Related Manuals for Dynapac DFP12D
Summary of Contents for Dynapac DFP12D
- Page 1 Operating Instruction Original Operating Instructions DFP12D Forward plate S/N 101 924 26 1001> DL8 203 75 EN © 06/2018...
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Page 3: Table Of Contents
3.7.2 Operation........................... 28 3.7.3 Parking the machine........................28 3.8 Refuelling............................. 29 3.9 Maintenance work........................30 3.9.1 Preliminary remarks........................30 3.9.2 Working on the engine....................... 30 3.9.3 Cleaning work..........................30 3.9.4 After maintenance work......................30 3.10 Repair............................31 3.11 Signage............................32 DFP12D... - Page 4 8.6.1 Checking, cleaning the air filter....................72 8.6.2 Checking and cleaning the water separator................73 8.7 Annually............................75 8.7.1 Changing the engine oil and cleaning the oil filter..............75 8.7.2 Checking, adjusting the valve clearance..................77 8.7.3 Replacing the air filter........................ 79 DFP12D...
- Page 5 8.8.1 Cleaning the cooling fins and the cooling air intake openings........... 87 8.8.2 Cleaning the machine........................ 87 8.8.3 Cleaning the water spraying system..................88 8.8.4 Measures prior to extended shut-down period................88 Troubleshooting..........................91 9.1 Preliminary remarks........................92 9.2 Engine malfunctions........................93 Disposal............................... 95 10.1 Final shut-down of machine..................... 96 DFP12D...
- Page 6 Table of contents DFP12D...
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Page 7: Introduction
Introduction Introduction DFP12D... -
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. DFP12D...
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Page 10: Machine Type Plate And Engine Type Plate
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 (1): Engine number (2): Fig. 2: Engine type plate (example) DFP12D... -
Page 11: Technical Data
Technical data Technical data DFP12D... - Page 12 (27.9) (37.9) (27.6) (42.7) (21.3) (19.7) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) (269) (lbs) Basic weight (271) (lbs) Water spraying system (optional equipment) + 10 (+ 22) (lbs) Transport wheels (optional equipment) (+ 9) (lbs) DFP12D...
- Page 13 Exciter system Frequency (5520) (vpm) Centrifugal force (5620) (lbf) Amplitude 1.75 (0,069) (in) Water sprinkling system (optional equipment) Type of sprinkling Gravity feed Filling capacities Fuel (diesel) (0.8 each) (gal us) Water sprinkling system 13.5 (3.6 each) (gal us) DFP12D...
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Page 14: Noise And Vibration Data
£ 2.5 m/s Total vibration value a on crushed rock determined acc. to ISO 5349 and EN 500. Associated uncertainty K = 0.1 m/s , determined acc. to EN 12096. Observe the daily vibration load (work safety acc. to 2002/44/EC). DFP12D... -
Page 15: Concerning Your Safety
Concerning your safety Concerning your safety DFP12D... -
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. DFP12D... -
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. DFP12D... -
Page 18: Intended Use
Dangers may arise from the machine when it is used for purposes other than the one it is intended for. Any danger caused by improper use is the sole responsibility of the operating company or driver/operator, the manufacturer cannot be made liable. DFP12D... - 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). DFP12D...
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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, DFP12D... - 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. DFP12D...
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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. DFP12D... -
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 DFP12D... -
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. DFP12D... -
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. DFP12D... -
Page 26: 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. DFP12D... -
Page 27: 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. DFP12D... -
Page 28: Operation
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. DFP12D... -
Page 29: 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. DFP12D... -
Page 30: Maintenance 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. 3.9.4 After maintenance work Reassemble all guards and protections. DFP12D... -
Page 31: Repair
Only operate the machine after it has 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. DFP12D... -
Page 32: Signage
Replace damaged and illegible stickers or signage immediately. Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No. Patent Protection 008 338 08 START Water OPERATION STOP 008 338 21 B-230-0121 Fig. 6 DFP12D... - Page 33 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 7 Warning sticker - Starter rope Fig. 8 Instruction sticker - Wear ear defenders Fig. 9 Information sticker - Lifting point Fig. 10 DFP12D...
- Page 34 Concerning your safety – Signage Information sticker - Lashing point Fig. 11 Information sticker - Guaranteed sound capacity level Fig. 12 Information sticker - Filler opening for water Water B-DEC-0218 Fig. 13 Information sticker Shut-down pin / throttle lever Fig. 14 DFP12D...
- Page 35 Concerning your safety – Signage Brief operating instructions Fig. 15 DFP12D...
- Page 36 Concerning your safety – Signage Maintenance sticker Fig. 16 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. 17 DFP12D...
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Page 37: Indicators And Control Elements
Indicators and control elements Indicators and control elements DFP12D... -
Page 38: Engine
Indicators and control elements – Engine 4.1 Engine 4.1.1 Throttle lever Position “MIN” Idle speed position Position “MAX” Full load position Fig. 18 4.1.2 Shut-down pin press Shut down the engine Fig. 19 4.1.3 Recoil starter Fig. 20 DFP12D... -
Page 39: Water Spraying System
Rotary button for water spraying system Water level gauge B-230-0114 Fig. 21 4.2.1 Rotary button for water sprinkling system Position "0" Water sprinkling system off turn anticlockwise Water sprinkling system on infinite adjustment of the sprinkling quantity up to position “MAX” Fig. 22 DFP12D... -
Page 40: Transport Wheels
Indicators and control elements – Transport wheels 4.3 Transport wheels Fig. 23 Locking of guide handle Locking of transport wheels Optional equipment DFP12D... -
Page 41: Transport Wheels With Steering Bow In Middle Position
Indicators and control elements – Transport wheels 4.3.1 Transport wheels with steering bow in middle position Fig. 24 Locking of guide handle Locking of transport wheels DFP12D... - Page 42 Indicators and control elements – Transport wheels DFP12D...
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Page 43: Checks Prior To Start Up
Checks prior to start up Checks prior to start up DFP12D... -
Page 44: Notes On Safety
Danger of injury caused by rotating parts! – Before starting work on the machine make sure that the engine can not be started. Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58. DFP12D... -
Page 45: Visual Inspections And Function Tests
5.2 Visual inspections and function tests Check fuel tank and lines for condition and leaks. Check bolted connections for tight fit. Check machine for contamination and damage. Check the hydraulic oil cooler for dirt. Check starter rope for chafing. DFP12D... -
Page 46: Checking The Engine Oil Level
ð The oil level must be between the “MIN” and “MAX” marks. NOTICE! B-HAT-0003 Danger of engine damage! Fig. 26 – Do not fill in too much engine oil. If the oil level is too low, top up oil to the “MAX” mark. Screw the oil dipstick in. DFP12D... -
Page 47: Checking The Fuel Level; Topping Up Fuel
Protective equipment: Working clothes Safety shoes Protective gloves Clean the area around the filling port. Remove the cap and check the filling level visually. Fill in fuel through a funnel with screen filter. Close the cap. B-230-0122 Fig. 28 DFP12D... -
Page 48: Checking The Rubber Buffers
B-SYM-1073 Fig. 29 Protective equipment: Working clothes Safety shoes Protective gloves Check the rubber buffer pairs, left and right, for tight fit, cracks and tear-offs. ð Have damaged rubber buffers replaced by authorised service personnel immediately. B-230-0066 Fig. 30 DFP12D... -
Page 49: Checking The Water Level, Topping Up
Pull out the bolt (2) and take off the water tank. Insert the bolt through the guides on the water tank and insert the split pin to lock. ð The water tank can now be carried by the bolt. B-230-0068 Fig. 32 DFP12D... - Page 50 Checks prior to start up – Checking the water level, topping up DFP12D...
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Page 51: Operation
Operation Operation DFP12D... -
Page 52: Mounting The Guide Handle
6.1 Mounting the guide handle Protective equipment: Working clothes Safety shoes Protective gloves Force the guide handle apart and plug it onto the brackets. Lock and secure the guide handle on both sides with clip pins. B-230-0064 Fig. 33 DFP12D... -
Page 53: Starting The Engine
Hearing protection Working clothes Protective gloves Safety shoes Mounting the guide handle Ä Chapter 6.1 „Mounting the guide handle“ on page 52. Fold down the guide handle into working position. Set the throttle lever to position “MIN”. Fig. 34 DFP12D... - Page 54 ð At idle speed vibration is switched off. If white smoke comes out of the exhaust after a few unsuc- cessful starting attempts: Set the throttle lever to position “MIN”. Pull the starter handle 5-times completely out. Repeat the starting procedure. DFP12D...
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Page 55: Operation
The centrifugal clutch may be damaged! – Operate the machine only with the throttle lever in position “MAX”. Set the throttle lever to position “MAX”. ð Machine vibrates forwards. Guide the machine by means of the guide handle. Fig. 37 DFP12D... - Page 56 Always shift the throttle lever to position “MIN” (idle speed) for short work breaks. ð Vibration is switched off. For short work interruptions you should always park the Ä Chapter 6.5 „Parking the machine in secured condition machine in secured condition“ on page 58. Fig. 38 DFP12D...
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Page 57: Switching The Water Sprinkling System On/Off
6.4 Switching the water sprinkling system on/off Switch the water sprinkling system on or off with the rotary button: Position "0" Water sprinkling system off turn anticlockwise Water sprinkling system on infinite adjustment of the sprinkling quantity up to position “MAX” Fig. 39 DFP12D... -
Page 58: Parking The Machine In Secured Condition
Press and hold the shut-down pin until the engine switches off. Release the shut-down pin and make sure that it returns to its initial position. If necessary, pull the shut-down pin gently to return it to its initial position. Secure the machine against unauthorized use. Fig. 41 DFP12D... -
Page 59: Loading/Transporting The Machine
Loading/transporting the machine Loading/transporting the machine DFP12D... -
Page 60: Loading The Machine
– Do not step or stand under suspended loads. Lift the machine carefully and set down again at the intended location. Fig. 42 If necessary, pull the machine by the handles (1) on an even surface. Fig. 43 DFP12D... -
Page 61: Lashing The Machine To The Transport Vehicle
Protective gloves Fasten the lashing tackle to the marked lashing point. B-230-0123 Fig. 44 Lash the machine securely to the transport vehicle as shown. Use suitable gear to prevent the guide handle from swinging over unintentionally. B-230-0091 Fig. 45 DFP12D... -
Page 62: Transport Wheels
Unlock the locking bolts (2) and fold down the transport wheels. B-230-0076 Fig. 47 Push the machine up by the guide handle and fold the trans- port wheels under the base plate. ð The machine can now be moved. B-230-0119 Fig. 48 DFP12D... -
Page 63: Transport Wheels With Guide Handle In Middle Position
Unlock the locking bolts (2) and fold down the transport wheels. B-230-0043 Fig. 50 Push the machine up by the guide handle and fold the trans- port wheels under the base plate. ð The machine can now be moved. B-230-0120 Fig. 51 DFP12D... - Page 64 Loading/transporting the machine – Transport wheels DFP12D...
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Page 65: Maintenance
Maintenance Maintenance DFP12D... -
Page 66: 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. DFP12D... -
Page 67: Fuels And Lubricants
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 In order to fulfil national emission regulations one must strictly use the legally required fuels (e.g. sulphur content). DFP12D... -
Page 68: Oil For Exciter Shaft Housing
8.2.3 Oil for exciter shaft housing Use only engine oils according to the following specifications: API CI-4 or higher quality Avoid mixing engine oils. NOTICE! Components may get damaged! – Do not use low-ash engine oils for the exciter shaft housing. DFP12D... -
Page 69: List Of Fuels And Lubricants
Ä Chapter 8.2.3 „Oil for exciter shaft Specification: (0.08 gal us) housing“ on page 68 Components may get damaged! Do not use low-ash engine oils for the exciter shaft housing. SAE 15W-40 SAE 10W-30 Water tank Water 13.5 l (3.6 gal us) DFP12D... -
Page 70: Running-In Instructions
8.7.2 „Checking, adjusting the valve clearance“ on page 77. Check engine and machine for leaks. Retighten the fastening screws on air filter, exhaust and other attachments. Retighten the bolted connections on the machine. Check the V-belt. Check the oil level in the exciter shaft housing. DFP12D... -
Page 71: Maintenance Table
Changing the oil in the exciter housing 8.7.8 Cleaning the exhaust screen As required 8.8.1 Cleaning the cooling fins and the cooling air intake openings 8.8.2 Cleaning the machine 8.8.3 Cleaning the water spraying system 8.8.4 Measures prior to extended shut-down period DFP12D... -
Page 72: Weekly
Clean the cover. NOTICE! Danger of engine damage! – Prevent dirt from getting into the air intake opening. B-HAT-0006 – Do not clean the air filter housing with compressed air. Fig. 54 Clean the filter housing with a clean, lint-free cloth. DFP12D... -
Page 73: 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 precisely. After taking the engine into operation you should B-SYM-1075 check for signs of water and dirt initially every day. Fig. 57 DFP12D... - Page 74 Loosen the drain plug and collect escaping fluid. Drain the fuel off until there is no water left. Screw the drain plug tightly back in. Ensure leak tightness. Dispose of collected fluid in line with environmental regula- tions. B-HAT-0005 Fig. 58 DFP12D...
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Page 75: Annually
(protective gloves, protective clothing). – Avoid touching hot components. Unscrew the drain plug and collect any oil running out. Fig. 59 Clean the drain plug and screw it back in with a new seal ring, tightening torque: 50 Nm (37 ft·lbf). DFP12D... - Page 76 Slightly oil the seal rings (1) and (2). Insert the oil filter (2) into the housing and press it against the end stop. Before tightening the screw (1) make sure that the tensioning springs touch the oil filter with both ends. Tighten the screw. Fig. 62 DFP12D...
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Page 77: Checking, Adjusting The Valve Clearance
Ä Chapter 6.5 Park the machine in secured condition „Parking the machine in secured condition“ on page 58. Let the engine to cool down to ambient temperature. Remove the air filter cover (2). Disassemble the covering (1). Fig. 64 DFP12D... - Page 78 Adjusting the valve clearance Loosen screw (3) on the rocker arm. Adjust the hexagon nut (2), until the feeler gauge (1) can be inserted and pulled out with noticeable resistance after the screw (3) has been tightened. Fig. 67 DFP12D...
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Page 79: Replacing The Air Filter
Do not start the engine after having removed the air filter. Protective equipment: Working clothes Protective gloves Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58. Allow the engine to cool down. DFP12D... -
Page 80: Replacing The V-Belt
Safety shoes Protective gloves Ä Chapter 6.5 „Parking the machine Park the machine safely in secured condition“ on page 58. Allow the engine to cool down. Loosen the fastening screws (2) and remove the V-belt guard (1). B-230-0124 Fig. 72 DFP12D... - Page 81 Assemble the V-belt guard (1) with fastening screws (2). Check the V-belt tension again after 25 operating hours, tighten if necessary. B-230-0124 Fig. 76 8.7.4.1 Checking the frequency of the base plate Keep feet and hands clear of the vibrating base plate. DFP12D...
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Page 82: Replacing The Fuel Filter
Protective equipment: Working clothes Protective gloves Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58. Clean the area around the tank filler cap. Remove the tank filler cap. DFP12D... -
Page 83: Replacing The Starter Rope
Pull the starter rope with the starter handle (1) out com- pletely. Secure the coil (2) against winding up. Loosen the knot (3) in the starter rope and remove the old starter rope. Carefully turn the coil back, until the recoil spring is relieved. Fig. 79 DFP12D... - Page 84 Slowly guide the starter handle back to initial position . Pull the starter handle to check the function and light move- ment of the recoil starter. Fig. 82 Assemble the recoil starter (2) with fastening screws (1). Fig. 83 DFP12D...
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Page 85: Changing The Oil In The Exciter Housing
Dispose of oil in an environmentally friendly way. 8.7.8 Cleaning the exhaust screen Protective equipment: Working clothes Protective gloves Ä Chapter 6.5 Park the machine in secured condition „Parking the machine in secured condition“ on page 58. Allow the engine to cool down. DFP12D... - Page 86 Fig. 88 Reassemble the screen insert and the fastening strap. Tighten the fastening nut for approx.one turn. Slide on the exhaust manifold with fastening strap. Hook the fastening strap into the bore (A). Tighten the fastening nut. Fig. 89 DFP12D...
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Page 87: As Required
8.8.2 Cleaning the machine Protective equipment: Working clothes Protective gloves Ä Chapter 6.5 Park the machine in secured condition „Parking the machine in secured condition“ on page 58. Let the machine cool down to ambient temperature. DFP12D... -
Page 88: Cleaning The Water Spraying System
Change the engine oil and clean the oil filter. 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. DFP12D... - Page 89 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. Check the oil levels. Clean the machine thoroughly. DFP12D...
- Page 90 Maintenance – As required DFP12D...
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Page 91: Troubleshooting
Troubleshooting Troubleshooting DFP12D... -
Page 92: 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. DFP12D... -
Page 93: Engine Malfunctions
Air in the fuel system Check the fuel system for air entry. Check the ventilation valve. Engine looses Air filter dirty Clean, replace if necessary power and speed, Incorrect valve clearance Check the valve clearance, adjust if nec- black exhaust essary smoke DFP12D... - Page 94 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 Centrifugal clutch defective Have it checked by qualified expert per- high speed, but no sonnel vibration V-belt torn Replacing the V-belt DFP12D...
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Page 95: Disposal
Disposal Disposal DFP12D... -
Page 96: Final Shut-Down Of Machine
Ä Chapter 3.4 „Han- dling fuels and lubricants dling fuels and lubricants“ on page 23. Protective equipment: Working clothes Safety shoes Protective gloves Safety goggles Empty the fuel tank. Drain engine oil from engine and exciter housing. DFP12D...
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