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DR6X
Operating Instruction
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Dynapac DR6X Operating Instruction

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Page 1
Operang Instrucon
Original Oper
DR6X Vibra
tory tamper
ang
Instrucons
S/N 101 924 01 1001> / S/N 101 924 02 1001> DL8 203 62 EN © 04/2018
Page 2
2
Page 3

Table of contents

Table of contents
Introduction........................................................................................................................................... 7
1
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data...................................................................................................................................... 1
2.1 Noise and vibration data............................................................................................................ 13
2.1.1 Noise data.................................................................................................................................. 13
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 oil............................ 24
3.4.3 Safety regulations and environmental protection regulations for handling gasoline.................. 25
3.4.4 Safety regulations and environmental protection regulations for handling fuel stabiliser........... 26
3.5 Loading/transporting the machine............................................................................................ 27
3.6 Start-up procedure...................................................................................................................... 28
3.6.1 Prior to starting up...................................................................................................................... 28
3.6.2 Starting the engine..................................................................................................................... 28
3.6.3 Operation in trenches................................................................................................................. 29
3.7 Operation..................................................................................................................................... 30
3.7.1 Persons in the danger area........................................................................................................ 30
3.7.2 Operation................................................................................................................................... 30
3.7.3 Parking the machine.................................................................................................................. 30
3.8 Refuelling..................................................................................................................................... 31
3.9 Maintenance work....................................................................................................................... 32
3.9.1 Preliminary remarks................................................................................................................... 32
3.9.2 Working on the engine............................................................................................................... 32
3.9.3 Working on the tamper foot........................................................................................................ 32
3.9.4 Cleaning work............................................................................................................................ 32
3.9.5 After maintenance work............................................................................................................. 32
1
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Table of contents
3.10 Repair......................................................................................................................................... 33
3.11 Signage...................................................................................................................................... 34
4 Indicators and control elements........................................................................................................ 39
5 Checks prior to start up...................................................................................................................... 41
5.1 Notes on safety........................................................................................................................... 42
5.2 Visual inspections and function tests....................................................................................... 43
5.3 Checking the engine oil level..................................................................................................... 44
5.4 Checking the fuel level; topping up fuel................................................................................... 45
5.5 Checking the rubber buffers...................................................................................................... 46
6 Operation............................................................................................................................................. 47
6.1 Adjusting the guide handle........................................................................................................ 48
6.2 Starting the engine...................................................................................................................... 49
6.3 Operation..................................................................................................................................... 53
6.4 Parking the machine in secured condition............................................................................... 55
6.5 Operating hour meter/engine rpm-meter.................................................................................. 56
7 Loading/transporting the machine.................................................................................................... 59
7.1 Loading the machine.................................................................................................................. 60
7.2 Lashing the machine to the transport vehicle.......................................................................... 62
8 Maintenance........................................................................................................................................ 63
8.1 Preliminary remarks and safety notes...................................................................................... 64
8.2 Fuels and lubricants................................................................................................................... 65
8.2.1 Engine oil................................................................................................................................... 65
8.2.2 Fuel............................................................................................................................................ 65
8.2.3 Gear oil SAE 75W-90................................................................................................................. 66
8.3 List of fuels and lubricants........................................................................................................ 67
8.4 Running-in instructions.............................................................................................................. 68
8.4.1 General...................................................................................................................................... 68
8.4.2 After 25 operating hours............................................................................................................. 68
8.5 Maintenance Table...................................................................................................................... 69
8.6 Weekly.......................................................................................................................................... 70
8.6.1 Checking, cleaning the air filter.................................................................................................. 70
8.7 Monthly........................................................................................................................................ 73
8.7.1 Checking the tamper foot........................................................................................................... 73
8.8 Semi-annually.............................................................................................................................. 75
8.8.1 Changing the engine oil............................................................................................................. 75
8.9 Annually....................................................................................................................................... 76
8.9.1 Checking, adjusting the valve clearance.................................................................................... 76
8.9.2 Replacing the spark plug............................................................................................................ 81
8.9.3 Replacing the fuel filter............................................................................................................... 82
8.9.4 Cleaning the fuel screen............................................................................................................ 85
8.9.5 Replacing the air filter................................................................................................................ 87
8.9.6 Checking, adjusting the engine speed....................................................................................... 89
8.9.7 Replacing the starter rope.......................................................................................................... 92
8.9.8 Changing the oil in the tamper foot............................................................................................ 94
8.10 As required................................................................................................................................ 96
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Table of contents
8.10.1 Cleaning the machine.............................................................................................................. 96
8.10.2 Checking, cleaning the spark plug........................................................................................... 96
9 Setting up / refitting............................................................................................................................ 99
9.1 Changing the tamper foot plate............................................................................................... 100
10 Troubleshooting................................................................................................................................ 101
10.1 Preliminary remarks................................................................................................................ 102
10.2 Engine faults............................................................................................................................ 103
10.3 What to do if the engine has flooded.................................................................................... 105
11 Disposal............................................................................................................................................. 109
11.1 Final shut-down of machine................................................................................................... 110
12 List of special tools........................................................................................................................... 111
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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 ments“ on page 39.
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 47.
Before every start up, carry out all required visual inspections and function tests
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 found in the chapter “Maintenance” nance“ on page 63.
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.
.
Ä
Chapter 4 „Indicators and control ele-
Ä
Chapter 5 „Checks prior to start up“ on page 41.
Ä
Chapter 8 „Mainte-
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.
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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 and engine number
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2 Technical data
Technical data
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H
L
L1
W
B
B-924-0005
Technical data
Dimensions
Fig. 3
B H L L
350
(13.8)
Dimensions in millimetres
(Dimensions in inch)
Weights
Basic weight 57
Operating weight (CECE) 58
Travel characteristics
Max. working speed 20
1030
(40.6)
728
(28.7)
1
335
(13.2)
W
230
(9.1)
(126)
(128)
(66)
(lbs)
(lbs)
m/min
(ft/min)
kg
kg
Max. area output (depending on soil) 276
(2971)
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m2/h
(ft2/h)
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Technical data – Noise and vibration data
Drive
Engine manufacturer Honda
Type GXR 120
Cooling Air
Number of cylinders 1
Displacement 121
cm
3
Rated power SAE J 1349 2.8
(3.8)
Rated speed 4200
Exciter system
Drive system mechanical
Frequency 10 - 11.8
(600 - 708)
Impact force 15
(3372)
Filling capacities
Fuel (gasoline) 3.0
(0.8)
kW
(hp)
min
Hz
(bpm)
kN
(lbf)
(gal us)
-1
l
2.1 Noise and vibration data
2.1.1
tor's stand
Noise 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
ibration Protection Directive 2002/44/EU
n V
During operation these values may vary because of the prevailing operating conditions.
LpA = 93 dB(A), determined acc. to ISO 11201 and EN 500.Sound pressure level at the opera-
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Technical data – Noise and vibration data
WARNING! Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
L
Guaranteed sound power level
2.1.2 Vibration data
= 108 dB(A), determined acc. to ISO 3744 and EN 500.
W
A
protection).
Hand-arm vibration
Vector total of the weighted effective acceleration in three orthog­onal directions:
Total vibration value ahv = 4.8 m/s2 on crushed rock determined
acc. to EN 500/ISO 5349.
Associated uncertainty K = 0.7 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 vant 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 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.
, the operating company must obtain the rele-
. This also applies for local
,
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
ork in trenches
n W 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 Working in horizontal direction n Ramming of poles n Vibrating of paving blocks
It is not permitted to stand on the machine while working.
starting and operation of the machine in explosive environments and in underground mining is prohibited.
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Concerning your safety – Definition of responsible persons
3.2 Definition of responsible persons
3.2.1
Operating company
3.2.2 Expert / qualified person
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.
3.2.3 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
3.3.2 Regular safety inspections
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.
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 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. 4
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 – Handling fuels and lubricants
3.4.3
Fig. 5
Safety regulations and environmental protection regulations for handling gas­oline
DANGER! Danger to life caused by explosive gas-air
mixes!
– Do not allow gasoline to come into contact with
hot components.
–
Smoking and open fire is prohibited.
– Keep away from heat sources, sparks and
other sources of ignition.
– Do not spill any gasoline.
WARNING! Health hazard caused by contact with gasoline!
– Wear your personal protective outfit (protective
gloves, protective clothing). Do not inhale any fuel fumes.
– – Do not swallow gasoline. – Avoid contact with gasoline.
ENVIRONMENT! Gasoline is an environmentally hazardous sub-
stance!
– Always keep gasoline in proper containers.
Immediately bind spilled gasoline with an oil-
–
binding agent and dispose of in accordance with regulations.
– Dispose of gasoline and fuel filter according to
regulations.
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Concerning your safety – Handling fuels and lubricants
3.4.4
Safety regulations and environmental protection regulations for handling fuel stabiliser
WARNING! Danger of burning by ignited fuel stabilizer!
– Do not allow fuel stabilizer to come into contact
with hot components.
–
Smoking and open fire is prohibited.
WARNING! Health hazard caused by contact with fuel sta-
bilizer!
– Wear your personal protective outfit (protective
gloves, protective clothing). Do not inhale any fuel stabilizer fumes.
– – Do not swallow fuel stabilizer. – Avoid contact with fuel stabilizer.
ENVIRONMENT! Fuel stabilizer is an environmentally hazardous
substance!
– Immediately bind spilled fuel stabilizer with an
oil-binding agent and dispose of according to regulations.
Dispose of fuel stabilizer 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 of
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.
f.
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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.
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 are no persons inside the danger zone.
Keep your feet clear of the tamper foot plate.
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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3.6.3 Operation in trenches
Concerning your safety – Start-up procedure
Applies only to Germany.
The vibratory tamper or the vibratory plate were tested outdoors by BG Bau (Germany) regarding CO emissions. The tests were car­ried out in a trench with a width of 1.5 metres, a depth of 3 metres and a length of 10 metres.
These test showed CO emissions below the occupational exposure limit (OEL) according to TRGS 900 when operating a maximum of 4 times 15 minutes per shift (8 hours).
For this reason, take care to ensure sufficient ventilation when operating the vibratory tamper or vibratory plate in more than shoulder-deep trenches which have a width of less than
1.5 metres, a maximum depth of less than 3 metres or a maximum length of less than 10 metres.
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Concerning your safety – Operation
3.7 Operation
3.7.1
Persons in the danger area
3.7.2 Operation
3.7.3 Parking the machine
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.
Steer the machine only be the steering bow.
Guide the machine so hat 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.
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.
Keep away from ignition and heat sources.
Apply measures against electrostatic charging.
Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.
Wipe of
A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
f spilled fuel. Keep dirt and water away from the fuel.
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Concerning your safety – Maintenance work
3.9 Maintenance work
3.9.1
Preliminary remarks
3.9.2 Working on the engine
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 and the spark plug connector disconnected.
Make sure that the engine cannot be accidentally started during maintenance work.
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 Working on the tamper foot
Drain the tamper foot oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ­mentally.
Store oil contaminated materials in a separate, specially marked container and dispose of environmentally.
3.9.4 Cleaning work
Do not perform cleaning work while the motor is running.
Allow the engine to cool down before starting cleaning work.
Do not use gasoline or other easily inflammable substances for cleaning.
3.9.5 After maintenance work
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.
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OPERATION
STOP
1
2
6
2
3
4
1
2
1
5
=
=
Low Oil Level = No Start
Max: 0,3 l
18.3 in
3
3-6 Sec.
1-2 MINUTEN
MIN
MAX
3600 - 4200 min 1-2 MINUTEN
MIN
MAXMAX
3850 - 4200 min
-1
MIN
1850 - 2000 min
-1
-1
OFF
ON
OFF
ON
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Made in Germany
Ammerländer Str. 93 D-26203 Wardenburg
B-924-0006
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
34
DR6X
Page 35
Fig. 7
Concerning your safety – Signage
Warning sticker - Follow operating instructions
Warning sticker - Do not inhale exhaust gases
Do not operate inside closed areas.
Fig. 8
Fig. 9
Warning sign - Fire hazard
Fill up with fuel only when engine is stopped and has cooled down.
Instruction sticker - Wear ear defenders
Fig. 10
35
DR6X
Page 36
Concerning your safety – Signage
Information sticker - Lifting point
Fig. 11
Information sticker - Lashing point
Fig. 12
Fig. 13
Information sticker - Guaranteed sound capacity level
Information sticker - pre-tensioned spring
Fig. 14
36
DR6X
Page 37
Fig. 15
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
Brief operating instructions
Machine type plate (example)
Fig. 16
37
DR6X
Page 38
Concerning your safety – Signage
38
DR6X
Page 39
Indicators and control elements
4 Indicators and control elements
39
DR6X
Page 40
2
6
4
5
1
3
RUN
B-924-0007
Indicators and control elements
Fig. 17
1 Engine oil level warning light 2 Engine stop switch 3 Operating hour meter/engine rpm-meter 4 Throttle lever 5 Recoil starter 6 Choke lever
40
DR6X
Page 41
Checks prior to start up
5 Checks prior to start up
41
DR6X
Page 42
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 inef
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
fective.
tion regulations must be followed when han-
Ä
dling fuels and lubricants dling fuels and lubricants“ on page 23.
that the engine can not be started.
Chapter 3.4 „Han-
1.
Park the machine safely in secured condition“ on page 55.
Ä
Chapter 6.4 „Parking the machine
42
DR6X
Page 43
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.
43
DR6X
Page 44
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 65.
The engine cannot be started if the engine oil level is too low
.
Fig. 18
Protective equipment:
1. Park the machine so that the tamper foot is in horizontal posi­tion.
2. Clean the area around the oil dipstick (1).
3. Unscrew the dipstick and wipe it clean with a lint-free, clean
cloth.
4. Insert the dipstick into the oil filler socket, do not screw it in, but pull it out again to check the oil level.
5.
NOTICE! Danger of engine damage!
– Do not overfill the engine.
The oil level must always be between the "MIN"- and "MAX"­marks. If the oil level is too low immediately.
orking clothes
W
n
Protective gloves
n
, top up oil to the "MAX" mark
44
DR6X
Page 45
B-541-0068
Checks prior to start up – Checking the fuel level; topping up fuel
5.4 Checking the fuel level; topping up fuel
DANGER! Danger to life caused by explosive gas-air
mixes!
– Do not allow gasoline to come into contact with
hot components. Smoking and open fire is prohibited.
– – Keep away from heat sources, sparks and
other sources of ignition.
– Do not spill any gasoline.
NOTICE! Danger of engine damage!
– Monitor the entire refuelling process. – Contaminated fuel can cause malfunction or
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 65.
Fig. 19
Protective equipment:
orking clothes
W
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.
.
45
DR6X
Page 46
Checks prior to start up – Checking the rubber buffers
5.5 Checking the rubber buffers
Fig. 20
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Allow the engine to cool down.
3. Check all rubber buf
4. Replace damaged rubber buf
orking clothes
W
n
Protective gloves
n
Ä
Chapter 6.4
fers for tight fit, cracks and tear-offs.
fers immediately.
46
DR6X
Page 47
6 Operation
Operation
47
DR6X
Page 48
Operation – Adjusting the guide handle
6.1 Adjusting the guide handle
Adjust the guide handle to the size of the operator using bores (A) and (B):
(A) - Lower guide handle position
(B) - Upper guide handle position
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Disassemble the fastening screws and washers on both sides.
Fig. 21
3. Set the steering bow to the desired height.
4. Assemble the fastening screws and washers on both sides.
Ä
Chapter 6.4
48
DR6X
Page 49
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.
WARNING! Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
Fig. 22
Protective equipment:
The engine does not start if the oil level is too low.
The engine oil level warning lamp flashes when operating the recoil starter
1. Set the engine stop switch to position "ON".
Hearing protection
n
Safety shoes
n
.
Fig. 23
49
DR6X
Page 50
Operation – Starting the engine
Fig. 24
2. Set the throttle lever to position "MAX".
3. Close the choke.
Always close the choke to start a cold and warm engine.
Fig. 25
Fig. 26
4. Pull the rope by the starter handle, until resistance can be felt.
5. Guide the starter handle back to initial position.
50
DR6X
Page 51
Fig. 27
Operation – Starting the engine
6.
CAUTION! Danger of injury caused by uncontrolled
machine movement!
– Keep your feet clear of the tamper foot
plate.
–
Always hold on to a running machine.
– Always keep an eye on a running
machine.
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.
9. Open the choke 3 to 6 seconds after the engine has started running.
Fig. 28
Fig. 29
10. Set the throttle lever to position "MIN" and let the engine run at idle speed to warm up for 1 to 2 minutes.
NOTICE! Danger of engine damage!
– Warm up engine for a short while before
starting work. Do not operate the engine immediately under full load.
11. Should the engine stop again after approx. 3 to 5 seconds:
n Close the choke again. n Repeat the starting procedure.
51
DR6X
Page 52
Operation – Starting the engine
If the recoil starter is frequently operated with the choke closed, the engine will draw in too much fuel and is unable to start ( if the engine has flooded“ on page 105).
Ä
Chapter 10.3 „What to do
52
DR6X
Page 53
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.
For longer work breaks you should always park the machine is
Ä
safe condition dition“ on page 55.
Chapter 6.4 „Parking the machine in secured con-
CAUTION! Danger of injury caused by uncontrolled
machine movement!
– Keep your feet clear of the tamper foot plate. –
Always hold on to a running machine.
– Always keep an eye on a running machine.
WARNING! Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
Fig. 30
The layer thickness of the material to be com­pacted should not be higher than is possible for the vibratory tamper to cope with.
Protective equipment:
1. Set the throttle lever to position “MAX”.
The machine works with highest frequency.
ð
Hearing protection
n
Safety shoes
n
53
DR6X
Page 54
Operation – Operation
Fig. 31
2. To achieve uniform running you should actuate the throttle lever within the working range (I), depending on condition and density of the soil.
Working range (I) = 3600 to 4200 min
ð
-1
3. If the machine jumps out of rhythm on heavily compacted soil, you may need to slightly change the engine speed and/or inclination of the tamper.
NOTICE! The centrifugal clutch may be damaged!
– Do not work with engine speeds which are
below the working range.
4. If the display [LOW] appears, increase the engine speed.
Fig. 32
Fig. 33
5. Adapt the marching speed by applying load to the guide handle:
(A) No load - slowly forward
(B) Heavy load - fast forward
6. Always shift the throttle lever to position “MIN” for short work breaks.
Fig. 34
54
DR6X
Page 55
Operation – Parking the machine in secured condition
6.4 Parking the machine in secured condition
1. 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.
Fig. 35
2. Set the engine stop switch to position "OFF".
The engine is shut down.
ð
Fig. 36
Fig. 37
3. Park the machine so that it cannot turn over
4. Pull the rope by the starter handle, until resistance can be
felt. Guide the starter handle back to initial position.
This procedure protects against moisture deposits inside
ð
the engine.
.
55
DR6X
Page 56
Operation – Operating hour meter/engine rpm-meter
6.5 Operating hour meter/engine rpm-meter
Engine off Operating the function key (1) switches
between operating hours, hour counter and service indicator
Engine on Engine speed
If the remaining period until the next maintenance is under two hours, the maintenance indicator appears for approx. 30 seconds after starting the engine.
Fig. 38
Display Description
Engine speed in the working range
Engine speed below the working range.
Display [LOW] alternately displayed with the engine speed.
to increase the engine speed.
Operating hours
Hour meter
Maintenance display
[in ...] together with the remaining period (in hours) until the next maintenance.
Set maintenance intervals:
n after the first 25 operating hours n then every 100 operating hours
56
DR6X
Page 57
Operation – Operating hour meter/engine rpm-meter
Resetting the maintenance indi­cator / hour meter
Fig. 39
1. Shut down the engine.
2. Keep pressing the function key (1), until the maintenance
indicator or the hour meter is displayed.
3. Press the function key for three seconds.
The maintenance indicator is reset to 100 hours.
ð
The hour meter is reset to zero hours.
57
DR6X
Page 58
Operation – Operating hour meter/engine rpm-meter
58
DR6X
Page 59
Loading/transporting the machine
7 Loading/transporting the machine
59
DR6X
Page 60
B-541-0018
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 and lashing tackle with sufficient load bearing capacity for the weight to be loaded. Minimum load bearing capacity of lifting tackle: see operating weight nical data“ on page 11.
Always use appropriate lifting and lashing tackle at the lifting and 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:
Protective gloves
n
Safety shoes
n
Ä
Chapter 2 „Tech-
Fig. 40
1.
Park the machine safely in secured condition“ on page 55.
2. Make sure that no fuel will be spilled from the tank during transport:
n Close the fuel tank tightly n Consider the filling quantity in the tank in case of temper-
ature fluctuations (pressure relief valve in tank lid); drain off fuel if necessary.
3. Attach the lifting tackle to the dedicated lifting eye.
4.
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.
Ä
Chapter 6.4 „Parking the machine
.
60
DR6X
Page 61
B-541-0017
Fig. 41
Loading/transporting the machine – Loading the machine
5.
WARNING! Danger of burning on hot components!
– Wear your personal protective equipment
(protective gloves, protective clothing).
–
Avoid touching hot components.
Lay the machine on the rollers.
61
DR6X
Page 62
B-541-0019
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.
Use lifting tackle only in the specified loading direction.
Lifting tackle must not be damaged by machine parts.
Protective equipment:
WARNING! Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing). Avoid touching hot components.
–
1. Lean the tamper foot against the side wall of the transport vehicle.
2. Fasten the tamper on the transport vehicle with at least two suitable lashing belts.
Protective gloves
n
Safety shoes
n
Fig. 42
62
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Page 63
8 Maintenance
Maintenance
63
DR6X
Page 64
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
work work“ on page 32.
WARNING! Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations must be followed when han­dling fuels and lubricants
dling fuels and lubricants“ on page 23.
Chapter 3.9 „Maintenance
Ä
Chapter 3.4 „Han-
Wear your personal protective equipment.
Do not touch hot components.
Park the machine on horizontal, level, firm ground.
Secure the machine against accidental tipping over.
Perform maintenance work only with the engine shut down and the spark plug connector disconnected.
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.
64
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Page 65
8.2 Fuels and lubricants
Maintenance – Fuels and lubricants
8.2.1
8.2.1.1 Oil quality
8.2.1.2
Fig. 43
Engine oil
Oil viscosity
The following engine oil specifications are permitted:
n Engine oils for four-stroke engines acc. to API-classification SJ
or higher
Avoid mixing of 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 refers to fresh oils. In travel operation engine oil ages because of soot and fuel resi­dues. This adversely affects the properties of the engine oil, espe­cially under low ambient temperatures.
SAE 10W-30 is recommended for general use.
You may alternatively use 15W-40 (except under low tempera­tures).
8.2.1.3 Oil change intervals
8.2.2 Fuel
8.2.2.1 Fuel quality
Oil change interval: semi-annually or every 100 operating hours.
Use unleaded gasoline with a research octane number of 91 or higher (or octane number 86 or higher).
Use unleaded standard grade gasoline with maximum 10 percent by volume of ethanol (E10) or maximum 5 percent by volume of methanol.
Methanol must also contain co-solvents and corrosion inhibitors.
Do not use any fuel with a higher ethanol or methanol content.
The use of fuels with a higher ethanol or methanol content will cause starting and/or power problems or even cause damage in the fuel system.
65
DR6X
Page 66
Maintenance – Fuels and lubricants
8.2.2.2 Fuel stabilizer
If the machine is only occasionally used (if it is out of use for longer than four weeks), mix in the correct amount of fuel stabilizer directly after you have purchased fresh fuel.
The fuel stabilizer has a limited shelf life.
Please follow the instructions of the manufacturer concerning the correct mixing ratio and shelf life.
Mixing in fuel stabilizer does not regenerate old fuel.
8.2.3
Gear oil SAE 75W-90
Use a fully synthetic gear oil in accordance with SAE 75W-90, API GL5 with a kinematic viscosity of at least 16 mm2/s at 100 °C (212 °F).
66
DR6X
Page 67
8.3 List of fuels and lubricants
Maintenance – List of fuels and lubricants
Assembly group Fuel or lubricant Spare parts
Summer Winter Observe the
Engine oil SAE 10W-30
Specification:
SAE 30
Fuel Gasoline (unleaded)
Specification:
Specification:
Tamper foot SAE 75W-90, API GL-5
Specification:
Ä
Chapter 8.2.1 „Engine
oil“ on page 65
Ä
Chapter 8.2.2
„Fuel“ on page 65
Fuel stabilizer
Ä
Chapter 8.2.2.2 „Fuel stabil-
izer“ on page 66
Ä
Chapter 8.2.3 „Gear oil SAE
75W-90“ on page 66
number
0.3 l
3 l
as required
0.75 l
Filling quantity
level mark!
(0.08 gal us)
(0.8 gal us)
(0.20 gal us)
67
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Page 68
Maintenance – Running-in instructions
8.4 Running-in instructions
8.4.1
General
8.4.2 After 25 operating hours
The following maintenance work must be performed when running in new machines or overhauled engines.
NOTICE! Danger of engine damage!
– Up to approx. 250 operating hours check the
engine oil level twice every day
Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours.
1.
Change the engine oil oil“ on page 75.
2. Check the idle speed and the max. speed of the engine, adjust if necessary engine speed“ on page 89.
3. Check engine and machine for leaks.
4. Retighten the fastening screws on air filter
attachments.
5. Retighten the bolted connections on the machine.
Ä
Chapter 8.8.1 „Changing the engine
Ä
Chapter 8.9.6 „Checking, adjusting the
.
, exhaust and other
68
DR6X
Page 69
Maintenance – Maintenance Table
8.5 Maintenance Table
No. Maintenance works Page
Weekly
8.6.1 Checking, cleaning the air filter 70
Monthly
8.7.1 Checking the tamper foot 73
Semi-annually
8.8.1 Changing the engine oil 75
Annually
8.9.1 Checking, adjusting the valve clearance 76
8.9.2 Replacing the spark plug 81
8.9.3 Replacing the fuel filter 82
8.9.4 Cleaning the fuel screen 85
8.9.5 Replacing the air filter 87
8.9.6 Checking, adjusting the engine speed 89
8.9.7 Replacing the starter rope 92
8.9.8 Changing the oil in the tamper foot 94
As required
8.10.1 Cleaning the machine 96
8.10.2 Checking, cleaning the spark plug 96
69
DR6X
Page 70
2
1
B-541-0073
B-GEN-0042
Maintenance – Weekly
8.6 Weekly
8.6.1
Checking, cleaning the air filter
Protective equipment:
1.
2. Allow the engine to cool down.
NOTICE! Danger of engine damage!
– Never start the engine after removing the air
.
filter – Do not let dirt drop into the air duct. – Do not continue using a damaged or soiled air
filter. If in doubt use a new air filter.
orking clothes
W
n
Safety shoes
n
Protective gloves
n
Safety goggles
n
Ä
Park the machine safely in secured condition“ on page 55.
Chapter 6.4 „Parking the machine
Fig. 44
Fig. 45
Fig. 46
3. Disassemble the cover (1) and air filter (2).
4. Clean the cover
5.
Blow the air filter out with dry compressed air (max. 6 bar (87 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust.
6. Check seals and air filter for damage.
7. Replace the air filter if it is damaged.
8. Insert the air filter and reassemble the cover.
.
CAUTION! Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
70
DR6X
Page 71
B-924-0008
Fig. 47
1
3
2
B-541-0072
1
2
B-541-0081
B-541-0082
Maintenance – Weekly
9. Disassemble the left engine guard.
10. Pull the air feed hose (1) and the hose clamp (2) off the cover
(3).
Fig. 48
Fig. 49
Fig. 50
11. Unscrew the fastening screws (1).
12. Disassemble the cover and air filter (2).
13. Wipe the inside of the air filter housing with a clean cloth.
14. 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 from inside to outside with dry com­pressed air (max.
2 bar (29 psi)), until all dust has been
removed.
15. Check seals and air filter for damage.
16. Replace the air filter if it is damaged.
71
DR6X
Page 72
1
2
B-541-0097
3 Nm
1
3
2
B-541-0072
B-924-0008
Maintenance – Weekly
Fig. 51
17. Slide the air filter (2) carefully into the housing.
18. Assemble the cover (3) with fastening screws (1), tightening
torque: 3 Nm (2 ft·lbf).
19. Connect the air hose (1) with the hose clamp (2) to the cover
(3).
Fig. 52
Fig. 53
20. Assemble the left engine guard.
72
DR6X
Page 73
8.7 Monthly
Maintenance – Monthly
8.7.1
Checking the tamper foot
NOTICE! Components may get damaged!
– Use only oil of the permitted specification
Ä
Chapter 8.3 „List of fuels and lubri-
cants“ on page 67.
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Park the machine so that the tamper foot is in horizontal posi-
tion.
3. Allow the machine to cool down.
4. Clean the sight glass.
5. Check the oil level.
6. The oil must be visible between the middle and the upper
edge of the oil level inspection glass, if necessary top up oil up to the bottom edge of the filling opening.
orking clothes
W
n
Protective gloves
n
Ä
Chapter 6.4
Fig. 54
Fig. 55
The upper edge of the inspection glass equals the bottom edge of the oil filling bore.
7. Check concertina wall for condition, damage and tight fit.
8. Check the hose clamps for tight fit, tightening torque for
screws (1): 10 Nm (7.4 ft·lbf).
73
DR6X
Page 74
Maintenance – Monthly
Fig. 56
9. Retighten 4 screws (1) on the tamper foot plate, tightening
torque: 60 - 70 Nm (44 - 52 ft·lbf).
10. Retighten 5 screws (1) on the tamper foot plate, tightening
torque: 15 Nm
(11 ft·lbf).
Fig. 57
74
DR6X
Page 75
8.8 Semi-annually
Maintenance – Semi-annually
8.8.1
Changing the engine oil
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 65.
Ä
– Filling quantity:
lubricants“ on page 67
Protective equipment:
1.
Park the machine in secured condition Ä Chapter 6.4 „Parking the machine in secured condition“ on page 55.
2. Park the machine so that the tamper foot is in horizontal posi-
tion.
3. WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment
–
n n
(protective gloves, protective clothing). Avoid touching hot components.
Chapter 8.3 „List of fuels and
orking clothes
W Protective gloves
Fig. 58
Fig. 59
Clean the area around oil dipstick (1) and drain plug (3).
4. Unscrew the oil dipstick.
5. Unscrew the drain plug and collect any oil running out.
6. Clean the oil drain plug and screw it back in with a new seal
ring (2).
7. Fill in fresh oil up to the bottom edge of the filler bore.
8. Push the oil dipstick (1) back in.
9. Check for leaks after a short test run.
10. Check the oil level on the dipstick, correct if necessary
11. Dispose of oil in an environmentally friendly way
.
.
75
DR6X
Page 76
1
3
2
B-541-0072
2
1
B-541-0073
Maintenance – Annually
8.9 Annually
8.9.1
Preparations
Checking, adjusting the valve clearance
NOTICE! Danger of engine damage!
e recommend to have this work carried out by
W trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down.
Protective equipment:
1.
Park the machine safely in secured condition“ on page 55.
2. Let the engine cool down to ambient temperature.
3. Pull the air feed hose (1) and the hose clamp (2) of
(3).
orking clothes
W
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.4 „Parking the machine
f the cover
Fig. 60
4. Disassemble the cover (1) and air filter (2).
Fig. 61
76
DR6X
Page 77
Fig. 62
Maintenance – Annually
5. Disassemble the guide handle fastening screws.
6. NOTICE!
Components may get damaged!
– Do not tear off any hoses or cables.
Remove the guide handle and secure it to the housing with a fastening screw
Tighten the fastening screw hand-tight.
.
Fig. 63
Fig. 64
1 Pipe clamp 2 Screw M6x18 3 Screw M6x14 4 Screw M6x18
7. Disassemble the recoil starter
.
77
DR6X
Page 78
Maintenance – Annually
Fig. 65
8. If necessary, remove the spacer ring (2) from the engine.
Checking, adjusting the valve clear­ance
Fig. 66
Valve clearance:
Intake valve (IN) 0.15 mm (0.006 in)
Exhaust valve (EX) 0.20 mm (0.008 in)
1. Unscrew the fastening screws for the cylinder head cover
2. NOTICE!
Components may get damaged!
– Do not apply force to remove the cylinder
head cover
.
.
Fig. 67
Insert a screwdriver into the recess and lever the cylinder head cover carefully of
3. Check the cylinder head cover for damage.
4. Replace a damaged or bent cylinder head cover
78
DR6X
f.
.
Page 79
Fig. 68
Maintenance – Annually
5. Align the alignment mark on the flywheel rib with the top bore
of the fan cover.
The piston is in top dead centre position of the compres-
ð
sion stroke.
6. However, if the exhaust valve is open when aligning the
marks, the flywheel must be turned further by 360°.
7. Check the valve clearance with a feeler gauge (2).
8. T
9. T
10. Retighten the locking nut, tightening torque:
o adjust the valve, hold the valve adjustment screw (1) and
loosen the locking nut (3).
urn the valve adjustment screw in or out, as required.
8 Nm (6 ft·lbf).
Fig. 69
Fig. 70
11. Clean the sealing faces on cylinder head cover and cylinder
block.
12. Apply a bead of liquid sealant, approx.
(0.06 to 0.08 in) in diameter, to the inner side of the cylinder head cover.
Liquid sealant: Three Bond 1207B or similar.
13. Attach the cylinder head cover to the cylinder block within the
next 10 minutes.
14. T
ighten the fastening screws.
1.5 to 2.0 mm
Fig. 71
79
DR6X
Page 80
Maintenance – Annually
Concluding work
Fig. 72
1. Clip in the spacer ring (2) on the recoil starter (1).
2. NOTICE!
The recoil starter may get damaged!
– Do not mix up the fastening screws for
the recoil starter by mistake.
Fig. 73
1 Pipe clamp 2 Fastening screw M6x18 3 Fastening screw M6x14 4 Fastening screw M6x18
Fig. 74
Assemble the recoil starter.
3. Attach the guide handle and tighten the right hand fastening
screws hand-tight.
80
DR6X
Page 81
1
3
2
B-541-0072
Fig. 75
2
1
B-541-0073
Maintenance – Annually
4. Connect the air hose (1) with the hose clamp (2) to the cover
(3).
Fig. 76
Fig. 77
5. Assemble the fastening screws, tightening torque:
(37 ft·lbf).
6. Assemble air filter (2) and cover (1).
7. W
8. After a short test run, check the engine for leaks.
ait another 20 minutes before starting the engine.
50 Nm
8.9.2
Replacing the spark plug
NOTICE! Danger of engine damage!
– Do not use spark plugs with incorrect heat
value.
Recommended spark plugs:
NGK CR5HSB
DENSO U16FSR-UB
81
DR6X
Page 82
Maintenance – Annually
Fig. 78
8.9.3 Replacing the fuel filter
Protective equipment:
Special tool:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Allow the engine to cool down for at least
3. Pull of
4. Clean the area around the spark plug.
5. Unscrew the spark plug with a
6. Check the electrode gap of the new spark plug with a feeler
7. Carefully screw in the spark plug by hand.
8. Once the sealing surface of the new spark plug is in contact,
f the spark plug connector (1).
(2).
gauge, if necessary
Nominal value: 0.6 - 0.7 mm (0.024 - 0.028 in)
ð
tighten for another
orking clothes
W
n
Protective gloves
n
16 mm spark plug spanner
n
Ä
Chapter 6.4
15 minutes.
16 mm spark plug spanner
, adjust the gap.
1/2 turn with the spark plug spanner.
Preparations
DANGER! Danger to life caused by explosive gas-air
mixes!
– Do not allow gasoline to come into contact with
hot components.
–
Smoking and open fire is prohibited.
– Keep away from heat sources, sparks and
other sources of ignition.
– Do not spill any gasoline.
Protective equipment:
1.
Park the machine safely in secured condition“ on page 55.
n n n
orking clothes
W Safety shoes Protective gloves
Ä
Chapter 6.4 „Parking the machine
82
DR6X
Page 83
Fig. 79
B-924-0008
Maintenance – Annually
3. Set the engine stop switch to position “OFF”.
The fuel valve is closed.
ð
4. Disassemble the left engine guard.
Fig. 80
Disassembling the fuel filter
Fig. 81
5. Loosen the hose clamps (1) and (4) and pull the fuel hoses
of
f the fuel filter (2).
6. Loosen fastening screw (3).
7. T
ake off the old fuel filter.
83
DR6X
Page 84
B-924-0008
Maintenance – Annually
Assembling the fuel filter and filling it with fuel
Fig. 82
8. Install the new fuel filter (2) by observing the flow direction.
9. Tighten the fastening screw (3), tightening torque: 10 Nm
(7.4 ft·lbf).
10. Connect the lower fuel hoses to the fuel filter with hose clamp
(4).
11. Open the fuel valve (engine stop switch in position “ON”),
until the fuel filter is filled with fuel.
12. Close the fuel valve (engine stop switch in position “OFF”).
13. Connect the upper fuel hose to the fuel filter with the hose
clamp (1).
Fig. 83
Concluding work
Fig. 84
14. Assemble the left engine guard.
15. Dispose of fuel and fuel filters in line with environmental reg-
ulations.
84
DR6X
Page 85
8.9.4 Cleaning the fuel screen
Maintenance – Annually
DANGER! Danger to life caused by explosive gas-air
mixes!
– Do not allow gasoline to come into contact with
hot components.
–
Smoking and open fire is prohibited.
– Keep away from heat sources, sparks and
other sources of ignition.
– Do not spill any gasoline.
Fig. 85
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Loosen hose clamp (1) and pull the fuel hoses of
valve (2).
3. Open the fuel valve (engine stop switch in position "ON") and
catch runni9ng out fuel.
orking clothes
W
n
Protective gloves
n
Ä
Chapter 6.4
f the fuel
Fig. 86
85
DR6X
Page 86
Maintenance – Annually
Fig. 87
4. Unscrew the screws (2) and remove the engine stop switch
(1).
5. Unscrew the fuel valve (2) and remove the seal (1).
6. Clean the screen and check for damage.
7. Replace the fuel valve if damaged.
8. Assemble the fuel valve with a new seal
Fig. 88
Fig. 89
9. Assemble the engine stop switch (1) with screws (2).
10. Connect the fuel hose with the hose clamp (1) to the fuel
valve (2).
Fig. 90
86
DR6X
Page 87
Fig. 91
2
1
B-541-0073
8.9.5 Replacing the air filter
Maintenance – Annually
11. Close the fuel valve (engine stop switch in position "OFF").
12. Dispose of fuel environmentally.
NOTICE! Danger of engine damage!
– Do not start the engine after having removed
the air filter
.
Fig. 92
Protective equipment:
1.
Park the machine safely in secured condition“ on page 55.
2. Allow the engine to cool down.
3. Disassemble the cover (1) and air filter (2).
4. Clean the cover
5. Replace the air filter
6. Insert the air filter and reassemble the cover
.
orking clothes
W
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.4 „Parking the machine
.
.
87
DR6X
Page 88
B-924-0008
1
3
2
B-541-0072
1
2
B-541-0081
1
2
B-541-0097
3 Nm
Maintenance – Annually
Fig. 93
7. Disassemble the left engine guard.
8. Pull the air feed hose (1) and the hose clamp (2) off the cover
(3).
Fig. 94
Fig. 95
9. Unscrew the fastening screws (1).
10. Disassemble the cover and air filter (2).
11. Wipe the inside of the air filter housing with a clean cloth.
12. Replace the air filter
.
13. Slide the air filter (2) carefully into the housing.
14. Assemble the cover with fastening screws (1), tightening
torque: 3 Nm (2 ft·lbf).
Fig. 96
88
DR6X
Page 89
1
3
2
B-541-0072
Fig. 97
B-924-0008
Maintenance – Annually
15. Connect the air hose (1) with the hose clamp (2) to the cover
(3).
16. Assemble the left engine guard.
Fig. 98
8.9.6
8.9.6.1 Checking the engine speed
Preparations
Checking the engine speed
Checking, adjusting the engine speed
1.
Replace the air filter filter“ on page 87.
2.
Check the engine oil level engine oil level“ on page 44.
Protective equipment:
CAUTION! Danger of injury caused by uncontrolled
machine movement!
– Keep your feet clear of the tamper foot plate. –
Always hold on to a running machine.
– Always keep an eye on a running machine.
Ä
Chapter 8.9.5 „Replacing the air
Ä
Chapter 5.3 „Checking the
Hearing protection
n
Safety shoes
n
WARNING! Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
89
DR6X
Page 90
Maintenance – Annually
Fig. 99
Nominal values:
Idle speed
Maximum engine speed
1850 to 2000 min
3850 to 4200 min
-1
-1
1. Start the engine and run it warm for approx. 15 minutes.
2. Run the machine on ground that can be compacted.
3. Set the throttle lever to position “MIN”.
Fig. 100
Fig. 101
4. After approx. 30 to 40 seconds read the idle speed from the
engine rpm-meter
.
5. Set the throttle lever to “MAX” position.
6. After approx. 30 to 40 seconds read the max. speed from the
engine rpm-meter
7. If necessary
.
, adjust the idle speed or maximum speed as
required.
90
DR6X
Page 91
8.9.6.2 Adjusting the engine speed
B-924-0008
B-924-0008
Maintenance – Annually
Fig. 102
Protective equipment:
1.
Park the machine safely
orking clothes
W
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.4 „Parking the machine
in secured condition“ on page 55.
2. Disassemble the left engine guard.
3. WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment
(protective gloves, protective clothing).
–
Avoid touching hot components.
Fig. 103
Fig. 104
Adjust the idle speed using the stop screw (2) on the throttle lever.
4. Adjust the maximum speed via the stop screw (1).
5. Secure the stop screws with counter nuts.
Adjust the throttle cable, if this should be necessary
.
6. Assemble the left engine guard.
91
DR6X
Page 92
Maintenance – Annually
8.9.7 Replacing the starter rope
Fig. 105
1 Pipe clamp 2 Screw M6x18 3 Screw M6x14 4 Screw M6x18
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Allow the engine to cool down.
3. Disassembling the recoil starter
4. Pull the starter rope with the starter handle out completely
orking clothes
W
n
Protective gloves
n
Ä
Chapter 6.4
.
.
Fig. 106
Fig. 107
5. If the starter rope has been torn or the coil has recoiled com-
pletely:
n Before assembling the rope, turn the coil (2) 5 revolutions
in anti-clockwise direction and align the rope openings in coil and housing (5) to one another (A).
92
DR6X
Page 93
Fig. 108
Fig. 109
Maintenance – Annually
6. Secure the coil against winding up. For this purpose tie the
coil (2) to the housing (5) with a cable strap (1).
7. Untie the knots of the starter rope at both ends and remove
the old starter rope.
8. Thread in the new starter rope (3) and fix it with knots on
both ends.
9. CAUTION!
Danger of injury caused by the starter handle hitting against your body!
– Do not let the starter handle hit back.
Remove the fixing of the coil and run the starter handle slowly back to initial position.
10. Pull the starter handle to check the function and light move-
ment of the recoil starter.
Fig. 110
Fig. 111
1 Pipe clamp 2 Screw M6x18 3 Screw M6x14
11. Clip in the spacer ring (2) on the recoil starter (1).
12. NOTICE!
The recoil starter may get damaged!
– Do not mix up the fastening screws for
the recoil starter by mistake.
Assemble the recoil starter.
93
DR6X
Page 94
Maintenance – Annually
4 Screw M6x18
8.9.8 Changing the oil in the tamper foot
NOTICE! Components may get damaged!
– Drain tamper foot oil only at operating tempera-
ture.
–
Ensure strict cleanliness.
– Use only tamper oil of the permitted specifica-
tion.
Ä
– Filling quantity:
lubricants“ on page 67.
Chapter 8.3 „List of fuels and
Protective equipment:
WARNING! Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
–
Avoid touching hot components.
1.
Park the machine safely in secured condition“ on page 55.
2. Clean the area around filler and drain plug.
3. Unscrew the drain plug, tilt the machine backward and collect
running out oil.
4. Stand the tamper on its foot again and secure it against tip-
ping over
5. Clean the drain plug and screw it in with sealing agent (low-
strength, e.g. spare parts number DL 009 700 16
.
orking clothes
W
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.4 „Parking the machine
).
Fig. 112
94
DR6X
Page 95
Fig. 113
Maintenance – Annually
7. Fill in fresh oil up to the bottom edge of the filler bore.
8. Clean the filling plug and screw it back in with a new seal
ring.
10. Check the oil level in the inspection glass, correct if neces-
sary
.
The upper edge of the inspection glass equals the bottom edge of the oil filling bore.
11. Dispose of oil in line with environmental regulations.
Fig. 114
95
DR6X
Page 96
OFF
ON
START
OIL
B-541-0084
Maintenance – As required
8.10 As required
8.10.1
Cleaning the machine
NOTICE! Danger of engine damage caused by reduced
cooling!
– Immediately remove any oil or fuel leaks near
fuel tank, cylinders or cooling air intake.
Protective equipment:
1.
Park the machine safely
orking clothes
W
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.4 „Parking the machine
in secured condition“ on page 55.
2. Allow the engine to cool down.
NOTICE! Components can be damaged by water
entering into the system!
– Do not guide the water jet directly into the air
intake and the recoil starter .
3. Clean the machine with a water jet.
4. W
arm up the engine for a while to avoid corrosion.
Fig. 115
8.10.2 Checking, cleaning the spark plug
NOTICE! Danger of engine damage!
– Do not use spark plugs with incorrect heat
value.
96
DR6X
Page 97
Maintenance – As required
Fig. 116
Protective equipment:
Special tool:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Allow the engine to cool down for at least
3. Pull of
4. Clean the area around the spark plug.
5. Unscrew the spark plug with a
6. Check the condition of the spark plug, clean if necessary
7. In case of excessive combustion residues or burned of
f the spark plug connector (1).
(2).
trodes, replace the spark plug the spark plug“ on page 81.
orking clothes
W
n
Protective gloves
n
16 mm spark plug spanner
n
Ä
16 mm spark plug spanner
Ä
Chapter 8.9.2 „Replacing
Chapter 6.4
15 minutes.
f elec-
.
Fig. 117
8. Check the electrode gap of the spark plug with a feeler
gauge, if necessary
Nominal value: 0.6 - 0.7 mm (0.024 - 0.028 in)
ð
9. Carefully screw in the spark plug by hand.
10. Once the sealing surface of the used spark plug is in contact,
tighten for another spanner.
, adjust the gap.
1/8 to 1/4 turn with the spark plug
97
DR6X
Page 98
Maintenance – As required
98
DR6X
Page 99
9 Setting up / refitting
Setting up / refitting
99
DR6X
Page 100
Setting up / refitting – Changing the tamper foot plate
9.1 Changing the tamper foot plate
Only use genuine spare parts when changing the tamper foot plate to a different width.
Fig. 118
Protective equipment:
1.
Park the machine in secured condition „Parking the machine in secured condition“ on page 55.
2. Allow the machine to cool down.
3. Lay the machine carefully on the rollers.
4. Unscrew the fastening screws.
5. T
6. Fasten the new tamper foot plate with the fastening screws,
7.
ake off the tamper foot plate and lay the tamper foot on the
floor.
tightening torque:
Check the engine speed, readjust if necessary
8.9.6 „Checking, adjusting the engine speed“ on page 89.
Protective gloves
n
orking clothes
W
n
Ä
Chapter 6.4
60 bis 70 Nm (44 bis 52 ft·lbf).
Ä
Chapter
Fig. 119
100
DR6X
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