Page 1
Operang Ins
trucon
Original Oper
DTR100
alk behind twin drum roller
W
ang Instrucons
S/N 861 924 75 1001> / S/N 861 924 76 1001>
DL8 203 77 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
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil............. 26
3.4.5 Safety regulations and environmental protection regulations for handling battery acid............. 27
3.4.6 Safety regulations and environmental protection regulations when handling lubrication
grease........................................................................................................................................ 28
3.5 Loading / transporting the machine.......................................................................................... 29
3.6 Start-up procedure...................................................................................................................... 30
3.6.1 Prior to starting up...................................................................................................................... 30
3.6.2 Starting the engine..................................................................................................................... 30
3.7 Operation..................................................................................................................................... 31
3.7.1 Persons in the danger area........................................................................................................ 31
3.7.2 Operation................................................................................................................................... 31
3.7.3 Driving up and down slopes....................................................................................................... 31
3.7.4 Working with vibration................................................................................................................ 31
3.7.5 Parking the machine.................................................................................................................. 32
3.8 Refuelling..................................................................................................................................... 33
3.9 Emergency procedures.............................................................................................................. 34
3.10 Maintenance work..................................................................................................................... 35
3
DTR100
Page 4
Table of contents
3.10.1 Preliminary remarks................................................................................................................. 35
3.10.2 Working on hydraulic lines....................................................................................................... 35
3.10.3 Working on the engine............................................................................................................. 35
3.10.4 Maintenance work on electric components and battery........................................................... 36
3.10.5 Cleaning work.......................................................................................................................... 36
3.10.6 After maintenance work........................................................................................................... 36
3.11 Repair......................................................................................................................................... 37
3.12 Signage...................................................................................................................................... 38
4 Indicators and control elements........................................................................................................ 43
4.1 Machine........................................................................................................................................ 44
4.1.1 Travel lever................................................................................................................................ 44
4.1.2 Throttle lever.............................................................................................................................. 44
4.1.3 Vibration lever............................................................................................................................ 44
4.1.4 Reversing protection.................................................................................................................. 45
4.1.5 Parking brake lever.................................................................................................................... 45
4.1.6 Starter switch............................................................................................................................. 45
4.1.7 Water spraying system............................................................................................................... 46
4.2 Engine.......................................................................................................................................... 47
4.2.1 Fuel valve................................................................................................................................... 47
4.2.2 Decompression lever................................................................................................................. 47
4.2.3 Recoil starter.............................................................................................................................. 47
5 Checks prior to start up...................................................................................................................... 49
5.1 Notes on safety........................................................................................................................... 50
5.2 Visual inspections and function tests....................................................................................... 51
5.3 Checking the engine oil level..................................................................................................... 52
5.4 Checking the fuel level; topping up fuel................................................................................... 53
5.5 Checking the hydraulic oil level................................................................................................ 54
5.6 Checking the rubber buffers...................................................................................................... 55
5.7 Checking the water level, topping up........................................................................................ 56
6 Operation............................................................................................................................................. 57
6.1 Adjusting the steering rod......................................................................................................... 58
6.2 Starting the engine...................................................................................................................... 59
6.3 Travel operation.......................................................................................................................... 62
6.4 Operation..................................................................................................................................... 64
6.4.1 Preliminary remarks and safety notes........................................................................................ 64
6.4.2 Working with vibration................................................................................................................ 64
6.5 Water spraying system............................................................................................................... 67
6.6 Parking the machine in secured condition............................................................................... 68
7 Loading / transporting the machine.................................................................................................. 71
7.1 Loading the machine.................................................................................................................. 72
7.2 Lashing the machine to the transport vehicle.......................................................................... 73
7.3 Loading by crane........................................................................................................................ 74
7.4 After transport............................................................................................................................. 75
8 Maintenance........................................................................................................................................ 77
8.1 Preliminary remarks and safety notes...................................................................................... 78
4
DTR100
Page 5
Table of contents
8.2 Fuels and lubricants................................................................................................................... 79
8.2.1 Engine oil................................................................................................................................... 79
8.2.2 Fuel............................................................................................................................................ 79
8.2.3 Hydraulic oil................................................................................................................................ 80
8.2.4 Lubrication grease...................................................................................................................... 81
8.3 List of fuels and lubricants........................................................................................................ 82
8.4 Running-in instructions.............................................................................................................. 83
8.4.1 General...................................................................................................................................... 83
8.4.2 After 25 operating hours............................................................................................................. 83
8.5 Maintenance Table...................................................................................................................... 84
8.6 Weekly.......................................................................................................................................... 85
8.6.1 Checking, cleaning the air filter.................................................................................................. 85
8.6.2 Draining the fuel tank sludge...................................................................................................... 87
8.7 Semi-annually.............................................................................................................................. 88
8.7.1 Battery service........................................................................................................................... 88
8.7.2 Servicing the V-belt.................................................................................................................... 89
8.7.3 Servicing the toothed belt........................................................................................................... 90
8.7.4 Greasing the gears..................................................................................................................... 92
8.8 Annually....................................................................................................................................... 93
8.8.1 Checking, adjusting the valve clearance.................................................................................... 93
8.8.2 Changing engine oil and oil filter element.................................................................................. 94
8.8.3 Replacing the fuel filter............................................................................................................... 96
8.8.4 Replacing the V-belt................................................................................................................... 98
8.8.5 Replacing the toothed belt......................................................................................................... 99
8.8.6 Replacing the air filter.............................................................................................................. 101
8.9 Every 2 years............................................................................................................................. 103
8.9.1 Changing hydraulic oil and hydraulic oil filter........................................................................... 103
8.10 As required.............................................................................................................................. 105
8.10.1 Cleaning the water spraying system...................................................................................... 105
8.10.2 Adjusting the scrapers............................................................................................................ 107
8.10.3 Cleaning the machine............................................................................................................ 107
8.10.4 Cleaning the cooling fins and the cooling air intake openings............................................... 108
8.10.5 Measures if there is a risk of frost.......................................................................................... 109
8.10.6 Measures prior to extended shut-down period....................................................................... 109
9 Troubleshooting................................................................................................................................ 113
9.1 Preliminary remarks.................................................................................................................. 114
9.2 Starting the engine with the recoil starter.............................................................................. 115
9.3 Starting the engine with jump leads........................................................................................ 118
9.4 Engine malfunctions................................................................................................................. 119
10 Disposal............................................................................................................................................. 121
10.1 Final shut-down of machine................................................................................................... 122
5
DTR100
Page 6
Table of contents
6
DTR100
Page 7
1 Introduction
Introduction
7
DTR100
Page 8
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 43.
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 57.
Before every start up, carry out all required visual inspections and
function tests Ä Chapter 5 „Checks prior to start up“ on page 49.
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 77.
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-
8
DTR100
Page 9
Introduction – Foreword
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of Dynapac GmbH.
We wish you successful work with your Dynapac machine.
9
DTR100
Page 10
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:
Engine number:
Fig. 2: Engine type plate
10
DTR100
Page 11
2 Technical data
Technical data
11
DTR100
Page 12
Technical data
Dimensions
Fig. 3
A B C D H H
620
(24.4)
865
(34.1)
250
(9.8)
500
(19.7)
1100
(43.3)
1
1159
(45.6)
K L L
128
(5.0)
2910
(114.6)
1
O S W
3010
(118.5)20(0.8)10(0.4)
750
(29.5)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (CECE) 1040
(2293)
Basic weight 1010
(2227)
Mean axle load (CECE) 520
(1146)
Average static linear load (CECE) 6.9
(39)
kg
(lbs)
kg
(lbs)
kg
(lbs)
kg/cm
(pli)
12
DTR100
Page 13
Technical data
Travel characteristics
Max. travel speed forward 5.0
(3.1)
Max. travel speed reverse 2.5
(1.6)
km/h
(mph)
km/h
(mph)
Max. gradability without/with vibration (soil dependent) 40/35 %
Drive
Engine manufacturer Yanmar
Type L100
Cooling Air
Number of cylinders 1
Rated power ISO 3046 6.2
(8.3)
Rated speed 3100
kW
(hp)
min
Drive system hydrostatic
Driven drums front + rear
-1
Brakes
Service brake hydrostatic
Parking brake mechanical
Exciter system
Vibrating drum front + rear
Drive system mechanical
Frequency 55
(3300)
Amplitude 0.50
(0,020)
Centrifugal force 22
(8992)
Hz
(vpm)
mm
(in)
kN
(lbf)
13
DTR100
Page 14
Technical data – Noise and vibration data
Filling capacities
Fuel (diesel) 5.5
(1.5)
Water 60
(18.5)
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
l
(gal us)
l
(gal us)
Sound pressure level at the operator's stand
Guaranteed sound power level
2.1.2 Vibration data
Hand-arm vibration
LpA = 89 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 = 3.6 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.6 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
14
DTR100
Page 15
Concerning your safety
3 Concerning your safety
15
DTR100
Page 16
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.
16
DTR100
Page 17
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.
17
DTR100
Page 18
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 Soil compaction
n Paving of walkways
n Work in trenches
n Underfilling and compaction of hard shoulders
n Compaction of bituminous material (road surface layers)
Intended use also includes compliance with the specified operating, maintenance and repair measures.
Dangers may arise with the machine if it is used other than for its
intended purpose.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
held liable.
18
DTR100
Page 19
Concerning your safety – Basic prerequisites
Examples of improper use are:
n Work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n Cleaning the drums while driving
The transport of persons is prohibited.
Do not use the steering rod as a seat when 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).
19
DTR100
Page 20
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,
20
DTR100
Page 21
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.
21
DTR100
Page 22
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.
22
DTR100
Page 23
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
23
DTR100
Page 24
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.
24
DTR100
Page 25
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.
25
DTR100
Page 26
Concerning your safety – Handling fuels and lubricants
3.4.4
Fig. 6
Safety regulations and environmental protection regulations for handling
hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
Should pressure fluid penetrate the skin, immediate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil 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 hydraulic
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.
26
DTR100
Page 27
Concerning your safety – Handling fuels and lubricants
3.4.5
Fig. 7:
Safety regulations and environmental protection regulations for handling battery acid
WARNING!
Danger of cauterization with acid!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with
lots of water.
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately call for medical advice in case of cauterization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Smoking and open fire is prohibited!
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
27
DTR100
Page 28
B-SYM-0210
Concerning your safety – Handling fuels and lubricants
3.4.6
Fig. 8
Safety regulations and environmental protection regulations when handling
lubrication grease
CAUTION!
Health hazard caused by contact with lubrica-
tion grease!
– Wear your personal protective equipment (pro-
tective gloves, safety goggles, protective
clothing).
– Avoid contact.
CAUTION!
Danger of slipping on lubrication grease!
– Collect and remove excess lubrication grease
immediately.
ENVIRONMENT!
Lubrication grease is an environmentally haz-
ardous substance!
– Always keep lubrication grease in proper con-
tainers.
– Collect excess lubrication grease and dispose
of it according to regulations.
– Dispose of cloths soiled with lubrication grease
according to regulations.
28
DTR100
Page 29
Concerning your safety – Loading / transporting the machine
3.5 Loading / transporting the machine
Use only stable loading ramps of sufficient load bearing capacity.
Loading ramps and transport vehicle must be free of grease, oil,
snow and ice.
The ramp inclination must be less than the gradeability of 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 lifting points.
Always use appropriate lifting and lashing tackle on the lifting and
lashing points.
Use lifting tackle 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 / qualified
person.
Use only lifting and lashing 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.
29
DTR100
Page 30
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 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.
30
DTR100
Page 31
3.7 Operation
B-834-0279
3.7.1 Persons in the danger area
3.7.2 Operation
Concerning your safety – Operation
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.
Use only the handles to steer the machine.
Change the travel direction only at standstill.
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.
3.7.3 Driving up and down slopes
Do not drive on gradients or slopes exceeding the maximum gradeability of the machine Ä Chapter 2 „Technical data“ on page 11.
Drive extremely carefully on gradients and always directly up or
down the slope.
The steering rod must always point uphill.
The operator must always stand above the machine.
Soil conditions and weather influences impair the gradeability of
the machine.
Wet and loose soil considerably reduces traction of the machine on
inclinations and slopes. Greater danger of accident!
Fig. 9
3.7.4 Working with vibration
When compacting with vibration you must always check the effect
of the vibration on nearby buildings and underground supply lines
(gas, water, sewage, electric power). If necessary stop compacting
with vibration.
31
DTR100
Page 32
Concerning your safety – Operation
Do not activate the vibration on hard (frozen, concrete) ground.
Components may get damaged.
3.7.5 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.
32
DTR100
Page 33
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 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.
33
DTR100
Page 34
Concerning your safety – Emergency procedures
3.9 Emergency procedures
In events of emergency, e.g. in case of a cable fire, disconnect the
battery from the vehicle’s electric system.
34
DTR100
Page 35
3.10 Maintenance work
3.10.1 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.
3.10.2 Working on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. Immediately call for medical assistance if
injured by hydraulic oil.
Do not step in front of or behind the machine when performing
adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be collected and disposed of in an environmentally friendly way.
Always collect and dispose of hydraulic oils separately.
Do not start the engine after draining off the hydraulic oil. Once all
work is completed (with the system still depressurized!) check all
connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine replacement hydraulic hoses ensure that the correct
hose type (pressure range) is used at the right location.
Concerning your safety – Maintenance work
3.10.3 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.
35
DTR100
Page 36
Concerning your safety – Maintenance work
3.10.4 Maintenance work on electric components and battery
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses.
When working on the battery, smoking or open fire is prohibited!
Do not lay any tools or other metal objects on the battery.
Do not wear jewellery (watch, bracelets, etc.) when working on the
battery.
The connection cables of the battery must not touch or rub against
machine parts.
3.10.5 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.
3.10.6 After maintenance work
Reassemble all guards and protections.
36
DTR100
Page 37
3.11 Repair
Concerning your safety – Repair
Identify a defective machine with a warning sign.
Only operate the machine after it has been repaired.
Repairs must only be performed by an expert/qualified person.
When replacing safety relevant components, only original spare
parts must be used.
37
DTR100
Page 38
Water
Hydraulic Oil
MAX
MAX
1-2 MINUTEN
MIN
1-2 MINUTEN
MIN
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
START
OPERATION
STOP
Diesel
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
B-924-0020
Concerning your safety – Signage
3.12 Signage
Keep stickers and signage in good and legible condition and
comply with their meaning.
Replace damaged and illegible stickers or signage immediately.
Fig. 10
38
DTR100
Page 39
Fig. 11
Concerning your safety – Signage
Warning sticker - Follow operating instructions
Information sticker - Guaranteed sound capacity level
Fig. 12
Fig. 13
Information sticker - Lashing point
Information sticker - Lifting point
Fig. 14
39
DTR100
Page 40
B-DEC-0218
Water
B-DEC-0214
Hydraulic Oil
Concerning your safety – Signage
Information sticker - Filler opening for water
Fig. 15
Information sticker - Filler opening for hydraulic oil
Fig. 16
Fig. 17
Information sticker - Ultra-low sulphur fuel
Operation sticker - Travel lever
Fig. 18
40
DTR100
Page 41
Fig. 19
B-DEC-0267
B-DEC-0269
MAX
MAX
1-2 MINUTEN
MIN
1-2 MINUTEN
MIN
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
START
OPERATION
STOP
B-DEC-0277
Concerning your safety – Signage
Operation sticker - Throttle lever
Operation sticker - Vibration lever
Fig. 20
Fig. 21
Operation sticker - Throttle lever
Operation sticker
Fig. 22
41
DTR100
Page 42
B-DEC-0268
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. 23
Machine type plate (example)
Fig. 24
42
DTR100
Page 43
Indicators and control elements
4 Indicators and control elements
43
DTR100
Page 44
B-834-0232
STOP
B-834-0235
B-834-0233
Indicators and control elements – Machine
4.1 Machine
4.1.1 Travel lever
Shift forward Forward travel
Pull back Backward travel
Fig. 25
4.1.2 Throttle lever
Position “STOP” Engine off
Position “MIN” Idle speed
Fig. 26
4.1.3 Vibration lever
Fig. 27
Position “MAX” Maximum speed
Position “Rear” Vibration off
Position “Front” Vibration on
44
DTR100
Page 45
4.1.4 Reversing protection
B-834-0234
B-100-0010
B-ELE-0069
Fig. 28
4.1.5 Parking brake lever
Indicators and control elements – Machine
actuated Machine stops
Only slow forward travel possible
release Backward travel and forward travel pos-
sible
Position “rear” Parking brake released
Operating position
Position “front” Parking brake applied
Fig. 29
4.1.6 Starter switch
Fig. 30
Position “P”/“0” Switch the ignition off
Ignition key can be removed
Position “I”/“II” Ignition on
The warning buzzer sounds
Position “III” Turn further against spring pressure, the
engine starts
Turn the ignition key back to position “I”
when the engine starts
The starter switch is designed with a re-start lock.
The ignition key must first be turned back to position “0” before a new starting attempt can be
made.
45
DTR100
Page 46
MAX
B-100-0011
Indicators and control elements – Machine
4.1.7 Water spraying system
Position “0” Water spraying system off
Turn anticlockwise Water spraying system on
Fig. 31
infinite adjustment of the spraying quantity up to “MAX” position
46
DTR100
Page 47
4.2 Engine
B-100-0015
B-100-0002
B-100-0035
4.2.1 Fuel valve
Fig. 32
4.2.2 Decompression lever
Indicators and control elements – Engine
Position “O” Fuel valve open
Position “S” Fuel valve closed
Position “bottom” Engine has compression
Normal operation
Fig. 33
4.2.3 Recoil starter
Position “top” Engine has no compression
Only for starting with recoil starter and
maintenance
NOTICE!
Danger of engine damage!
Opening the decompression lever while the engine
is running leads to engine damage.
– Never use the decompression lever for stop-
ping the engine.
Fig. 34
47
DTR100
Page 48
Indicators and control elements – Engine
48
DTR100
Page 49
Checks prior to start up
5 Checks prior to start up
49
DTR100
Page 50
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 68.
2. Open and secure the protection hood.
3. Close the protection hood again after work is completed.
Ä
Chapter 6.6 „Parking the machine
50
DTR100
Page 51
Checks prior to start up – Visual inspections and function tests
5.2 Visual inspections and function tests
1. Check hydraulic oil tank and hydraulic lines for condition and
leaks.
2. Check fuel tank and fuel lines for condition and leaks.
3. Check the bolted connections are tight and secure.
4. Check the machine for contamination and damage.
51
DTR100
Page 52
B-SYM-1068
MIN
MAX
B-100-0003
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 79.
Fig. 35
Fig. 36
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Clean the area around the oil dipstick.
2. Screw the dipstick out, wipe it off with a lint-free, clean cloth
and screw it back in to the end stop.
3. Unscrew the dipstick again.
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 engine oil to the “MAX” mark.
5. Screw the oil dipstick in.
52
DTR100
Page 53
B-SYM-1069
Diesel
B-100-0004
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. 37
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 79.
Fig. 38
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. If necessary, fill in fuel through a funnel with screen filter.
Only fill in fuel up to the red mark on the screen filter inside
the tank.
4. Close the cap.
53
DTR100
Page 54
B-SYM-1071
MIN
MAX
Hydraulic Oil
B-834-0237
Checks prior to start up – Checking the hydraulic oil level
5.5 Checking the hydraulic oil level
NOTICE!
Components may get damaged!
– Check the hydraulic oil level at room tempera-
ture (approx. 20 °C (68 °F)).
Fig. 39
– If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
– Use only oil of the permitted specification
Ä
Chapter 8.2.3.1 „Mineral oil based hydraulic
oil“ on page 80.
Fig. 40
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Clean the area around the filling port.
2. Unscrew the cap with the dipstick and pull it out.
3. Pull the dipstick out, wipe it off with a lint-free, clean cloth and
reinsert it until it bottoms.
4. Pull the dipstick out again.
The oil level must be between the “MIN” and “MAX”
ð
marks.
5. If the oil level is too low, top up hydraulic oil to the “MAX”
mark.
6. Fasten the cap and dipstick again.
54
DTR100
Page 55
B-SYM-1073
B-100-0036
B-100-0037
Checks prior to start up – Checking the rubber buffers
5.6 Checking the rubber buffers
Fig. 41
Fig. 42
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Check all rubber buffers between the frame and engine car-
rier for tight fit, cracks and tear-offs.
2. Check all rubber buffers between the engine and engine car-
rier for tight fit, cracks and tear-offs.
3. Replace damaged rubber buffers immediately.
Fig. 43
55
DTR100
Page 56
Water
B-100-0005
Checks prior to start up – Checking the water level, topping up
5.7 Checking the water level, topping up
NOTICE!
Dirty or contaminated water can block the bore-
holes!
– Fill only with clean water.
NOTICE!
Components may get damaged by frost!
– Follow the special maintenance instructions in
case of frost Ä Chapter 8.10.5 „Measures if
there is a risk of frost“ on page 109.
Fig. 44
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.
3. If necessary, fill in clean water.
4. Close the cap.
56
DTR100
Page 57
6 Operation
Operation
57
DTR100
Page 58
B-100-0012
Operation – Adjusting the steering rod
6.1 Adjusting the steering rod
1. Loosen the screws on both sides of the steering rod and fold
down the steering rod.
2. Set the steering rod to the required height and tighten the
screws.
Fig. 45
58
DTR100
Page 59
6.2 Starting the engine
B-834-0241
B-834-0244
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. 46
Operate the machine only with a correctly adjusted steering rod.
Protective equipment:
Working clothes
n
Safety shoes
n
Hearing protection
n
1. Shift the vibration lever to “Rear” position.
2. Set the throttle lever to position “MIN”.
Fig. 47
59
DTR100
Page 60
B-100-0013
B-ELE-0070
B-ELE-0072
Operation – Starting the engine
Fig. 48
3. Set the fuel valve to position "O".
4. Turn the ignition key to position “I”.
The warning buzzer sounds.
ð
Fig. 49
Fig. 50
5.
NOTICE!
Components may get damaged!
– Starting attempts should not exceed 30
seconds uninterrupted or max. 3 times
for 10 seconds. Then allow the starter to
cool down to ambient temperature.
– If the engine has not started after these
attempts, determine the cause.
Turn the ignition key through position “II” to position “III”.
The starter cranks the engine.
ð
The warning buzzer stops.
60
DTR100
Page 61
Operation – Starting the engine
6. As soon as the engine is running, turn the ignition key to
position “I”.
The starter switch is designed with a re-start
lock. The ignition key must first be turned
back to position “0” before a new starting
attempt can be made.
NOTICE!
Danger of engine damage!
– Warm up engine for a short while before
starting work. Do not operate the engine
immediately under full load.
61
DTR100
Page 62
B-100-0020
B-834-0245
B-834-0246
Operation – Travel operation
6.3 Travel operation
Fig. 51
Use only the handles to steer the machine.
Guide the machine so that your hands do not hit against solid
objects.
1. Pull out the parking brake lever, turn it to position “rear” and
lock it in place.
The parking brake is released.
ð
2. Set the throttle lever to “MAX” position.
Fig. 52
Driving forward
Fig. 53
3. Shift the travel lever forward.
The machine drives forward with a speed which corre-
ð
sponds to the travel lever position.
62
DTR100
Page 63
Driving backwards
B-834-0247
B-834-0248
Fig. 54
4.
CAUTION!
Danger of injury caused by the crushing
of body parts!
– When reversing, steer the machine from
Pull the travel lever back.
The machine drives backwards with a speed which corre-
ð
sponds to the travel lever position.
Operation – Travel operation
the side using the steering handle.
Steering the machine
Stopping the machine
Fig. 55
5. Steer the machine by pushing from the side or pulling the
steering rod handles.
6. Release the travel lever.
Travel lever moves to neutral position.
ð
Machine stops.
63
DTR100
Page 64
B-834-0245
Operation – Operation
6.4 Operation
6.4.1 Preliminary remarks and safety notes
NOTICE!
Possible damage to neighbouring buildings!
– When compacting with vibration you must
– If necessary stop compacting with vibration.
NOTICE!
Components may get damaged!
– Do not activate the vibration on hard (frozen,
Vibration at standstill causes transverse marks:
always check the effect of the vibration on
nearby buildings and underground supply lines
(gas, water, sewage, electric power).
concrete) ground.
6.4.2 Working with vibration
Fig. 56
n Switch the vibration on only after shifting the travel lever in the
desired travel direction.
n Switch the vibration off before stopping the machine.
1. Set the throttle lever to “MAX” position.
64
DTR100
Page 65
Vibration during forward travel
B-834-0254
B-834-0242
B-834-0247
Fig. 57
Operation – Operation
2. Shift the travel lever half a position forward.
The machine drives forward with half speed.
ð
Vibration cannot be switched on if the
travel lever is fully shifted to forward position.
NOTICE!
Vibration at standstill causes transverse
marks!
– Do not switch on vibration with the machine at
standstill.
3. Shift the vibration lever to “Front” position.
Vibration is switched on.
ð
Fig. 58
Vibration during backward travel
Fig. 59
4.
CAUTION!
Danger of injury caused by the crushing
of body parts!
– When reversing, steer the machine from
Pull the travel lever back.
The machine drives backwards with a speed which corre-
ð
sponds to the travel lever position.
the side using the steering handle.
65
DTR100
Page 66
B-834-0242
B-834-0241
Operation – Operation
Fig. 60
Switching the vibration off
NOTICE!
Vibration at standstill causes transverse
marks!
– Do not switch on vibration with the machine at
standstill.
5. Shift the vibration lever to “Front” position.
Vibration is switched on.
ð
6. Shift the vibration lever to “Rear” position.
Vibration is switched off after a short time.
ð
Fig. 61
66
DTR100
Page 67
6.5 Water spraying system
MAX
B-100-0011
Fig. 62
Operation – Water spraying system
1. Switch the water spraying system on or off with the lever:
Position “0” Water spraying system off
Turn anticlockwise Water spraying system on
infinite adjustment of the spraying
quantity up to “MAX” position
67
DTR100
Page 68
B-834-0248
B-834-0244
STOP
B-834-0243
B-ELE-0069
Operation – Parking the machine in secured condition
6.6 Parking the machine in secured condition
1. Drive the machine onto horizontal, level, firm ground.
2. Release the travel lever.
Travel lever moves to neutral position.
ð
Machine stops.
Fig. 63
3. Set the throttle lever to “MIN” position (idle speed).
Fig. 64
Fig. 65
4.
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.
Set the throttle lever to position “STOP”.
The engine is shut down.
ð
The warning buzzer sounds.
5. Turn the ignition key to position “0” and pull it out.
Fig. 66
68
DTR100
Page 69
B-100-0014
Fig. 67
B-100-0021
Operation – Parking the machine in secured condition
6. Set the fuel valve to position "S".
7. Pull out the parking brake lever, turn it to position “front” and
lock it in place.
The parking brake is applied.
ð
Fig. 68
69
DTR100
Page 70
Operation – Parking the machine in secured condition
70
DTR100
Page 71
Loading / transporting the machine
7 Loading / transporting the machine
71
DTR100
Page 72
Loading / transporting the machine – Loading the machine
7.1 Loading the machine
Use only stable loading ramps of sufficient load bearing capacity.
Loading ramps and transport vehicle must be free of grease, oil,
snow and ice.
The ramp inclination must be less than the gradeability of the
machine.
Make sure that any persons keep a safety distance of at least 2
metres while the machine is driven onto or down from the transport
vehicle. The instructing person should not be inside the travel
range of the machine.
Use only transport vehicles with a sufficient load bearing capacity
for the weight to be loaded Ä Chapter 2 „Technical
data“ on page 11.
Protective equipment:
1.
DANGER!
Danger to life caused by the machine slipping or turning over!
– Make sure that no persons are in the
danger zone.
Working clothes
n
Protective gloves
n
Drive the machine carefully onto the transport vehicle.
2.
Park the machine safely
in secured condition“ on page 68.
Ä
Chapter 6.6 „Parking the machine
72
DTR100
Page 73
B-100-0017
B-100-0016
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 way.
Always use appropriate lifting tackles at the lifting points.
Use lifting tackle only in the specified loading direction.
Lifting tackle must not be damaged by machine parts.
Protective equipment:
1. Fold up the steering rod into transport position and lock it.
Working clothes
n
Safety shoes
n
Protective gloves
n
Fig. 69
Fig. 70
2. Fasten four ratchet straps to the marked lashing points.
3. Lash the machine securely to the transport vehicle.
73
DTR100
Page 74
B-100-0018
Loading / transporting the machine – Loading by crane
7.3 Loading by crane
Loads must only be attached and hoisted by an expert / capable
person.
Do not use damaged or in any other way impaired lashing points.
Use only lifting gear and lifting tackle with sufficient load bearing
capacity for the weight to be loaded. Minimum load bearing
capacity of lifting gear: see max. operating weight Ä Chapter 2
„Technical data“ on page 11.
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.
When lifting the machine avoid uncontrolled movements of the
load. If necessary hold the load with guide ropes.
Fig. 71
Protective equipment:
Working clothes
n
Safety shoes
n
Protective gloves
n
1. Fasten the lifting tackle to the intended lifting points.
2.
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.
74
DTR100
Page 75
7.4 After transport
Loading / transporting the machine – After transport
1. Release the parking brake.
2.
DANGER!
Danger to life caused by the machine slipping or turning over!
– Make sure that no persons are in the
danger zone.
Drive the machine carefully off the transport vehicle.
75
DTR100
Page 76
Loading / transporting the machine – After transport
76
DTR100
Page 77
8 Maintenance
Maintenance
77
DTR100
Page 78
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 3.10 „Maintenance
work“ on page 35.
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.
78
DTR100
Page 79
8.2 Fuels and lubricants
B-100-0019
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 CD or higher quality
n ACEA E–3, E–4 and E–5
n JASO DH–1
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. 72: 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
n ISO 8217 DMX
n JIS K2204 Grade No. 2
n KSM-2610
n GB252
79
DTR100
Page 80
Maintenance – Fuels and lubricants
In order to fulfil national emission regulations, the legally required
fuels must be used (e.g. sulphur content).
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.
NOTICE!
Danger of engine damage!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
8.2.2.3 Storage
8.2.3 Hydraulic oil
8.2.3.1 Mineral oil based hydraulic oil
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.
The hydraulic system is operated with hydraulic oil HV 32 (ISO)
with a kinematic viscosity of 32 mm2/s at 40 °C (104 °F).
When refilling or changing oil, use only hydraulic oil type HVLP
according to DIN 51524, part 3, or hydraulic oil type HV according
to ISO 6743/4.
The viscosity index must be at least 150 (observe information of
manufacturer).
8.2.3.2 Bio-degradable hydraulic oil
The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
80
DTR100
Page 81
Maintenance – Fuels and lubricants
The biologically quickly degradable hydraulic oil Panolin HLP
Synth.46 meets all demands of a mineral oil based hydraulic oil
according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use
the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Danger of damage to the hydraulic system!
– After the changeover check the hydraulic oil fil-
ters increasingly for contamination.
– Have regular oil analyses performed regarding
the water content and mineral oil.
– Replace the hydraulic oil filter at the latest after
500 operating hours.
8.2.4 Lubrication grease
For lubrication purposes use an EP-high pressure grease, lithium
saponified (penetration 2), acc. to DIN 51502 KP 2G.
81
DTR100
Page 82
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-30
Specification: Ä Chapter 8.2.1 „Engine oil“ on page 79
SAE 15W-40
SAE 20 SAE 10W
SAE 30 SAE 20W
SAE 40
Fuel Diesel Winter diesel fuel 5.5 l
Specification: Ä Chapter 8.2.2 „Fuel“ on page 79
Hydraulic system Hydraulic oil (ISO), HV 32
Specification: Ä Chapter 8.2.3.1 „Mineral oil based
hydraulic oil“ on page 80
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 8.2.3.2 „Bio-degradable
hydraulic oil“ on page 80
Water tank Water 60 l
Gears High pressure grease (lithium saponified) as required
1.0 l
(0.3 gal us)
(1.5 gal us)
13.0 l
(3.4 gal us)
(15.8 gal us)
82
DTR100
Page 83
8.4 Running-in instructions
8.4.1 General
8.4.2 After 25 operating hours
Maintenance – Running-in instructions
The following maintenance work must be performed when running
in new machines or overhauled engines.
1.
Change the engine oil
and oil filter element“ on page 94.
2.
Check the valve clearance, adjust if necessary Ä Chapter
8.8.1 „Checking, adjusting the valve clearance“ on page 93.
3. Check engine and machine for leaks.
4. Retighten the fastening screws on air filter, exhaust and other
attachment parts.
5. Retighten the bolted connections on the machine.
6.
Check tension of V-belt, tighten if necessary
„Servicing the V-belt“ on page 89.
7.
Check tension of toothed belt, tighten if necessary Ä Chapter
8.7.3 „Servicing the toothed belt“ on page 90.
Ä
Chapter 8.8.2 „Changing engine oil
Ä
Chapter 8.7.2
83
DTR100
Page 84
Maintenance – Maintenance Table
8.5 Maintenance Table
No. Maintenance works Page
Weekly
8.6.1 Checking, cleaning the air filter 85
8.6.2 Draining the fuel tank sludge 87
Semi-annually
8.7.1 Battery service 88
8.7.2 Servicing the V-belt 89
8.7.3 Servicing the toothed belt 90
8.7.4 Greasing the gears 92
Annually
8.8.1 Checking, adjusting the valve clearance 93
8.8.2 Changing engine oil and oil filter element 94
8.8.3 Replacing the fuel filter 96
8.8.4 Replacing the V-belt 98
8.8.5 Replacing the toothed belt 99
8.8.6 Replacing the air filter 101
Every 2 years
8.9.1 Changing hydraulic oil and hydraulic oil filter 103
As required
8.10.1 Cleaning the water spraying system 105
8.10.2 Adjusting the scrapers 107
8.10.3 Cleaning the machine 107
8.10.4 Cleaning the cooling fins and the cooling air intake openings 108
8.10.5 Measures if there is a risk of frost 109
8.10.6 Measures prior to extended shut-down period 109
84
DTR100
Page 85
8.6 Weekly
B-SYM-1074
1
2
B-100-0009
8.6.1 Checking, cleaning the air filter
Fig. 73
Maintenance – Weekly
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. 74
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
in secured condition“ on page 68.
2. Allow the engine to cool down.
3. Release both snap bows (1) and take off the cover (2).
4. Clean the cover and dust discharge valve.
5. Pull out the air filter with a slight turning motion.
NOTICE!
Danger of engine damage!
– Prevent dirt from getting into the air intake
opening.
– Do not clean the air filter housing with com-
pressed air.
Working clothes
n
Protective gloves
n
Safety goggles
n
Fig. 75
6. Thoroughly clean the filter housing and sealing faces.
7. Clean the inside of the drain pipe in the filter housing thor-
oughly.
85
DTR100
Page 86
Maintenance – Weekly
Fig. 76
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
8. Blow the air filter out with dry compressed air (max. 2.1 bar
(30 psi)) from inside to outside by moving the gun up and
down inside the element, until it is free of dust.
Fig. 77
Fig. 78
9. Examine the air filter with a torch for cracks and holes in the
paper bellows.
10. Replace the air filter if it is damaged.
11. Slide the air filter carefully into the housing.
NOTICE!
Danger of engine damage!
– The dust discharge valve must point vertically
downwards.
– Make sure that the cover locks engage cor-
rectly.
12. Reinstall the cover.
86
DTR100
Page 87
8.6.2 Draining the fuel tank sludge
B-SYM-1075
Diesel
B-100-0004
B-100-0030
Fig. 79
Maintenance – Weekly
When performing this work, the fuel tank should
only hold a small amount of fuel.
Fig. 80
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
in secured condition“ on page 68.
2. Clean the area around the filling port and remove the cap.
3. Use a suitable vessel to collect running out fuel.
4. Unscrew the drain plug and drain off fuel.
5. Screw the drain plug back on tightly. Ensure leak tightness.
6. Dispose of collected fuel in line with environmental regula-
tions.
Fig. 81
87
DTR100
Page 88
B-SYM-1077
B-100-0006
1
2
2
3
B-834-0259
Maintenance – Semi-annually
8.7 Semi-annually
8.7.1 Battery service
Fig. 82
Maintenance free batteries also need care. Maintenance free only means that the fluid level does not
need to be checked.
Every battery has a self-discharge, which may, if
not checked occasionally, even cause damage to
the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under warranty!
Fig. 83
Fig. 84
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
Safety goggles
n
in secured condition“ on page 68.
2. Unscrew fastening screws and fold the cover forward.
3. Remove the bracket (1) of the battery.
4. Remove the battery (3).
5. Check the condition of the vibration insulation mats (2),
replace if necessary.
6. Clean the outside of the battery.
7. Clean the battery poles and terminals and grease them with
pole grease (Vaseline).
8. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
9. Install the battery.
10. Install the bracket of the battery.
11. Close the cover and tighten the fastening screws.
88
DTR100
Page 89
8.7.2 Servicing the V-belt
B-SYM-1079
B-100-0032
1
B-834-0251
Fig. 85
Maintenance – Semi-annually
Fig. 86
Checking the V-belt
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
in secured condition“ on page 68.
2. Allow the engine to cool down.
3. Unscrew the screws and take off the cover.
4. Check condition and tension of V-belt (1).
Compression measurement: 10 - 15 mm (0.4 - 0.6 in).
ð
Fig. 87
5.
Replace the V-belt if damaged Ä Chapter 8.8.4 „Replacing
the V-belt“ on page 98.
6. If necessary, retighten the V-belt.
89
DTR100
Page 90
1
B-834-0252
B-SYM-1111
B-100-0033
Maintenance – Semi-annually
Retightening the V-belt
Fig. 88
8.7.3 Servicing the toothed belt
7. Loosen four fastening screws (1) on both sides.
8. Insert two prybars between the rubber buffer and the frame.
9. Push the engine carrier forward until the required compres-
sion measurement is reached.
10. Tighten the fastening screws.
11. Fasten the cover with screws.
Fig. 89
Fig. 90
Protective equipment:
1.
Park the machine safely
Working clothes
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.6 „Parking the machine
in secured condition“ on page 68.
2. Unscrew the screws and take off the cover.
90
DTR100
Page 91
Checking the toothed belt
B-834-0272
90 – 120 N
66 – 89 lbs
1
1
B-834-0273
Fig. 91
Retightening the toothed belt
Maintenance – Semi-annually
3. Check condition and tension of toothed belt.
Compression measurement: 10 - 15 mm (0.4 - 0.6 in).
ð
4.
Replace the toothed belt if damaged Ä Chapter 8.8.5
„Replacing the toothed belt“ on page 99.
5. If necessary, retighten the toothed belt.
6. Loosen the fastening screws (1).
7. Use a suitable tool (e.g. spring balance) with a tensile force
of 90 to 120 N (66 to 88.5 lbs) to pull the coupling upwards
until the required compression measurement is reached.
8. Tighten the fastening screws.
Fig. 92
9. Fasten the cover with screws.
91
DTR100
Page 92
B-SYM-1112
B-100-0033
Grease
Fett
Graisse
Grassa
B-834-0274
Maintenance – Semi-annually
8.7.4 Greasing the gears
Fig. 93
NOTICE!
Inadequate lubrication will cause damage to
components!
– Use only grease of the permitted specification
Ä
Chapter 8.2.4 „Lubrication
grease“ on page 81.
Fig. 94
Protective equipment:
1.
Park the machine safely
Working clothes
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.6 „Parking the machine
in secured condition“ on page 68.
2. Unscrew the screws and take off the cover.
3. Remove old grease and apply new grease to all gears.
4. Fasten the cover with screws.
5. Dispose of grease in line with environmental regulations.
Fig. 95
92
DTR100
Page 93
8.8 Annually
B-100-0023
B-100-0022
8.8.1 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.
Maintenance – Annually
Preparations
Fig. 96
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Protective gloves
n
in secured condition“ on page 68.
2. Let the engine cool down to ambient temperature.
3. Check the position of the decompression lever, if necessary
move it to the initial position.
4. Remove the valve cover with the seal.
Fig. 97
Checking the valve clearance
Valve clearance:
Intake valve 0.15 mm (0.006 in)
Exhaust valve 0.15 mm (0.006 in)
1. Turn the engine using a recoil starter until first the exhaust
valve and then the intake valve are opened and closed again.
2. Then turn the engine a bit more using a recoil starter until the
compression resistance can be felt.
93
DTR100
Page 94
2
3
1
B-100-0025
B-100-0022
Maintenance – Annually
Fig. 98
3. Check the valve clearance on both valves with a feeler gauge
(1), adjust if necessary.
Adjusting the valve clearance
Concluding work
Fig. 99
1. Loosen screw (3) on the rocker arm.
2. Adjust the screw (2), until the feeler gauge (1) can be
inserted and pulled out with a barely noticeable resistance
after the hexagon nut (3) has been tightened.
1. Install the valve cover with a new seal and tighten the screws
evenly.
2. After a short test run check the valve cover for leaks.
8.8.2 Changing engine oil and oil filter element
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 79.
– Filling quantity:
lubricants“ on page 82
Ä
Chapter 8.3 „List of fuels and
94
DTR100
Page 95
B-100-0027
B-100-0026
4
1
2
3
B-100-0028
Maintenance – Annually
Draining off engine oil
Fig. 100
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
Safety goggles
n
in secured condition“ on page 68.
2. Clean the area around the dipstick and pull the dipstick out.
3. Clean the area around the drain plug.
Fig. 101
Changing the oil filter element
Fig. 102
WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Avoid touching hot components.
4. 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: 20 Nm (15 ft·lbf).
6. Clean the area around the cover (1).
7. Unscrew the screw (4) and pull the oil filter element (2) out.
8. Replace the oil filter element.
9. Clean the sealing face on the engine.
10. Check the seal ring (3) on the cover for damage, replace if
necessary.
11. Slightly lubricate the seal ring.
12. Insert the cover with oil filter element and seal ring.
13. Screw the cover back on tightly.
95
DTR100
Page 96
MIN
MAX
B-100-0003
Diesel
B-100-0004
Maintenance – Annually
Filling in engine oil
Fig. 103
14. Fill in fresh engine oil through the filler opening.
15. Push the dipstick in.
16. After a short test run, check the oil level on the dipstick, top
up oil if necessary.
Concluding work
8.8.3 Replacing the fuel filter
17. Check oil filter and drain plug for leaks.
18. Dispose of oil and oil filter insert in an environmentally
friendly way.
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 safely
Working clothes
n
Safety shoes
n
Protective gloves
n
Ä
Chapter 6.6 „Parking the machine
in secured condition“ on page 68.
2. Clean the area around the filling port and remove the cap.
3. Use a suitable vessel to collect running out fuel.
Fig. 104
96
DTR100
Page 97
B-100-0030
Fig. 105
3
2
1
B-100-0031
1
2
3
B-100-0029
Maintenance – Annually
4. Unscrew the drain plug and drain off fuel.
5. Provide a cleaning cloth for collecting escaping fuel.
6. Unscrew the screws (3) and take off the fuel valve (2) with
seal (1).
Fig. 106
Fig. 107
7. Pull out the screen filter (1).
8. Remove the fuel filter (2) and seal (3).
9. Replace the fuel filter.
10. Install fuel filter with a new seal.
11. Clean and insert screen filter.
12. Fasten the fuel valve with new seal.
13. Screw the drain plug back in. Ensure leak tightness.
14.
Fill the fuel tank
Ä
Chapter 5.4 „Checking the fuel level; top-
ping up fuel“ on page 53.
15. Close the cap.
16. After a short test run check fuel filter, fuel valve and fuel lines
for leaks.
17. Dispose of fuel and fuel filters in line with environmental reg-
ulations.
97
DTR100
Page 98
B-100-0032
2
1
B-834-0253
1
B-834-0252
Maintenance – Annually
8.8.4 Replacing the V-belt
Fig. 108
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
in secured condition“ on page 68.
2. Allow the engine to cool down.
3. Unscrew the screws and take off the cover.
4. Loosen four fastening screws (2) on both sides.
5. Insert two prybars between the rubber buffer and the frame.
6. Push the engine carrier back until the V-belt (1) is relieved.
7. Take the V-belt off and replace it.
8. Install the new V-belt.
Fig. 109
Fig. 110
9. Insert the prybars on the opposite side between the rubber
buffer and the frame.
10. Push the engine carrier forward until the required compres-
sion measurement is reached.
Compression measurement: 10 - 15 mm (0.4 - 0.6 in).
ð
11. Tighten the fastening screws (1).
12. Fasten the cover with screws.
13. Check the V-belt tension again after 25 operating hours,
tighten if necessary.
98
DTR100
Page 99
8.8.5 Replacing the toothed belt
B-100-0033
1
1
2
B-834-0275
1
1
B-834-0276
Maintenance – Annually
Fig. 111
Replacing the toothed belt
Protective equipment:
1.
Park the machine safely Ä Chapter 6.6 „Parking the machine
Working clothes
n
Safety shoes
n
Protective gloves
n
in secured condition“ on page 68.
2. Unscrew the screws and take off the cover.
3. Loosen the fastening screws (1) and push the coupling down.
4. Remove and replace the toothed belt (2).
Fig. 112
5. Mark the position of the exciter shafts (1) with a downward
arrow.
Fig. 113
99
DTR100
Page 100
2
1
B-834-0277
90 – 120 N
66 – 89 lbs
1
1
B-834-0273
Maintenance – Annually
Fig. 114
Tensioning the toothed belt
6. Turn the left exciter shaft (2) by 180° and hold it in this posi-
tion.
7. Install the new toothed belt (1).
8. Use a suitable tool (e.g. spring balance) with a tensile force
of 90 – 120 N (66 – 89 lbs) to pull the coupling upwards until
the required compression measurement is reached.
Compression measurement: 10 - 15 mm (0.4 - 0.6 in).
ð
9. Tighten the fastening screws (1).
10. Fasten the cover with screws.
Fig. 115
100
DTR100
Loading...