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DFP12D
Operating Instruction
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Dynapac DFP12D Operating Instruction

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Page 1
Operang Ins
trucon
Original Oper
DFP12D
orward plate
F
ang Instrucons
S/N 101 924 26 1001> DL8 203 75 EN © 06/2018
Page 2
2
Page 3

Table of contents

Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data...................................................................................................................................... 11
2.1 Noise and vibration data............................................................................................................ 14
2.1.1 Noise data.................................................................................................................................. 14
2.1.2 Vibration data............................................................................................................................. 14
3 Concerning your safety...................................................................................................................... 15
3.1 Basic prerequisites..................................................................................................................... 16
3.1.1 General...................................................................................................................................... 16
3.1.2 Explanation of signal words used:.............................................................................................. 16
3.1.3 Personal protective equipment................................................................................................... 17
3.1.4 Intended use.............................................................................................................................. 18
3.1.5 Improper use.............................................................................................................................. 18
3.2 Definition of responsible persons............................................................................................. 20
3.2.1 Operating company.................................................................................................................... 20
3.2.2 Expert / qualified person............................................................................................................ 20
3.2.3 Driver / operator......................................................................................................................... 20
3.3 Basic safety regulations for safe operation............................................................................. 22
3.3.1 Remaining dangers, remaining risks.......................................................................................... 22
3.3.2 Regular safety inspections......................................................................................................... 22
3.3.3 Modifications and alterations to the machine............................................................................. 22
3.3.4 Damage, defects, misuse of safety devices............................................................................... 22
3.4 Handling fuels and lubricants.................................................................................................... 23
3.4.1 Preliminary remarks................................................................................................................... 23
3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel............... 24
3.4.3 Safety regulations and environmental protection regulations for handling oil............................ 25
3.5 Loading/transporting the machine............................................................................................ 26
3.6 Start-up procedure...................................................................................................................... 27
3.6.1 Prior to starting up...................................................................................................................... 27
3.6.2 Starting the engine..................................................................................................................... 27
3.7 Operation..................................................................................................................................... 28
3.7.1 Persons in the danger area........................................................................................................ 28
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
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Table of contents
4 Indicators and control elements........................................................................................................ 37
4.1 Engine.......................................................................................................................................... 38
4.1.1 Throttle lever.............................................................................................................................. 38
4.1.2 Shut-down pin............................................................................................................................ 38
4.1.3 Recoil starter.............................................................................................................................. 38
4.2 Water spraying system............................................................................................................... 39
4.2.1 Rotary button for water sprinkling system.................................................................................. 39
4.3 Transport wheels......................................................................................................................... 40
4.3.1 Transport wheels with steering bow in middle position.............................................................. 41
5 Checks prior to start up...................................................................................................................... 43
5.1 Notes on safety........................................................................................................................... 44
5.2 Visual inspections and function tests....................................................................................... 45
5.3 Checking the engine oil level..................................................................................................... 46
5.4 Checking the fuel level; topping up fuel................................................................................... 47
5.5 Checking the rubber buffers...................................................................................................... 48
5.6 Checking the water level, topping up........................................................................................ 49
6 Operation............................................................................................................................................. 51
6.1 Mounting the guide handle........................................................................................................ 52
6.2 Starting the engine...................................................................................................................... 53
6.3 Operation..................................................................................................................................... 55
6.4 Switching the water sprinkling system on/off.......................................................................... 57
6.5 Parking the machine in secured condition............................................................................... 58
7 Loading/transporting the machine.................................................................................................... 59
7.1 Loading the machine.................................................................................................................. 60
7.2 Lashing the machine to the transport vehicle.......................................................................... 61
7.3 Transport wheels......................................................................................................................... 62
7.3.1 Transport wheels with guide handle in middle position.............................................................. 63
8 Maintenance........................................................................................................................................ 65
8.1 Preliminary remarks and safety notes...................................................................................... 66
8.2 Fuels and lubricants................................................................................................................... 67
8.2.1 Engine oil................................................................................................................................... 67
8.2.2 Fuel............................................................................................................................................ 67
8.2.3 Oil for exciter shaft housing........................................................................................................ 68
8.3 List of fuels and lubricants........................................................................................................ 69
8.4 Running-in instructions.............................................................................................................. 70
8.4.1 General...................................................................................................................................... 70
8.4.2 After 25 operating hours............................................................................................................. 70
8.5 Maintenance Table...................................................................................................................... 71
8.6 Weekly.......................................................................................................................................... 72
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
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Table of contents
8.7.4 Replacing the V-belt................................................................................................................... 80
8.7.5 Replacing the fuel filter............................................................................................................... 82
8.7.6 Replacing the starter rope.......................................................................................................... 83
8.7.7 Changing the oil in the exciter housing...................................................................................... 85
8.7.8 Cleaning the exhaust screen...................................................................................................... 85
8.8 As required.................................................................................................................................. 87
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
9 Troubleshooting.................................................................................................................................. 91
9.1 Preliminary remarks.................................................................................................................... 92
9.2 Engine malfunctions................................................................................................................... 93
10 Disposal............................................................................................................................................... 95
10.1 Final shut-down of machine..................................................................................................... 96
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Table of contents
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1 Introduction
Introduction
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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.
Please observe the safety regulations strictly and follow all instruc­tions to ensure safe operation.
If you are not yet acquainted with the indicators and control ele­ments on this machine, you should thoroughly read the corre­sponding chapter Ä Chapter 4 „Indicators and control ele­ments“ on page 37.
The description of the individual operating steps including the notes on safety to be followed can be found in chapter “Operation”
Ä
Chapter 6 „Operation“ on page 51.
Before every start up, carry out all required visual inspections and function tests Ä Chapter 5 „Checks prior to start up“ on page 43.
Ensure the compliance with the specified operating, maintenance and repair measures to maintain the functional safety of your machine.
A description of all necessary maintenance work, maintenance intervals as well as information on fuels and lubricants can be
Ä
found in the chapter “Maintenance” nance“ on page 65.
Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and authorised personnel.
Contact our customer service to carry out the required mainte­nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of unapproved fuels and lubricants all warranty claims will become null and void.
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.
These operating and maintenance instructions are also available in other languages.
Apart from that, you can also order the spare parts catalogue against the serial number of your machine.
Chapter 8 „Mainte-
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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.
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Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Made in Germany
Ammerländer Str. 93 D-26203 Wardenburg
1
2
B-924-0001
Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Fig. 1: Machine type plate (example)
Please enter here:
Engine type (1):
Engine number (2):
Fig. 2: Engine type plate (example)
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2 Technical data
Technical data
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B-230-0098
W
L1
L
H
H2
H1
Technical data
Dimensions
Fig. 3
H H
708
(27.9)
1
962
(37.9)
H
2
700
(27.6)
L L
1084
(42.7)
1
542
(21.3)
W
500
(19.7)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (CECE) 122
(269)
(lbs)
Basic weight 123
(271)
(lbs)
Water spraying system (optional equipment) + 10
Transport wheels (optional equipment) + 4
(+ 22)
(+ 9)
(lbs)
(lbs)
kg
kg
kg
kg
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Technical data
Travel characteristics
Max. working speed 30
(98)
m/min
(ft/min)
Max. gradability (depending on soil) 30 %
Drive
Engine manufacturer Hatz
Type 1B20
Cooling Air
Number of cylinders 1
Rated power ISO 3046 3.1
(4.2)
Rated speed 3000
kW
(hp)
min
Drive system mechanical
Exciter system
Frequency 92
(5520)
Hz
(vpm)
-1
Centrifugal force 25
(5620)
Amplitude 1.75
(0,069)
kN
(lbf)
mm
(in)
Water sprinkling system (optional equipment)
Type of sprinkling Gravity feed
Filling capacities
Fuel (diesel) 3.0
(0.8 each)
(gal us)
Water sprinkling system 13.5
(3.6 each)
(gal us)
l
l
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Technical data – Noise and vibration data
2.1 Noise and vibration data
The following noise and vibration data were determined in accord­ance with the following guidelines under equipment specific condi­tions and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing operating conditions.
2.1.1 Noise data
Sound pressure level at the opera­tor's stand
Guaranteed sound power level
2.1.2 Vibration data
Hand-arm vibration
LpA = 93 dB(A), determined acc. to ISO 11201 and EN 500.
WARNING! Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500.
Vector total of the weighted effective acceleration in three orthog­onal directions:
Total vibration value ahv = 4.3 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.4 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
Hand-arm vibration with comfort guide handle (optional equipment)
Vector total of the weighted effective acceleration in three orthog­onal directions:
Total vibration value ahv £ 2.5 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.1 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
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Concerning your safety
3 Concerning your safety
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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 tech­nical rules.
However, dangers for persons and property may arise from this machine, if:
n it is used for purposes other than the ones it is intended for, n it is operated by untrained personnel, n it is changed or converted in an unprofessional way, n the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety reg­ulations. If necessary, the operating company must obtain the rele­vant signatures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions, n generally accepted safety and road traffic regulations, n country/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu­lations and to apply these accordingly. This also applies for local regulations and regulations concerning different types of handling activities. Should the recommendations in these instructions be dif­ferent from the regulations valid in your country, you must comply with the safety regulations valid in your country.
3.1.2 Explanation of signal words used:
DANGER! Danger to life if failing to comply!
Sections marked accordingly indicate an extremely dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded.
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.
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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.
Sections marked accordingly indicate technical information or notes on using the machine or its components.
ENVIRONMENT! Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices for safe and environment-friendly disposal of fuels and lubricants as well as replacement parts.
3.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against being caught by moving components.
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.
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Concerning your safety – Basic prerequisites
Safety goggles To protect the eyes against airborne particles and
squirting fluids.
Face protection To protect the face against airborne particles and
squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-
3.1.4 Intended use
3.1.5 Improper use
cles.
This machine must only be used for:
n Compaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders
Intended use also includes compliance with the specified oper­ating, maintenance and repair measures.
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.
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Concerning your safety – Basic prerequisites
Examples for improper use are:
n dragging the machine along as a measure of transportation n throwing the machine off the transport vehicle n attaching an additional weight to the machine
It is not permitted to stand on the machine while working.
Lifting tackle must be removed before starting work.
Starting and operating the machine in explosive environments and in underground mining is prohibited.
The lifting and lashing points specified in these instructions must be used. It is prohibited to use other lifting and lashing points (e.g. guide handle, steering rod).
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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 mainte­nance instructions.
The operating company must determine and assess the danger in its company. It must then take appropriate action to ensure health and safety at work for its employees and point out any remaining dangers.
The operating company must determine whether there are special operational hazards such as a toxic atmosphere or limiting soil conditions. Such conditions require special, additional measures to remove or reduce the hazard.
The operating company must make sure that all users read and understand the information concerning safety.
The operating company is responsible for the planning and profes­sional execution of regular safety inspections.
3.2.2 Expert / qualified person
3.2.3 Driver / operator
An expert / qualified person is a person who, based on his/her pro­fessional education and experience, has profound knowledge in the field of construction equipment and the machine in question in particular.
This person is acquainted with the applicable governmental indus­trial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations (standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is nec­essary to be able to judge the safe condition of this machine.
This machine must only be operated by trained, instructed persons entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
n be instructed about his rights and obligations, n wear protective equipment as appropriate for the application, n have read and understood the operating instructions,
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Concerning your safety – Definition of responsible persons
n have made himself familiar with the operation of the machine, n 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.
Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists.
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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 regula­tions it cannot be ruled out that further dangers may arise when working with and handling the machine.
Both the machine as well as all other system components comply with the currently valid safety regulations. Nevertheless, remaining risks cannot be ruled out completely, even when using the machine for the purpose it is intended for and following all information given in the operating instructions.
A remaining risk can also not be excluded beyond the actual danger zone of the machine. Persons remaining in this area must pay particular attention to the machine, so that they can react immediately in case of a possible malfunction, an incident or failure etc.
All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine.
3.3.2 Regular safety inspections
Have the machine inspected by an expert / qualified person as required for the conditions the machine is working under, but at least once every year.
3.3.3 Modifications and alterations to the machine
Unauthorized changes to the machine are prohibited for safety rea­sons.
Original parts and accessories have been specially designed for this machine.
We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse effect on the active and/or passive safety.
3.3.4 Damage, defects, misuse of safety devices
Machines which are not safe to operate or in traffic must be imme­diately taken out of service and shall not be used, until these defi­ciencies have been properly rectified.
Safety installations and switches must neither be removed nor must they be made ineffective.
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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:
n name of substance n possible dangers n composition / information on constituents n first-aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure / personal protective
equipment
n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n information on transport n legislation n other data
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Concerning your safety – Handling fuels and lubricants
3.4.2
Fig. 4
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. – Smoking and open fire is prohibited! – Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION! Health hazard caused by contact with diesel
fuel!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing). – Do not inhale any fuel fumes. – Avoid contact.
CAUTION! Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT! Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers. – Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly. – Dispose of diesel fuel and fuel filters according
to regulations.
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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 is prohibited! – Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 5
CAUTION! Health hazard caused by contact with oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing). – Do not inhale any oil vapours. – Avoid contact.
CAUTION! Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT! Oil is an environmentally hazardous substance!
– Always keep oil in proper containers. – Immediately bind spilled oil with an oil-binding
agent. – Dispose of oil and oil filter according to regula-
tions.
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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.
Use lifting and lashing gear only in the prescribed direction of load application.
Lifting tackle must not be damaged by machine components.
Secure the machine on the transport vehicle against rolling, slip­ping and turning over.
Loads must only be attached and hoisted by an expert / capable person.
Use only lifting gear and lifting tackle with sufficient load bearing capacity for the weight to be loaded.
Fasten the lifting gear only at the specified lifting points.
Danger to the life of persons if they step or stand under a sus­pended load.
When lifting the machine avoid uncontrolled movements of the load. If necessary hold the load with guide ropes.
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3.6 Start-up procedure
3.6.1 Prior to starting up
Concerning your safety – Start-up procedure
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.
Use your personal protective equipment (hard hat, safety boots, if necessary also goggles and ear protection).
Do not take any loose objects with you or fasten them to the machine.
Before start up, check whether:
n persons or obstructions are beside or in front of the machine, n the machine is free of oily and combustible materials, n all safety elements are in place, n all grips are free of grease, oils, fuel, dirt, snow and ice.
Before start up, carry out all required visual inspections and func­tion tests.
If the following tests reveal damages or other faults, the machine must not be operated, until these deficiencies have been corrected.
Do not operate the machine with defective indicators and control elements.
3.6.2 Starting the engine
Do not use any starting aids like start pilot or ether.
The machine must not be operated with damaged, missing or non­functional safety installations.
Before starting and moving the machine, make sure that there is nobody in the danger zone.
Always keep an eye on the machine when the engine is running and hold it by the steering bow.
Do not inhale exhaust fumes, because they contain toxic sub­stances, which could cause damage to health, unconsciousness or even death.
Avoid operation in closed or partly closed rooms, or ensure ade­quate ventilation when working in trenches.
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Concerning your safety – Operation
3.7 Operation
3.7.1 Persons in the danger area
Before taking up work, also after breaks, you should always con­vince yourself that the danger zone is free of persons or obstruc­tions.
Give warning signals, if necessary. Stop work immediately if per­sons remain in the danger zone, despite the warning.
3.7.2 Operation
Guide the machine only by the guide handle.
Guide the machine so that your hands do not hit against solid objects.
Watch out for unusual noises and development of smoke. Perform trouble shooting and have the fault corrected.
Always keep a safe distance to excavation pit borders, embank­ments and edges.
Refrain from any work that could adversely affect the stability of the machine.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
3.7.3 Parking the machine
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n Shut down the engine, n Secure the machine against accidental tipping over, n Secure the machine against unauthorized use.
Mark machines, which could be in the way, with a clearly visible sign.
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3.8 Refuelling
Concerning your safety – 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.
Apply measures against electrostatic charging.
Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
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Concerning your safety – Maintenance work
3.9 Maintenance work
3.9.1 Preliminary remarks
Adhere to the specified operating, maintenance and repair meas­ures.
The machine must only be serviced by qualified personnel author­ised by the operating company.
Keep unauthorised persons away from the machine.
Perform maintenance work only with the engine shut down.
Make sure that the engine cannot be accidentally started during maintenance work.
3.9.2 Working on the engine
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ­mentally.
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 sepa­rate, specially marked container and dispose of environmentally.
3.9.3 Cleaning work
3.9.4 After 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.
Reassemble all guards and protections.
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3.10 Repair
Concerning your safety – 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.
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X
008 338 08
008 338 21
START
OPERATION
STOP
Water
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Patent Protection
B-230-0121
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.
Fig. 6
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Fig. 7
Concerning your safety – Signage
Warning sticker - Follow operating instructions
Warning sticker - Starter rope
Fig. 8
Fig. 9
Instruction sticker - Wear ear defenders
Information sticker - Lifting point
Fig. 10
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B-DEC-0218
Water
Concerning your safety – Signage
Information sticker - Lashing point
Fig. 11
Information sticker - Guaranteed sound capacity level
Fig. 12
Fig. 13
Information sticker - Filler opening for water
Information sticker Shut-down pin / throttle lever
Fig. 14
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Concerning your safety – Signage
Brief operating instructions
Fig. 15
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Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Made in Germany
Ammerländer Str. 93 D-26203 Wardenburg
B-924-0002
Concerning your safety – Signage
Maintenance sticker
Fig. 16
Fig. 17
Machine type plate (example)
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Indicators and control elements
4 Indicators and control elements
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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
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1
2
B-230-0114
Indicators and control elements – Water spraying system
4.2 Water spraying system
1 Rotary button for water spraying system 2 Water level gauge
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
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Indicators and control elements – Transport wheels
4.3 Transport wheels
Fig. 23
1 Locking of guide handle 2 Locking of transport wheels
Optional equipment
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Indicators and control elements – Transport wheels
4.3.1 Transport wheels with steering bow in middle position
Fig. 24
1 Locking of guide handle 2 Locking of transport wheels
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Indicators and control elements – Transport wheels
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Checks prior to start up
5 Checks prior to start up
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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.
Safety installations must not be removed or made ineffective.
Do not change any fixed settings.
WARNING! Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
WARNING! Danger of injury caused by rotating parts!
– Before starting work on the machine make sure
tion regulations must be followed when han-
dling fuels and lubricants Ä Chapter 3.4 „Han-
dling fuels and lubricants“ on page 23.
that the engine can not be started.
1.
Park the machine safely in secured condition“ on page 58.
Ä
Chapter 6.5 „Parking the machine
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Checks prior to start up – Visual inspections and function tests
5.2 Visual inspections and function tests
1. Check fuel tank and lines for condition and leaks.
2. Check bolted connections for tight fit.
3. Check machine for contamination and damage.
4. Check the hydraulic oil cooler for dirt.
5. Check starter rope for chafing.
45
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B-SYM-1068
B-HAT-0003
Checks prior to start up – Checking the engine oil level
5.3 Checking the engine oil level
NOTICE! Danger of engine damage!
– +Use only oil of the permitted specification
Ä
Chapter 8.2.1 „Engine oil“ on page 67.
Fig. 25
Fig. 26
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Clean the area around the oil dipstick.
2. Unscrew the dipstick and wipe it clean with a lint-free, clean
cloth.
3. Screw the dipstick back in and pull it out again to check the oil level.
The oil level must be between the “MIN” and “MAX”
ð
marks.
4.
NOTICE! Danger of engine damage!
– Do not fill in too much engine oil.
If the oil level is too low, top up oil to the “MAX” mark.
5. Screw the oil dipstick in.
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B-SYM-1069
B-230-0122
Checks prior to start up – Checking the fuel level; topping up fuel
5.4 Checking the fuel level; topping up fuel
NOTICE! Danger of engine damage!
– Monitor the entire refuelling process. – Contaminated fuel can cause malfunction or
Fig. 27
even damage of the engine. If necessary, fill in fuel through a screen filter.
– Use only fuel of the permitted specification
Ä
Chapter 8.2.2 „Fuel“ on page 67.
Fig. 28
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Clean the area around the filling port.
2. Remove the cap and check the filling level visually.
3. Fill in fuel through a funnel with screen filter.
4. Close the cap.
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B-SYM-1073
B-230-0066
Checks prior to start up – Checking the rubber buffers
5.5 Checking the rubber buffers
Fig. 29
Fig. 30
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Check the rubber buffer pairs, left and right, for tight fit, cracks and tear-offs.
Have damaged rubber buffers replaced by authorised
ð
service personnel immediately.
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Water
B-230-0116
2
1
B-230-0068
Checks prior to start up – Checking the water level, topping up
5.6 Checking the water level, topping up
NOTICE! Components may get damaged by frost!
– Drain all water off if there is a risk of frost.
Fig. 31
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Clean the area around the filling port.
2. Remove the cap and check the water supply in the water
tank.
NOTICE! Dirty or contaminated water can block the bore-
holes!
– Fill only with clean water.
3. If necessary, fill in clean water.
4. Close the cap.
Alternatively, the water tank can also be removed and transported for filling.
1. Pull out the split pin (1).
2. Pull out the bolt (2) and take off the water tank.
3. Insert the bolt through the guides on the water tank and
insert the split pin to lock.
The water tank can now be carried by the bolt.
ð
Fig. 32
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Checks prior to start up – Checking the water level, topping up
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6 Operation
Operation
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B-230-0064
Operation – Mounting the guide handle
6.1 Mounting the guide handle
Fig. 33
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Force the guide handle apart and plug it onto the brackets.
2. Lock and secure the guide handle on both sides with clip
pins.
52
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6.2 Starting the engine
Operation – 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.
Components can be very hot during or immediately after operation.
WARNING! Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Avoid touching hot components.
WARNING! Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
Operate the machine only with the guide handle mounted and low­ered.
Protective equipment:
1.
Mounting the guide handle Ä Chapter 6.1 „Mounting the guide handle“ on page 52.
2. Fold down the guide handle into working position.
3. Set the throttle lever to position “MIN”.
Hearing protection
n
Working clothes
n
Protective gloves
n
Safety shoes
n
Fig. 34
53
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Operation – Starting the engine
Fig. 35
4. Pull the rope by the starter handle, until resistance can be felt.
5. Guide the starter handle back to initial position.
6.
CAUTION! Danger of injury caused by uncontrolled
machine movement!
– Always hold on to a running machine. – Always keep an eye on a running
machine.
Fig. 36
NOTICE! The starter rope may tear off!
– Do not pull the starter rope all the way
against the end stop.
Pull the starter handle quickly and with power.
7. Manually guide the starter handle back to initial position.
8. If the engine does not start during the first attempt, repeat the
starting process.
NOTICE! Danger of engine damage!
– Warm up engine for a short while before
starting work. Do not operate the engine imme­diately under full load.
9. Run the engine warm for approx. 1 to 2 minutes in idle speed.
At idle speed vibration is switched off.
ð
10. If white smoke comes out of the exhaust after a few unsuc­cessful starting attempts:
n Set the throttle lever to position “MIN”. n Pull the starter handle 5-times completely out. n Repeat the starting procedure.
54
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6.3 Operation
Operation – Operation
Guide the machine only by the guide handle.
Guide the machine so that your hands do not hit against solid objects.
Keep feet clear of the vibrating base plate.
CAUTION! Danger of injury caused by uncontrolled
machine movement!
– Always hold on to a running machine. – Always keep an eye on a running machine.
Components can be very hot during or immediately after operation.
WARNING! Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Avoid touching hot components.
Fig. 37
Protective equipment:
1. Make sure that no persons are in the danger zone.
2.
NOTICE! The centrifugal clutch may be damaged!
– Operate the machine only with the
throttle lever in position “MAX”.
Set the throttle lever to position “MAX”.
Machine vibrates forwards.
ð
3. Guide the machine by means of the guide handle.
Hearing protection
n
Working clothes
n
Protective gloves
n
Safety shoes
n
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Operation – Operation
Fig. 38
4. Always shift the throttle lever to position “MIN” (idle speed) for short work breaks.
Vibration is switched off.
ð
5. For short work interruptions you should always park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
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Operation – Switching the water sprinkling system on/off
6.4 Switching the water sprinkling system on/off
1. Switch the water sprinkling system on or off with the rotary
button:
Position "0" Water sprinkling system off
turn anticlockwise Water sprinkling system on
Fig. 39
infinite adjustment of the sprinkling quantity up to position “MAX”
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Operation – Parking the machine in secured condition
6.5 Parking the machine in secured condition
Components can be very hot during or immediately after operation.
WARNING! Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Avoid touching hot components.
Fig. 40
Protective equipment:
1. Park the machine on level and firm ground.
2. Set the throttle lever to position “MIN” (idle speed).
NOTICE! Danger of engine damage!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two minutes.
3. Press and hold the shut-down pin until the engine switches off.
4. 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.
5. Secure the machine against unauthorized use.
Hearing protection
n
Working clothes
n
Protective gloves
n
Safety shoes
n
Fig. 41
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Loading/transporting the machine
7 Loading/transporting the machine
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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 lifting points that are damaged or impaired in any other way.
Only use lifting tackle with sufficient load bearing capacity for the weight to be loaded. Minimum load bearing capacity of lifting tackle: see operating weight Ä Chapter 2 „Technical data“ on page 11.
Always use appropriate lifting tackle at the lifting points.
Use lifting tackle only in the specified loading direction.
Lifting tackle must not be damaged by machine parts.
When lifting the machine, make sure the load does not move in an uncontrolled way. If necessary, hold the load steady with guide ropes.
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
Fig. 42
1.
Park the machine safely in secured condition“ on page 58.
2. Allow the engine to cool down.
3. Fold the guide handle forwards.
4. Attach the lifting tackle to the dedicated lifting eye.
5.
DANGER! Danger to life caused by suspended
loads!
– Do not step or stand under suspended
loads.
Lift the machine carefully and set down again at the intended location.
6. If necessary, pull the machine by the handles (1) on an even surface.
Ä
Chapter 6.5 „Parking the machine
Fig. 43
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B-230-0123
B-230-0091
Loading/transporting the machine – Lashing the machine to the transport vehicle
7.2 Lashing the machine to the transport vehicle
Do not use lashing points that are damaged or impaired in any way.
Always use appropriate lashing tackle at the lashing points.
Use lashing tackle only in the specified loading direction.
Lashing tackle must not be damaged by machine parts.
Protective equipment:
1. Fasten the lashing tackle to the marked lashing point.
Working clothes
n
Safety shoes
n
Protective gloves
n
Fig. 44
Fig. 45
2. Lash the machine securely to the transport vehicle as shown.
3. Use suitable gear to prevent the guide handle from swinging
over unintentionally.
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B-230-0075
1
B-230-0076
2
B-230-0119
Loading/transporting the machine – Transport wheels
7.3 Transport wheels
1.
Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Lock the guide handle with the locking bolts (1).
Fig. 46
3. Unlock the locking bolts (2) and fold down the transport wheels.
Fig. 47
Fig. 48
4. Push the machine up by the guide handle and fold the trans­port wheels under the base plate.
The machine can now be moved.
ð
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B-230-0042
1
B-230-0043
2
B-230-0120
Loading/transporting the machine – Transport wheels
7.3.1 Transport wheels with guide handle in middle position
1.
Park the machine safely in secured condition“ on page 58.
2. Lock the guide handle with the hook (1).
Fig. 49
3. Unlock the locking bolts (2) and fold down the transport wheels.
Ä
Chapter 6.5 „Parking the machine
Fig. 50
Fig. 51
4. Push the machine up by the guide handle and fold the trans­port wheels under the base plate.
The machine can now be moved.
ð
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Loading/transporting the machine – Transport wheels
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8 Maintenance
Maintenance
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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
work Ä Chapter 3.9 „Maintenance work“ on page 30.
WARNING! Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations must be followed when han­dling fuels and lubricants Ä Chapter 3.4 „Han­dling fuels and lubricants“ on page 23.
Wear your personal protective equipment.
Do not touch hot components.
Park the machine on horizontal, level, firm ground.
Perform maintenance work only with the engine shut down.
Make sure that the engine cannot be accidentally started during maintenance work.
Thoroughly clean machine and engine before starting maintenance work.
Do not leave any tools or other objects, that could cause damage, in or on the machine.
After maintenance work has been completed, dispose of fuels and lubricants, filters, sealing elements and cleaning cloths in an envi­ronmentally friendly way.
After all maintenance work is completed reinstall all guards and safety installations.
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8.2 Fuels and lubricants
8.2.1 Engine oil
8.2.1.1 Oil quality
8.2.1.2 Oil viscosity
Maintenance – Fuels and lubricants
The following engine oil specifications are permitted:
n API CF/CH-4 or higher quality n ACEA B3/E4 or higher quality
Avoid mixing engine oils.
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).
The temperature data of the SAE-class always refer to fresh oils. The engine oil ages during travel operation because of soot and fuel residues. This adversely affects the properties of the engine oil, especially at low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis­cosity chart as reference.
Fig. 52: Oil viscosity diagram
8.2.1.3 Oil change intervals
8.2.2 Fuel
8.2.2.1 Fuel quality
Annually or every 250 operating hours.
When changing to a higher alloyed oil quality after a longer period of operation, it is recommended to perform the first oil change of the higher quality oil already after 25 operating hours.
The following fuel specifications are permitted:
n EN 590 n ASTM D975 Grade-No. 1-D and 2-D n BS 2869 A1/A2
In order to fulfil national emission regulations one must strictly use the legally required fuels (e.g. sulphur content).
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Maintenance – Fuels and lubricants
8.2.2.2 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.
8.2.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the injection nozzles, especially in modern Common-Rail injection sys­tems.
Zinc and lead coatings in refuelling systems and fuel lines are not permitted.
Copper containing materials (copper lines, brass items) should be avoided, because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system.
NOTICE! Danger of engine damage!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is not permitted.
8.2.3 Oil for exciter shaft housing
Use only engine oils according to the following specifications:
n API CI-4 or higher quality
Avoid mixing engine oils.
NOTICE! Components may get damaged!
– Do not use low-ash engine oils for the exciter
shaft housing.
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Maintenance – List of fuels and lubricants
8.3 List of fuels and lubricants
Assembly group Fuel or lubricant Filling quantity
Summer Winter Observe the level
mark!
Engine oil SAE 10W-40
Specification: Ä Chapter 8.2.1 „Engine oil“ on page 67
SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 3.0 l
Specification: Ä Chapter 8.2.2 „Fuel“ on page 67
Exciter shaft housing SAE 10W-40
Specification: Ä Chapter 8.2.3 „Oil for exciter shaft
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
0.9 l
(0.24 gal us)
(0.8 gal us)
0.3 l
(0.08 gal us)
(3.6 gal us)
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Maintenance – Running-in instructions
8.4 Running-in instructions
8.4.1 General
The following maintenance work must be performed when running in new machines or overhauled engines.
8.4.2 After 25 operating hours
1. Change the engine oil.
2.
Check the valve clearance, adjust if necessary
8.7.2 „Checking, adjusting the valve clearance“ on page 77.
3. Check engine and machine for leaks.
4. Retighten the fastening screws on air filter, exhaust and other
attachments.
5. Retighten the bolted connections on the machine.
6. Check the V-belt.
7. Check the oil level in the exciter shaft housing.
Ä
Chapter
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Maintenance – Maintenance Table
8.5 Maintenance Table
No. Maintenance works Page
Weekly
8.6.1 Checking, cleaning the air filter 72
8.6.2 Checking and cleaning the water separator 73
Annually
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
8.7.4 Replacing the V-belt 80
8.7.5 Replacing the fuel filter 82
8.7.6 Replacing the starter rope 83
8.7.7 Changing the oil in the exciter housing 85
8.7.8 Cleaning the exhaust screen 85
As required
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
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B-SYM-1074
B-HAT-0006
1
2
3
Maintenance – Weekly
8.6 Weekly
8.6.1 Checking, cleaning the air filter
Fig. 53
NOTICE! Danger of engine damage!
– Do not start the engine after having removed
the air filter.
– If necessary, the air filter may be cleaned up to
six times.
– Cleaning does not make sense if the air filter
element is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the
filter element.
– After cleaning, the air filter must be inspected
for damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
Fig. 54
Protective equipment:
1.
Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Allow the engine to cool down.
3. Remove the cap (3).
4. Unscrew the knurled nut (2) and pull out the air filter (1).
5. Clean the cover.
6.
NOTICE! Danger of engine damage!
– Prevent dirt from getting into the air
intake opening.
– Do not clean the air filter housing with
compressed air.
Clean the filter housing with a clean, lint-free cloth.
Working clothes
n
Safety shoes
n
Protective gloves
n
Safety goggles
n
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B-GEN-0042
Fig. 55
B-HAT-0006
1
2
3
B-SYM-1075
Maintenance – Weekly
7.
CAUTION! Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
Blow the air filter out with dry compressed air (max. 5 bar (73 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust.
8. Examine the air filter with a torch for cracks and holes.
9. Replace the air filter if it is damaged.
10. Insert the air filter (1) carefully into the filter housing and
fasten it with the knurled nut (2).
11.
NOTICE! Danger of engine damage!
– Ensure correct fit of air filter cover and
seal.
Close the cap (3).
Fig. 56
8.6.2 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
Fig. 57
check for signs of water and dirt initially every day.
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B-HAT-0005
Maintenance – Weekly
Fig. 58
Protective equipment:
1.
Park the machine safely Ä Chapter 6.5 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
in secured condition“ on page 58.
2. Place the transparent container under the drain plug.
3. Loosen the drain plug and collect escaping fluid.
4. Drain the fuel off until there is no water left.
5. Screw the drain plug tightly back in. Ensure leak tightness.
6. Dispose of collected fluid in line with environmental regula-
tions.
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8.7 Annually
8.7.1 Changing the engine oil and cleaning the oil filter
Change the engine oil at the latest after 250 oper­ating hours.
NOTICE! Danger of engine damage!
– Change the oil only with the engine at oper-
ating temperature.
– Use only oil of the permitted specification
Ä
Chapter 8.2.1 „Engine oil“ on page 67.
– Filling quantity:
lubricants“ on page 69
Maintenance – Annually
Ä
Chapter 8.3 „List of fuels and
Draining off engine oil
Fig. 59
Protective equipment:
1.
Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Clean the area around oil dipstick (1) and drain plug (2).
3. Unscrew the oil dipstick.
4.
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.
5. Clean the drain plug and screw it back in with a new seal ring, tightening torque: 50 Nm (37 ft·lbf).
Working clothes
n
Protective gloves
n
Safety goggles
n
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Maintenance – Annually
Cleaning the oil filter
Fig. 60
6. Loosen the screw (1) for approx. five turns and pull the oil filter (2) out of the housing.
7.
CAUTION! Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
Fig. 61
Fig. 62
Use compressed air to blow the oil filter out from the inside to the outside.
8. Check the seal ring (2) for damage, change if necessary.
9. Slightly oil the seal rings (1) and (2).
10. Insert the oil filter (2) into the housing and press it against the
end stop.
11. Before tightening the screw (1) make sure that the tensioning springs touch the oil filter with both ends.
12. Tighten the screw.
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Filling in engine oil
Fig. 63
Maintenance – Annually
13. Fill in new engine oil.
14. Screw the oil dipstick in.
15. After a short test run check the oil level on the dipstick; if nec-
essary, top up to the top dipstick mark.
Final work
16. Check oil filter and drain plug for leaks.
17. Dispose of oil in an environmentally friendly way.
8.7.2 Checking, adjusting the valve clearance
NOTICE! Danger of engine damage!
We recommend to have this work carried out by trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down.
Preparations
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 58.
2. Let the engine to cool down to ambient temperature.
3. Remove the air filter cover (2).
4. Disassemble the covering (1).
Working clothes
n
Protective gloves
n
Ä
Chapter 6.5
Fig. 64
77
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Maintenance – Annually
Fig. 65
5. Unscrew the fastening screws (1).
6. Remove the valve cover (2) with gasket.
Checking the valve clearance
Fig. 66
Adjusting the valve clearance
Valve clearance:
Intake valve (IN) 0.20 mm (0.008 in)
Exhaust valve (EX) 0.20 mm (0.008 in)
1. Crank the engine, until the exhaust valve (EX) is fully open.
2. Check the valve clearance on the intake valve (IN) with a
feeler gauge (1), adjust if necessary.
3. Crank the engine further, until the intake valve is fully open.
4. Check the valve clearance on the exhaust valve, adjust if
necessary.
1. Loosen screw (3) on the rocker arm.
2. 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
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Final work
Fig. 68
Maintenance – Annually
1. Install the valve cover (2) with a new gasket.
2. Tighten the fastening screws (1) evenly.
3. Assemble covering (1) and air filter cover (2).
4. After a short test run check the valve cover for leaks.
Fig. 69
8.7.3 Replacing the air filter
NOTICE! Danger of engine damage!
– Do not start the engine after having removed
the air filter.
Protective equipment:
1.
Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Allow the engine to cool down.
Working clothes
n
Protective gloves
n
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1
2
B-230-0124
Maintenance – Annually
Fig. 70
3. Remove the cap (3).
4. Unscrew the knurled nut (2) and pull out the air filter (1).
5. Clean the cover.
6.
NOTICE! Danger of engine damage!
– Prevent dirt from getting into the air
intake opening.
– Do not clean the air filter housing with
compressed air.
Clean the filter housing with a clean, lint-free cloth.
7. Replace the air filter.
8. Insert the air filter (1) carefully into the filter housing and
fasten it with the knurled nut (2).
9.
NOTICE! Danger of engine damage!
– Ensure correct fit of air filter cover and
seal.
Fig. 71
8.7.4 Replacing the V-belt
Preparations
Close the cap (3).
Protective equipment:
1.
Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Allow the engine to cool down.
3. Loosen the fastening screws (2) and remove the V-belt guard
(1).
Working clothes
n
Safety shoes
n
Protective gloves
n
Fig. 72
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1
B-230-0029
Fig. 73
1
B-230-0030
1
2
B-230-0124
Maintenance – Annually
4. Slightly loosen the fastening screws (1) on both sides.
5. Pull the engine carrier forward, remove and replace the V-
belt.
6. Install the new V-belt and pull the engine carrier back.
7. Tighten the fastening screws (1) on both sides.
Fig. 74
Fig. 75
8. Check tension of V-belt, tighten if necessary.
Compression measurement: 5 - 10 mm (0.2 - 0.4 in).
ð
9. Assemble the V-belt guard (1) with fastening screws (2).
10. Check the V-belt tension again after 25 operating hours,
tighten if necessary.
Fig. 76
8.7.4.1 Checking the frequency of the base plate
Keep feet and hands clear of the vibrating base plate.
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Maintenance – Annually
CAUTION! Danger of injury caused by uncontrolled
machine movement!
– Always hold on to a running machine. – Always keep an eye on a running machine.
Protective equipment:
Special tool:
1. Park the machine on a rubber mat.
2.
Start the engine Ä Chapter 6.2 „Starting the engine“ on page 53.
3. Run the machine at maximum speed for one minute.
4. Check the base plate’s frequency with a suitable measuring
instrument (e.g. Sirometer).
Nominal value:
ð
data“ on page 11
5.
Park the machine safely Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
6. If frequency incorrect:
n Check the engine speed. n Check the V-belt. n If necessary, contact our customer service.
Working clothes
n
Hearing protection
n
Safety shoes
n
Sirometer
n
Ä
Chapter 2 „Technical
8.7.5 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:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 58.
2. Clean the area around the tank filler cap.
3. Remove the tank filler cap.
Working clothes
n
Protective gloves
n
Ä
Chapter 6.5
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Maintenance – Annually
4. Pull the fuel filter out of the tank by the string.
5. Pull the fuel hose (3) off the fuel filter (2).
6. Take the fuel filter out of the bracket (1) and replace it with a
new one.
7. Plug on the fuel line.
8. Insert the fuel filter into the tank.
9. Close the fuel tank tightly.
Fig. 77
8.7.6 Replacing the starter rope
The fuel system is self-bleeding.
10. Dispose of fuel and filter in an environmentally friendly way.
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 58.
2. Allow the engine to cool down.
3. Unscrew the fastening screws (1) and disassemble the recoil
starter (2).
Working clothes
n
Protective gloves
n
Ä
Chapter 6.5
Fig. 78
Fig. 79
4. Pull the starter rope with the starter handle (1) out com­pletely.
5. Secure the coil (2) against winding up.
6. Loosen the knot (3) in the starter rope and remove the old
starter rope.
7. Carefully turn the coil back, until the recoil spring is relieved.
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Maintenance – Annually
Fig. 80
8. Thread in the new starter rope and fix it with knots on both ends .
A = 15 mm (0.6 in)
9. Pre-tension the coil by approx. 4 rotations in direction of
arrow.
Thereby place the starter rope into the recess in the coil .
Fig. 81
Fig. 82
10.
CAUTION! Danger of injury caused by the starter
handle hitting against your body!
– Do not let the starter handle hit back.
Slowly guide the starter handle back to initial position .
11. Pull the starter handle to check the function and light move­ment of the recoil starter.
12. Assemble the recoil starter (2) with fastening screws (1).
Fig. 83
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8.7.7 Changing the oil in the exciter housing
NOTICE! Components may get damaged!
– Use only oil of the permitted specification
Ä
cants“ on page 69.
Maintenance – Annually
Chapter 8.3 „List of fuels and lubri-
Fig. 84
Protective equipment:
1. Park the machine on level ground.
2.
Park the machine in secured condition „Parking the machine in secured condition“ on page 58.
3. Tilt the machine slightly towards the oil drain side and sup­port it safely.
4. Unscrew the oil drain plug (1) and collect running out oil.
5. Stand the machine upright.
Working clothes
n
Protective gloves
n
Ä
Chapter 6.5
6. Fill in fresh oil up to the bottom edge of the opening.
7. Screw in the oil drain plug (1).
Fig. 85
8. Dispose of oil in an environmentally friendly way.
8.7.8 Cleaning the exhaust screen
Protective equipment:
1.
2. Allow the engine to cool down.
NOTICE! Components may get damaged!
Do not use low-ash engine oils for the exciter shaft housing.
Working clothes
n
Protective gloves
n
Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
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Maintenance – Annually
Fig. 86
3. Loosen the fastening nut (1).
4. Remove the exhaust manifold (3) with the fastening bracket
(2).
5. Disassemble the fastening nut (1) and the fastening strap (2).
6. Pull out the screen insert (3).
Fig. 87
Fig. 88
7. Remove deposits from the screen insert with an appropriate wire brush.
8. Check the screen insert for damage, replace if necessary.
9. Reassemble the screen insert and the fastening strap.
10. Tighten the fastening nut for approx.one turn.
11. Slide on the exhaust manifold with fastening strap.
12. Hook the fastening strap into the bore (A).
13. Tighten the fastening nut.
Fig. 89
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Maintenance – As required
8.8 As required
8.8.1 Cleaning the cooling fins and the cooling air intake openings
How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions; clean daily if necessary.
Fig. 90
Protective equipment:
1.
Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Allow the engine to cool down.
3. Remove dried dirt with a suitable brush from all cooling fins
and cooling air intake openings.
4.
CAUTION! Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
Blow out the cooling fins and cooling air intake openings with compressed air.
5. In case of damp or oily contamination you should consult our customer service department.
Working clothes
n
Protective gloves
n
Safety goggles
n
8.8.2 Cleaning the machine
Protective equipment:
1.
Park the machine in secured condition Ä Chapter 6.5 „Parking the machine in secured condition“ on page 58.
2. Let the machine cool down to ambient temperature.
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Working clothes
n
Protective gloves
n
Page 88
1
2
B-230-0073
Maintenance – As required
3.
Clean the machine with a water jet.
Fig. 91
8.8.3 Cleaning the water spraying system
4. Warm up the engine for a while to avoid corrosion.
NOTICE! Electric components can be damaged by
water entering into the system!
– Do not guide the water jet directly into the
cooling air openings of the recoil starter, into the dry air filter or onto electrical equipment.
Fig. 92
Protective equipment:
1. Remove the cap (2).
2. Open the rotary button (1) completely and let all water run
out.
Alternatively you may also remove the water tank for cleaning.
3. Flush the water tank with a strong water jet, until all dirt has run out.
4. Fill the water tank with clean water and close the cap.
n n n
8.8.4 Measures prior to extended shut-down period
8.8.4.1 Measures before shutting down
If the machine is shut down for a longer period of time, e.g. winter season, the following work must be carried out:
1. Clean the machine thoroughly.
Working clothes Safety shoes Protective gloves
2. Clean the water separator.
3. Fill the fuel tank with diesel fuel, to prevent the formation of
condensation water in the tank.
4. Change the engine oil and clean the oil filter.
5. Change the fuel filter.
6. After shutting down store the machine under cover in a dry
and well ventilated room.
7. Protect the cooled down engine against dust and moisture.
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8.8.4.2 Measures before restarting
Maintenance – As required
1. Replace the fuel filter.
2. Replace the air filter.
3. Change the engine oil and clean the oil filter.
4. Check cables, hoses and lines for cracks and leaks.
5. Start the engine and run it for 15 to 30 minutes with idle
speed.
6. Check the oil levels.
7. Clean the machine thoroughly.
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Maintenance – As required
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9 Troubleshooting
Troubleshooting
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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 fol­lowing the trouble shooting chart, you should contact our customer service department.
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Troubleshooting – Engine malfunctions
9.2 Engine malfunctions
Fault Possible cause Remedy
The engine is hard to start or does not start at all
Engine does not start or starts poorly at low temperatures
Engine does not crank when oper­ating the recoil starter
The starter rope does not return to the initial position
Shut-down pin in STOP position Pull the shut-down pin gently to move it
to operating position
No fuel at the injection pump Check the fuel level, top up if necessary
Check the fuel lines
Check the fuel filter, replace if necessary
Injection nozzle out of order Have it checked by qualified expert per-
sonnel
Incorrect valve clearance Check the valve clearance, adjust if nec-
essary
Cylinder or piston rings worn Have it checked by qualified expert per-
sonnel
Paraffin sweats in the fuel due to insuffi­cient low temperature resistance
Engine oil with wrong SAE viscosity class Changing the engine oil
Recoil starter defective Replace the recoil starter
Spring broken Replace the recoil starter
Recoil starter dirty Clean the recoil starter
Insufficient pretension of the spring Check the pretension of the spring, adjust
Use winter-grade fuel
if necessary
Spring broken Replace the recoil starter
Engine ignites, but does not run
Engine stops Fuel tank empty Check the fuel level, top up if necessary
Engine looses power and speed
Engine looses power and speed, black exhaust smoke
Fuel filter clogged Check the fuel filter, replace if necessary
Fuel filter clogged Check the fuel filter, replace if necessary
Tank ventilation blocked Ensure sufficient ventilation of the tank
Air in the fuel system Check the fuel system for air entry.
Check the ventilation valve.
Mechanical defect Have it checked by qualified expert per-
sonnel
Fuel tank empty Check the fuel level, top up if necessary
Tank ventilation blocked Ensure sufficient ventilation of the tank
Air in the fuel system Check the fuel system for air entry.
Check the ventilation valve.
Air filter dirty Clean, replace if necessary
Incorrect valve clearance Check the valve clearance, adjust if nec-
essary
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Troubleshooting – Engine malfunctions
Fault Possible cause Remedy
Injection nozzle does not work correctly Have it checked by qualified expert per-
sonnel
Engine overheats Engine oil level too high Check, drain off if necessary
Lack of cooling air Clean the cooling fins and the cooling air
intake openings.
Check air guide plates and ducts for com­pleteness and good sealing.
Engine runs with high speed, but no vibration
Centrifugal clutch defective Have it checked by qualified expert per-
sonnel
V-belt torn Replacing the V-belt
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10 Disposal
Disposal
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Disposal – Final shut-down of machine
10.1 Final shut-down of machine
If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized specialist workshop.
WARNING! Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations must be followed when han­dling fuels and lubricants Ä Chapter 3.4 „Han­dling fuels and lubricants“ on page 23.
Protective equipment:
1. Empty the fuel tank.
2. Drain engine oil from engine and exciter housing.
Working clothes
n
Safety shoes
n
Protective gloves
n
Safety goggles
n
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