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Fayat Group DYNAPAC DRP40DX Manual

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Operating Instruction/Maintenance Instruction
Original Operating Instructions
DRP40DX
Reversible plate
S/N 101 925 44 1001> / S/N 101 925 57 1001>
DL 8 207 05 EN
© 04/2023

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Summary of Contents for Fayat Group DYNAPAC DRP40DX

  • Page 1 Operating Instruction/Maintenance Instruction Original Operating Instructions DRP40DX Reversible plate S/N 101 925 44 1001> / S/N 101 925 57 1001> DL 8 207 05 EN © 04/2023...
  • Page 2 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.

  • Page 3: Table Of Contents

    Table of contents Table of contents Introduction............................7 1.1 Foreword............................8 1.2 Machine type plate and engine type plate................10 Technical data............................11 2.1 Noise and vibration data......................13 2.1.1 Noise data..........................14 2.1.2 Vibration data..........................14 Concerning your safety........................15 3.1 Basic prerequisites........................
  • Page 4 Table of contents 3.9.3 Maintenance work on electric components and battery............. 33 3.9.4 Cleaning work..........................33 3.9.5 Measures for longer shut-down periods..................34 3.9.6 After maintenance work......................34 3.10 Repair............................35 3.11 Signage............................36 3.12 Safety Components........................40 Indicators and control elements......................41 4.1 Machine............................
  • Page 5 Table of contents 8.4 List of fuels and lubricants......................72 8.5 Running-in instructions......................73 8.5.1 General information........................73 8.5.2 After the first 25 operating hours....................73 8.6 Maintenance Table........................74 8.7 Weekly............................75 8.7.1 Checking, cleaning the air filter....................75 8.7.2 Checking and cleaning the water separator................
  • Page 6 Table of contents DRP40DX...

  • Page 7: Introduction

    Introduction Introduction DRP40DX...

  • Page 8: Foreword

    Introduction – Foreword 1.1 Foreword These operating and maintenance instructions are part of your machine. They provide necessary information to operate your machine safely and properly. They also contain information on required operating, maintenance and repair measures. Carefully read the operating and maintenance instructions before taking your machine into operation.
  • 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. DRP40DX...

  • Page 10: Machine Type Plate And Engine Type Plate

    Introduction – Machine type plate and engine type plate 1.2 Machine type plate and engine type plate Please enter here: Machine type (1): Made by Designation 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...

  • Page 11: Technical Data

    Technical data Technical data DRP40DX...
  • Page 12 Technical data Dimensions B-695-0120 Fig. 3 Dimensions standard 1350 1700 (32.3) (38.6) (53.1) (66.9) (35.4) (17.7) (21.7) (29.5) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (W) (860) (lbs) Operating weight (W (893) (lbs) Operating weight (W (926) (lbs) Basic weight (882) (lbs)

  • Page 13: Noise And Vibration Data

    Technical data – Noise and vibration data Travel characteristics Max. working speed m/min (92) (ft/min) Max. gradeability (depending on soil; depending on weather) Drive Engine manufacturer Hatz Type 1B40 Cooling Number of cylinders Rated power ISO 3046 (9.0) (hp) Rated speed 3000 Drive system mechanical...

  • Page 14: Noise Data

    Technical data – Noise and vibration data During operation these values may vary because of the prevailing operating conditions. 2.1.1 Noise data Sound pressure level at the opera- = 95 dB(A), determined acc. to ISO 11201 and EN 500. tor's stand WARNING! Loss of hearing caused by too high noise bur- dens!

  • Page 15: Concerning Your Safety

    Concerning your safety Concerning your safety DRP40DX...

  • Page 16: Basic Prerequisites

    Concerning your safety – Basic prerequisites 3.1 Basic prerequisites 3.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and tech- nical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...

  • Page 17: Personal Protective Equipment

    Concerning your safety – Basic prerequisites CAUTION! Danger of injury if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. NOTICE! Danger of material damage if failing to comply! Sections marked accordingly indicate possible dangers for machines or components.

  • Page 18: Intended Use

    Concerning your safety – Basic prerequisites Safety goggles They protect the eyes against airborne particles and squirting fluids. Face protection This protects the face against airborne particles and squirting fluids. Hard hat This protects the head against falling parts and injuries. Hearing protection This protects against extreme noise.

  • Page 19: Improper Use

    Concerning your safety – Basic prerequisites 3.1.5 Improper use Dangers may arise with the machine if it is used other than for its intended purpose. Any hazard caused by improper use is the sole responsibility of the operating company or driver/operator; the manufacturer cannot be held liable.

  • Page 20: Definition Of Responsible Persons

    Concerning your safety – Definition of responsible persons 3.2 Definition of responsible persons 3.2.1 Operating company The operating company is the natural or juridical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating and main- tenance instructions.
  • Page 21 Concerning your safety – Definition of responsible persons have made himself familiar with the operation of the machine, be physically and psychologically able to drive and operate the machine. Persons under the influence of alcohol, medication or drugs are not allowed to operate, service or repair the machine.

  • Page 22: Basic Safety Regulations For Safe Operation

    Concerning your safety – Basic safety regulations for safe operation 3.3 Basic safety regulations for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regula- tions it cannot be ruled out that further dangers may arise when working with and handling the machine.

  • Page 23: Handling Fuels And Lubricants

    Concerning your safety – Handling fuels and lubricants 3.4 Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance...

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

    Concerning your safety – Handling fuels and lubricants 3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot components. –...

  • Page 25: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Concerning your safety – Handling fuels and lubricants 3.4.3 Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into contact with hot components. – Smoking and open fire are prohibited! –...

  • Page 26: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Concerning your safety – Handling fuels and lubricants 3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. –...

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

    Concerning your safety – Handling fuels and lubricants 3.4.5 Safety regulations and environmental protection regulations for handling bat- tery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.

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

    Concerning your safety – Handling fuels and lubricants 3.4.6 Safety regulations and environmental protection regulations when handling lubrication grease CAUTION! Health hazard caused by contact with lubrica- tion grease! – Wear your personal protective equipment (protective gloves, safety goggles, protective clothing).

  • Page 29: Loading/Transporting The Machine

    Concerning your safety – Loading/transporting the machine 3.5 Loading/transporting the machine Make sure that persons are not endangered by the machine tipping or sliding off. Do not use damaged or in any other way impaired lashing points. Always use appropriate lifting and lashing means on the lifting and lashing points.

  • Page 30: Start-Up Procedure

    Concerning your safety – Start-up procedure 3.6 Start-up procedure 3.6.1 Prior to starting up Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area.

  • Page 31: Work Mode

    Concerning your safety – Work mode 3.7 Work mode 3.7.1 Persons in the danger area Before taking up work, also after breaks, you should always con- vince yourself that the danger zone is free of persons or obstruc- tions. Give warning signals, if necessary. Stop work immediately if per- sons remain in the danger zone, despite the warning.

  • Page 32: Refuelling

    Concerning your safety – Refuelling 3.8 Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Ultra-low sulphur diesel fuel poses a higher risk of combustion caused by the static charging than diesel fuel with a higher sulphur content.

  • Page 33: Maintenance Work

    Concerning your safety – Maintenance work 3.9 Maintenance work 3.9.1 Preliminary remarks Always carry out the prescribed maintenance work and mainte- nance measures on time in order to maintain the safety, opera- tional readiness and long service life of the machine. The machine must only be serviced by qualified personnel author- ised by the operating company.

  • Page 34: Measures For Longer Shut-Down Periods

    Concerning your safety – Maintenance work 3.9.5 Measures for longer shut-down periods If the machine is taken out of operation for a longer period of time, various conditions must be met and maintenance work must Ä Chapter 8.11.5 be carried out both before and after shut-down ‘Measures prior to extended shut-down period’...

  • Page 35: Repair

    Concerning your safety – Repair 3.10 Repair Identify a defect machine with a warning sign. 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.

  • Page 36: Signage

    Concerning your safety – Signage 3.11 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or signage immediately. START OPERATION STOP DIESEL  before taking into operation weekly vor Inbetriebnahme wöchentlich avant la mise en service hebdomadairement...
  • Page 37 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 10 Warning sticker - Danger of injury due to defective starter rope Before use, check the starter rope for chafing. Do not use a defective starter rope. Fig. 11 Information sticker - Lashing point Fig.
  • Page 38 Concerning your safety – Signage Information sticker - Guaranteed sound capacity level Fig. 14 Operation sticker - Travel lever Fig. 15 Operation sticker - Throttle lever Fig. 16 Brief operating instructions START Instruction sticker - Wear ear protection Instruction sticker - Observe operating instructions OPERATION STOP B-DEC-0391...
  • Page 39 Concerning your safety – Signage Maintenance sticker DIESEL  before taking into operation weekly vor Inbetriebnahme wöchentlich avant la mise en service hebdomadairement anterior a la puesta en servicio cada semana annual / 250 h twice annual jährlich / 250 h halbjährlich annuellement / 250 h tous les 6 mois...

  • Page 40: Safety Components

    Concerning your safety – Safety Components 3.12 Safety Components B-695-0036 Fig. 20 Protection hood Heat protection cover Belt guard DRP40DX...

  • Page 41: Indicators And Control Elements

    Indicators and control elements Indicators and control elements DRP40DX...

  • Page 42: Machine

    Indicators and control elements – Machine 4.1 Machine B-695-0178 Fig. 21 DCI display (optional equipment) Recoil starter Starter switch Operating hour meter Shut-off device 4.1.1 Dynapac Compaction Indicator (DCI) display The DCI displays the compaction status of the layer to be com- pacted.

  • Page 43: Recoil Starter

    Indicators and control elements – Machine 4.1.2 Recoil starter B-GEN-0084 Fig. 23 4.1.3 Starter switch Position “P”/“0” Switch the ignition off Ignition key can be removed Position “I”/“II” Ignition on The warning buzzer sounds Position “III” Turn further against spring pressure, the engine starts Turn the ignition key back to position “I”...

  • Page 44: Operating Hour Meter

    Indicators and control elements – Machine 4.1.5 Operating hour meter Maintenance work is to be carried out in accordance with the indi- cated operating hours. B-GEN-0114 Fig. 26 4.1.6 Shut-off device Press The engine is shut down. Use it only if speed control is broken. B-695-0148 Fig.

  • Page 45: Steering Rod

    Indicators and control elements – Steering rod 4.2 Steering rod B-695-0098 Fig. 28 Height adjustment Locking pawl lever Throttle lever Handle 4.2.1 Height adjustment Setting the steering rod height to the operator’s level. B-695-0097 Fig. 29 DRP40DX...

  • Page 46: Locking Pawl Lever

    Indicators and control elements – Steering rod 4.2.2 Locking pawl lever For locking and unlocking the steering rod. B-695-0096 Fig. 30 4.2.3 Throttle lever Position “STOP” The engine is shut down Position “MIN” Idle speed Engine start position Position “MAX” Maximum speed B-695-0149 Fig.

  • Page 47: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up DRP40DX...

  • Page 48: Notes On Safety

    Checks prior to start up – Notes on safety 5.1 Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indicators and control elements.

  • Page 49: Visual Inspections And Function Tests

    Checks prior to start up – Visual inspections and function tests 5.2 Visual inspections and function tests Check the condition of the fuel tank and fuel lines and for leaks. Check the bolted connections are tight and secure. Check the machine for contamination and damage. Check the hydraulic oil cooler for dirt.

  • Page 50: Daily Maintenance

    Checks prior to start up – Daily maintenance 5.3 Daily maintenance 5.3.1 Checking the engine oil level NOTICE! Danger of engine damage! – +Use only oil of the permitted specification Ä Chapter 8.3.1 ‘Engine oil’ on page 69. B-SYM-1068 Fig. 33 Protective equipment: Working clothes Safety shoes...

  • Page 51: Checking The Fuel Level; Topping Up Fuel

    Checks prior to start up – Daily maintenance 5.3.2 Checking the fuel level; topping up fuel NOTICE! Danger of engine damage! – Monitor the entire refuelling process. – Contaminated fuel can cause malfunction or B-SYM-1069 even damage of the engine. If necessary, fill in Fig.

  • Page 52: Checking The Rubber Buffers

    Checks prior to start up – Daily maintenance 5.3.3 Checking the rubber buffers B-SYM-1073 Fig. 37 Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 59. Allow the engine to cool down.

  • Page 53: Operation

    Operation Operation DRP40DX...

  • Page 54: Folding Down And Adjusting The Steering Rod

    Operation – Folding down and adjusting the steering rod 6.1 Folding down and adjusting the steering rod Pull the locking pawl lever and fold the steering rod down. Do not click the locking pawl lever into posi- tion again. The steering rod must be able to swing freely.

  • Page 55: Starting The Engine

    Operation – Starting the engine 6.2 Starting the engine Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death. WARNING! Danger of poisoning by exhaust gases! – Do not inhale exhaust gases. – Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
  • Page 56 Operation – Starting the engine Turn the ignition key to position “I”. ð The warning buzzer sounds. B-ELE-0070 Fig. 43 The starter switch is designed with a re-start lock. The ignition key must first be turned back to position “0” before a new starting attempt can be made.

  • Page 57: Work Mode

    Operation – Work mode 6.3 Work mode Operate the machine only with the steering rod folded down and Ä Chapter 6.1 ‘Folding down and adjusting the adjusted to height steering rod’ on page 54. Guide the machine only by means of the steering rod. Guide the machine so that your hands do not hit against solid objects.
  • Page 58 Operation – Work mode CAUTION! Danger of injury caused by the crushing of body parts! – When reversing, steer the machine from the side using the steering handle. Pull the handle back. ð The machines vibrates backwards with a speed which B-695-0058 corresponds with the handle position.

  • Page 59: Parking The Machine In Secured Condition

    Operation – Parking the machine in secured condition 6.4 Parking the machine in secured condition Park the machine on level and firm ground. Set the throttle lever to “MIN” position (idle speed). ð Vibration is shut down. B-695-0060 Fig. 51 NOTICE! Danger of engine damage! –...

  • Page 60: Dynapac Compaction Indicator (Dci)

    Operation – Dynapac Compaction Indicator (DCI) 6.5 Dynapac Compaction Indicator (DCI) The DCI informs the driver about the compaction status of the sub- structure and enables the detection and selected re-compaction of weak spots. An acceleration sensor on the base plate measures the reaction of the subsoil to the base plate of the machine.

  • Page 61: Loading/Transporting The Machine

    Loading/transporting the machine Loading/transporting the machine DRP40DX...

  • Page 62: Loading The Machine

    Loading/transporting the machine – Loading the machine 7.1 Loading the machine Loads may only be attached and hoisted by an expert/qualified person. Do not use lashing points that are damaged or impaired in any way. Only use lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded.

  • Page 63: Lashing The Machine To The Transport Vehicle

    Loading/transporting the machine – Lashing the machine to the transport vehicle 7.2 Lashing the machine to the transport vehicle Do not use lifting points that are damaged or impaired in any other way. Always use appropriate lifting and lashing tackle at the lifting and lifting points.
  • Page 64 Loading/transporting the machine – Lashing the machine to the transport vehicle DRP40DX...

  • Page 65: Maintenance

    Maintenance Maintenance DRP40DX...

  • Page 66: Preliminary Remarks And Safety Notes

    Maintenance – Preliminary remarks and safety notes 8.1 Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serviced by quali- fied and authorized personnel. – Follow the safety regulations for maintenance Ä...

  • Page 67: Preparations/Concluding Work

    Maintenance – Preparations/concluding work 8.2 Preparations/concluding work Certain maintenance tasks require preparations and concluding activities. This includes e.g. opening and closing maintenance flaps and maintenance doors as well as securing certain components. After this work close all maintenance flaps and doors again and return all components to their operating condition.
  • Page 68 Maintenance – Preparations/concluding work 8.2.1.2 Closing the protection hood To fasten the protection hood, use only the prescribed original screws. Always screw in and tighten all screws and their washers. Protective equipment: Working clothes Protective gloves Loosen the screw (1) on both sides. Close the protection hood.

  • Page 69: Fuels And Lubricants

    Maintenance – Fuels and lubricants 8.3 Fuels and lubricants 8.3.1 Engine oil 8.3.1.1 Oil quality The following engine oil specifications are permitted: API CF/CH-4 or higher quality ACEA B3/E4 or higher quality Avoid mixing engine oils. 8.3.1.2 Oil viscosity Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class).

  • Page 70: Oil For Exciter Shaft Housing

    Maintenance – Fuels and lubricants 8.3.2.2 Winter fuel For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel. Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are available for Arctic climates.
  • Page 71 Maintenance – Fuels and lubricants The viscosity index must be at least 150 (observe information of manufacturer). 8.3.4.2 Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil. The biodegradable hydraulic oil Panolin HLP Synth. 46 or Plantohyd 46 S meets all the requirements of a mineral oil based hydraulic oil according to DIN 51524.

  • Page 72: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants 8.4 List of fuels and lubricants Fuel or lubricant Spare parts Filling quantity Assembly group number Summer Winter Observe the level mark! Engine oil SAE 10W-40 DL 009 920 06 1.5 l Ä Chapter 8.3.1 ‘Engine oil’ Specification: 20 l (0.4 gal us)

  • Page 73: Running-In Instructions

    Maintenance – Running-in instructions 8.5 Running-in instructions 8.5.1 General information When commissioning new machines, the running-in instructions listed in this chapter must be carried out after the specified oper- ating hours. The maintenance work listed must be carried out in addition to the regular maintenance intervals.

  • Page 74: Maintenance Table

    Maintenance – Maintenance Table 8.6 Maintenance Table Maintenance works Page Daily maintenance 5.3.1 Checking the engine oil level 5.3.2 Checking the fuel level; topping up fuel 5.3.3 Checking the rubber buffers Weekly 8.7.1 Checking, cleaning the air filter 8.7.2 Checking and cleaning the water separator Semi-annually 8.8.1 Battery service...

  • Page 75: Weekly

    Maintenance – Weekly 8.7 Weekly 8.7.1 Checking, cleaning the air filter NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. B-SYM-1074 – If necessary, the air filter may be cleaned up to Fig.
  • Page 76 Maintenance – Weekly CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (protective gloves, protective clothing, goggles). Blow the air filter out with dry compressed air (max. 5 bar (73 psi)) from inside to outside by moving the gun up and B-GEN-0042 down inside the element, until it is free of dust.

  • Page 77: Checking And Cleaning The Water Separator

    Maintenance – Weekly 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 precisely. After taking the engine into operation you should B-SYM-1075 check for signs of water and dirt initially every day.

  • Page 78: Semi-Annually

    Maintenance – Semi-annually 8.8 Semi-annually 8.8.1 Battery service Maintenance free batteries also need care. Mainte- nance free only means that the fluid level does not need to be checked. Every battery has a self-discharge, which may, if B-SYM-1077 not checked occasionally, even cause damage to Fig.

  • Page 79: Annually / Every 250 Operating Hours

    Maintenance – Annually / every 250 operating hours 8.9 Annually / every 250 operating hours 8.9.1 Replacing the V-belt Protective equipment: Working clothes Safety shoes Protective gloves Tool: Locking lever for V-belt pulley We recommend using the locking lever to unscrew and screw on the V-belt pulley.
  • Page 80 Maintenance – Annually / every 250 operating hours Insert two M8 screws according to the required hole spacing and tighten them with two M8 nuts. B-695-0146 Fig. 74 Insert the locking lever into the V-belt pulley. B-695-0137 Fig. 75 Unscrew the V-belt pulley (1). Replace the V-belt (3).
  • Page 81 Maintenance – Annually / every 250 operating hours Fasten the guard (1), tightening torque: 15 Nm (11 ft·lbf). B-692-0206 Fig. 78 Fasten the V-belt guard (1). B-692-0067 Fig. 79 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!

  • Page 82: Checking, Adjusting The Valve Clearance

    Maintenance – Annually / every 250 operating hours If frequency incorrect: Check the engine speed. Check the V-belt. 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.
  • Page 83 Maintenance – Annually / every 250 operating hours Checking the valve clearance Valve clearance: Intake valve (IN) 0.10 mm (0,004 in) Exhaust valve (EX) 0.10 mm (0,004 in) Crank the engine, until the exhaust valve (EX) is fully open. Check the valve clearance on the intake valve (IN) with a feeler gauge (1);...

  • Page 84: Changing The Engine Oil And Cleaning The Oil Filter

    Maintenance – Annually / every 250 operating hours Assemble cover (1) and air filter cover (2). After a short test run check the valve cover for leaks. B-HAT-0010 Fig. 85 8.9.3 Changing the engine oil and cleaning the oil filter NOTICE! Danger of engine damage! –...
  • Page 85 Maintenance – Annually / every 250 operating hours Loosen the hose clamp and route the drain hose to the out- side. WARNING! Danger of burning on hot components! – Wear your personal protective equipment (protective gloves, protective clothing). – Avoid touching hot components. Unscrew the drain plug and collect any oil running out.
  • Page 86 Maintenance – Annually / every 250 operating hours Check the seal rings for damage; replace if necessary. Cover the seal rings slightly with oil. B-HAT-0050 Fig. 90 Insert the oil filter into the housing and press it against the end stop. Before tightening the screw, make sure that the tensioning springs (1) touch the oil filter with both ends.

  • Page 87: Replacing The Fuel Filter

    Maintenance – Annually / every 250 operating hours 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: Working clothes Protective gloves...

  • Page 88: Changing The Oil In The Exciter Housing

    Maintenance – Annually / every 250 operating hours Remove the cap (3). Unscrew the knurled nut (2) and pull out the air filter (1). Clean the cover. NOTICE! Danger of engine damage! – Prevent dirt from getting into the air intake opening.
  • Page 89 Maintenance – Annually / every 250 operating hours Clean the area around the bleeding screw (1) and filling/drain plug (2). Tilt the machine slightly towards the oil drain side and secure it properly. Unscrew the bleeding screw. Unscrew the filling/drain plug and collect any oil running out. B-695-0179 Fig.

  • Page 90: Checking The Hydraulic Oil Level

    Maintenance – Annually / every 250 operating hours 8.9.7 Checking the hydraulic oil level Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 59. Adjust the steering rod using the height adjustment so that the area with the filler screw is horizontal.
  • Page 91 Maintenance – Annually / every 250 operating hours Press the handle forward against the stop and secure it using suitable means. B-692-0070 Fig. 102 Place a cloth underneath the bleeding screw to collect leaking oil. Slacken the bleeding screw. Wait until all air has escaped and then tighten the bleeding screw.

  • Page 92: Replacing The Starter Rope

    Maintenance – Annually / every 250 operating hours 8.9.8 Replacing the starter rope Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’ on page 59. Allow the engine to cool down. Unscrew the fastening screws (1) and disassemble the recoil starter (2).
  • Page 93 Maintenance – Annually / every 250 operating hours Pre-tension the coil by approx. 4 rotations in direction of arrow. Thereby place the starter rope into the recess in the coil . Fig. 109 CAUTION! Danger of injury caused by the starter handle hitting against your body! –...

  • Page 94: Lubricating The Machine

    Maintenance – Annually / every 250 operating hours 8.9.9 Lubricating the machine Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 59. Unscrew the four fastening screws (1) and remove the cover (2).

  • Page 95: Every 2 Years/Every 500 Operating Hours

    Maintenance – Every 2 years/every 500 operating hours 8.10 Every 2 years/every 500 operating hours 8.10.1 Changing the hydraulic oil Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 59. Adjust the steering rod using the height adjustment so that the area with the filler screw is horizontal.
  • Page 96 Maintenance – Every 2 years/every 500 operating hours NOTICE! Components may get damaged! – Use only oil of the permitted specifica- Ä Chapter 8.3.4.1 ‘Hydraulic oil’ tion on page 70. Fill in hydraulic oil up to the mark on the steering rod head. Mark: approx.

  • Page 97: As Required

    Maintenance – As required 8.11 As required 8.11.1 Cleaning the machine Protective equipment: Working clothes Protective gloves Park the machine in secured condition Ä Chapter 6.4 ‘Parking the machine in secured condition’ on page 59. Allow the engine to cool down for at least 30 minutes. NOTICE! Electric components can be damaged by water entering into the system!

  • Page 98: Servicing The V-Belt

    Maintenance – As required 8.11.3 Servicing the V-belt Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 59. Allow the engine to cool down. Unscrew the V-belt guard (1). B-692-0067 Fig.

  • Page 99: Checking The Oil Level In The Exciter Housing

    Maintenance – As required 8.11.4 Checking the oil level in the exciter housing NOTICE! Components may get damaged! – Use only oil of the permitted specification Ä Chapter 8.4 ‘List of fuels and lubricants’ on page 72. – Do not use low-ash engine oils for the exciter shaft housing.
  • Page 100 Maintenance – As required 8.11.5.2 Battery service during prolonged machine downtimes WARNING! Danger of injury caused by exploding gas mix- ture! – Remove the plugs when recharging the battery. – Ensure adequate ventilation. – Smoking and open fire are prohibited! –...
  • Page 101 Maintenance – As required Check the oil levels. Clean the machine thoroughly. DRP40DX...
  • Page 102 Maintenance – As required DRP40DX...

  • Page 103: Troubleshooting

    Troubleshooting Troubleshooting DRP40DX...

  • Page 104: Preliminary Remarks

    Troubleshooting – Preliminary remarks 9.1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. 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.

  • Page 105: Starting The Engine With The Recoil Starter

    Troubleshooting – Starting the engine with the recoil starter 9.2 Starting the engine with the recoil starter Start the engine with the recoil starter only if the battery is defective, empty or missing. Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death.
  • Page 106 Troubleshooting – Starting the engine with the recoil starter Set the handle to position “0”. B-695-0056 Fig. 129 Lightly pull the rope twice with the starter handle, until resist- ance can be felt (compression pressure). Guide the starter handle back to initial position. B-GEN-0083 Fig.

  • Page 107: Starting The Engine With Jump Leads

    Troubleshooting – Starting the engine with jump leads 9.3 Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. Open the protection hood and secure it to prevent unin- tended closing.

  • Page 108: Fuse Assignment

    Troubleshooting – Fuse assignment 9.4 Fuse assignment 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 DCI fuse (optional equipment) 25 A Main fuse B-692-0075 Fig.

  • Page 109: Malfunctions During Operation

    Troubleshooting – Malfunctions during operation 9.5 Malfunctions during operation Fault Possible cause Remedy The machines Air in the steering rod hydraulic system Release pressure from the steering rod vibrates forward The oil level in the exciter shaft housing is Check the oil level in the exciter shaft with a strongly too high housing...

  • Page 110: Shutting Down The Engine With The Shut-Off Device

    Troubleshooting – Shutting down the engine with the shut-off device 9.6 Shutting down the engine with the shut-off device WARNING! Danger of burning on hot components! – Wear your personal protective equipment (pro- tective gloves, protective clothing). – Avoid touching hot components. CAUTION! Danger of injury caused by uncontrolled machine movement!

  • Page 111: Engine Malfunctions

    Troubleshooting – Engine malfunctions 9.7 Engine malfunctions Fault Possible cause Remedy The engine is hard Shut-off device in STOP position Pull the shut-off device gently to move it to start or does not to operating position. start at all. No fuel at the injection pump Check the fuel level;...
  • Page 112 Troubleshooting – Engine malfunctions Fault Possible cause Remedy Engine looses Fuel tank empty Check the fuel level; top up if necessary. power and speed. Tank ventilation blocked Ensure sufficient ventilation of the tank. Air in the fuel system Check the fuel system for air ingress. Check the ventilation valve.

  • Page 113: Dci Faults

    Troubleshooting – DCI faults 9.8 DCI faults B-DIS-1054 Fig. 136 Fault Possible cause Remedy LED (a) flashes Switching on: The LED (a) flashes for approx 1 - 2 seconds after the vibration has been switched on. Vibration frequency too low LED (a) lights up No vibration detected Start the engine, set the throttle lever to...
  • Page 114 Troubleshooting – DCI faults DRP40DX...

  • Page 115: Disposal

    Disposal Disposal DRP40DX...

  • Page 116: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 10.1 Final shut-down of machine After the machine has reached the end of its service life, the indi- vidual components of the machine must be disposed of properly. Observe national regulations! Carry out the following work and have the machine dismantled by a state-approved recycling company.

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