary. Lack of cooling air Clean the cooling fins and the cooling air intake openings. Check air guide plates and ducts for com- pleteness and good sealing. DTR100...

  • Page 121: Disposal

    Disposal Disposal DTR100...

  • Page 122: Final Shut-Down Of Machine

    23. Protective equipment: Working clothes Safety shoes Protective gloves Safety goggles Remove the batteries and dispose of in compliance with legal regulations. Empty the fuel tank. Drain off engine oil. Drain off hydraulic oil. DTR100...

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