Fayat DYNAPAC DRP45DX Original Operating Instructions

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Operang Instrucon

Original Oper

ang

Instrucons

DRP45DX

versible vibratory plate

S/N 101 924 52 1001> DL8 203 55 EN © 04/2018

Table of contents

Introduction........................................................................................................................................... 7

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.................................................................................................................................. 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 Parking the machine.................................................................................................................. 31

3.8 Refuelling..................................................................................................................................... 32

3.9 Maintenance work....................................................................................................................... 33

3.9.1 Preliminary remarks................................................................................................................... 33

3.9.2 Working on the engine............................................................................................................... 33

3.9.3 Maintenance work on electric components and battery............................................................. 33

DRP45DX

Table of contents

3.9.4 Cleaning work............................................................................................................................ 33

3.9.5 After maintenance work............................................................................................................. 34

3.10 Repair......................................................................................................................................... 35

3.11 Signage...................................................................................................................................... 36

4 Indicators and control elements........................................................................................................ 41

5 Checks prior to start up...................................................................................................................... 43

5.1 Notes on safety........................................................................................................................... 44

5.2 Visual inspections and function tests....................................................................................... 45

5.3 Checking the engine oil level..................................................................................................... 46

5.4 Checking the fuel level; topping up fuel................................................................................... 47

5.5 Checking the rubber buffers...................................................................................................... 48

6 Operation............................................................................................................................................. 49

6.1 Folding down the steering rod................................................................................................... 50

6.2 Starting the engine...................................................................................................................... 51

6.3 Operation..................................................................................................................................... 53

6.4 Parking the machine in secured condition............................................................................... 55

7 Loading/transporting the machine.................................................................................................... 57

7.1 Loading the machine.................................................................................................................. 58

7.2 Lashing the machine to the transport vehicle.......................................................................... 60

8 Maintenance........................................................................................................................................ 61

8.1 Preliminary remarks and safety notes...................................................................................... 62

8.2 Preparations / concluding work................................................................................................. 63

8.2.1 Opening / closing the protection hood........................................................................................ 63

8.3 Fuels and lubricants................................................................................................................... 65

8.3.1 Engine oil................................................................................................................................... 65

8.3.2 Fuel............................................................................................................................................ 65

8.3.3 Oil for exciter shaft housing........................................................................................................ 66

8.3.4 Mineral oil based hydraulic oil.................................................................................................... 66

8.4 List of fuels and lubricants........................................................................................................ 68

8.5 Running-in instructions.............................................................................................................. 69

8.5.1 General...................................................................................................................................... 69

8.5.2 After 25 operating hours............................................................................................................. 69

8.6 Maintenance Table...................................................................................................................... 70

8.7 Weekly.......................................................................................................................................... 71

8.7.1 Checking, cleaning the air filter.................................................................................................. 71

8.7.2 Checking and cleaning the water separator............................................................................... 72

8.8 Semi-annually.............................................................................................................................. 74

8.8.1 Battery service........................................................................................................................... 74

8.9 Annually / every 250 operating hours....................................................................................... 75

8.9.1 Replacing the V-belt................................................................................................................... 75

8.9.2 Checking, adjusting the valve clearance.................................................................................... 77

8.9.3 Changing the engine oil and cleaning the oil filter...................................................................... 79

8.9.4 Replacing the fuel filter............................................................................................................... 81

8.9.5 Replacing the air filter................................................................................................................ 82

8.9.6 Changing the oil in the exciter housing...................................................................................... 83

DRP45DX

Table of contents

8.9.7 Checking the hydraulic oil level.................................................................................................. 85

8.9.8 Replacing the starter rope.......................................................................................................... 87

8.9.9 Lubricating the machine............................................................................................................. 89

8.10 Every 2 years / every 500 operating hours............................................................................. 90

8.10.1 Changing the hydraulic oil........................................................................................................ 90

8.11 As required................................................................................................................................ 92

8.11.1 Cleaning the machine............................................................................................................... 92

8.11.2 Cleaning the cooling fins and the cooling air intake openings.................................................. 92

8.11.3 Servicing the V-belt.................................................................................................................. 93

8.11.4 Checking the oil level in the exciter housing............................................................................ 94

8.11.5 Measures prior to extended shut-down period......................................................................... 94

9 Troubleshooting.................................................................................................................................. 97

9.1 Preliminary remarks.................................................................................................................... 98

9.2 Starting the engine with the recoil starter................................................................................ 99

9.3 Starting the engine with jump leads........................................................................................ 101

9.4 Fuse assignment....................................................................................................................... 102

9.5 Engine malfunctions................................................................................................................. 103

9.6 Malfunctions during operation................................................................................................ 105

10 Disposal............................................................................................................................................. 107

10.1 Final shut-down of machine................................................................................................... 108

DRP45DX

Table of contents

DRP45DX

1 Introduction

Introduction

DRP45DX

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 41.

The description of the individual operating steps including the notes on safety to be followed can be found in chapter “Operation”

Chapter 6 „Operation“ on page 49.

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 61.

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.

Chapter 4 „Indicators and control ele-

Chapter 5 „Checks prior to start up“ on page 43.

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.

DRP45DX

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.

DRP45DX

Made by

Designation Type

Nominal Power Operating Mass Year of Construction

Serial-No.

Made in Germany

Ammerländer Str. 93 D-26203 Wardenburg

B-924-0001

Introduction – Machine type plate and engine type plate

1.2 Machine type plate and engine type plate

Please enter here:

Machine type (1):

Serial number (2):

Fig. 1: Machine type plate (example)

Please enter here:

Engine type (1):

Engine number (2):

Fig. 2: Engine type plate (example)

DRP45DX

2 Technical data

Technical data

DRP45DX

B-692-0239

Technical data

Dimensions

Fig. 3

H H

L L

W W

Dimensions standard

790

(31.1)

980

(38.6)

1350

(53.1)

1700

(66.9)

900

(35.4)

450

(17.7)

650

(25.6)

750

(29.5)

Weights

Operating weight (CECE) (W) 440

(970)

(lbs)

Operating weight (CECE) (W1) 460

(1014)

(lbs)

Operating weight (CECE) (W2) 471

(1038)

(lbs)

Basic weight 455

(1003)

(lbs)

DRP45DX

Technical data – Noise and vibration data

Travel characteristics

Max. working speed 28

(92)

Max. gradeability (depending on soil) 35 %

Drive

Engine manufacturer Hatz

Type 1B40

Cooling Air

Number of cylinders 1

Rated power ISO 3046 6.7

(9.0)

Rated speed 3000

Drive system mechanical

Exciter system

Frequency 66

(3960)

m/min

(ft/min)

(hp)

min

(vpm)

-1

Centrifugal force 60

(13489)

Amplitude 1.96

(0,077)

Filling capacities

Fuel (diesel) 5.0

(1.3)

(lbf)

(gal us)

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

ibration Protection Directive 2002/44/EU

n V

(in)

DRP45DX

Technical data – Noise and vibration data

During operation these values may vary because of the prevailing operating conditions.

2.1.1 Noise data

Sound pressure level at the operator's stand

Guaranteed sound power level

2.1.2 Vibration data

Hand-arm vibration

LpA = 95 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 £ 2.5 m/s2 on crushed rock determined

acc. to ISO 5349 and EN 500.

Associated uncertainty K = 0.3 m/s2, determined acc. to EN

12096.

Observe the daily vibration load (work safety acc. to 2002/44/EC).

DRP45DX

Concerning your safety

3 Concerning your safety

DRP45DX

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.

DRP45DX

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.

DRP45DX

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.

DRP45DX

Concerning your safety – Basic prerequisites

Examples for improper use are:

n dragging the machine along as a measure of transportation n throwing the machine off the transport vehicle n attaching an additional weight to the machine

It is not permitted to stand on the machine while working.

Lifting tackle must be removed before starting work.

Starting and operating the machine in explosive environments and in underground mining is prohibited.

The lifting and lashing points specified in these instructions must be used. It is prohibited to use other lifting and lashing points (e.g. guide handle, steering rod).

DRP45DX

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,

DRP45DX

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.

DRP45DX

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.

DRP45DX

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

DRP45DX

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 oilbinding agent and dispose of properly.

– Dispose of diesel fuel and fuel filters according

to regulations.

DRP45DX

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.

DRP45DX

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 (protective 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.

DRP45DX

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.

DRP45DX

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.

DRP45DX

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.

DRP45DX

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.

DRP45DX

3.7 Operation

Concerning your safety – Operation

3.7.1

Persons in the danger area

3.7.2 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.

Operate the machine only with the steering rod folded down.

Only use the steering rod to steer the machine.

Guide the machine so that your hands do not hit against solid objects.

When reversing, steer the machine from the side using the steering handle.

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 Parking the machine

Park the machine on horizontal, level, firm ground.

Before leaving the machine:

n shut down the engine, pull of 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.

f the ignition key,

DRP45DX

Concerning your safety – Refuelling

3.8 Refuelling

Do not inhale any fuel fumes.

Refuel only with the engine shut down.

Do not refuel in closed rooms.

No open fire, do not smoke.

Ultra-low sulphur diesel fuel poses a higher risk of combustion caused by the static charging than diesel fuel with a higher sulphur content.

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.

DRP45DX

3.9 Maintenance work

Concerning your safety – 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.

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 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.

3.9.4 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.

DRP45DX

Concerning your safety – Maintenance work

3.9.5 After maintenance work

Reassemble all guards and protections.

DRP45DX

3.10 Repair

Concerning your safety – Repair

Identify a defect machine with a warning sign.

Only operate the machine after it has been repaired.

When replacing safety relevant components, only original spare parts must be used.

Repairs must only be performed by an expert/qualified person.

When performing welding work on the machine you should cover the fuel tank with insulating material.

DRP45DX

ULTRA LOW SULFUR

FUEL ONLY

START

OPERATION

STOP

2 3

008 327 46

MAX

START

STOP

1-2 MINUTEN

MAX

MIN

1-2 MINUTEN

MIN

STOP

Made by

Designation Type

Nominal Power Operating Mass Year of Construction

Serial-No.

Patent Protection

Made in Germany

before taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio

weekly wöchentlich hebdomadairement cada semana

twice annual halbjährlich tous les 6 mois cada 6 meses

annual / 250 h jährlich / 250 h annuellement / 250 h anualmente / 250 h

DIESEL

ASTM D975-09a 1-D S15 / 2-D S15

API CJ-4

ACEA E9/E7

B-924-0009

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. 9

DRP45DX

Fig. 10

Concerning your safety – Signage

Warning sticker - Follow operating instructions

Warning sticker - Danger of injury due to defective starter rope

n Before use, check the starter rope for chafing. n Do not use a defective starter rope.

Fig. 11

Fig. 12

Information sticker - Lashing point

Information sticker - Lifting point

Fig. 13

DRP45DX

B-DEC-0265

Concerning your safety – Signage

Information sticker - Guaranteed sound capacity level

Fig. 14

Information sticker - Ultra-low sulphur fuel

Fig. 15

Fig. 16

Information sticker - Low ash engine oil

Operation sticker - T

ravel lever

Fig. 17

DRP45DX

Fig. 18

B-692-0202

START

OPERATION

STOP

2 3

008 327 46

MAX

START

STOP

1-2 MINUTEN

MAX

MIN

1-2 MINUTEN

MIN

STOP

before taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio

weekly wöchentlich hebdomadairement cada semana

twice annual halbjährlich tous les 6 mois cada 6 meses

annual / 250 h jährlich / 250 h annuellement / 250 h anualmente / 250 h

DIESEL

ASTM D975-09a

1-D S15 / 2-D S15

API CJ-4

ACEA E9/E7

B-DEC-0273

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

Operation sticker - Throttle lever

Instruction sticker - Wear ear protection / brief operating instructions

Fig. 19

Fig. 20

Maintenance sticker

Machine type plate (example)

Fig. 21

DRP45DX

Concerning your safety – Signage

DRP45DX

Indicators and control elements

4 Indicators and control elements

DRP45DX

B-924-0016

Indicators and control elements

Fig. 22

1 Recoil starter 2 Operating hour meter 3 Starter switch 4 Handle 5 Throttle lever 6 Locking pawl lever 7 Steering rod height adjustment

DRP45DX

Checks prior to start up

5 Checks prior to start up

DRP45DX

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-

dling fuels and lubricants

dling fuels and lubricants“ on page 23.

that the engine can not be started.

Chapter 3.4 „Han-

Park the machine safely in secured condition“ on page 55.

2. Open and secure the protection hood.

3. Close the protection hood again after work is completed

Chapter 8.2.1.2 „Closing the protection

hood“ on page 64.

Chapter 6.4 „Parking the machine

DRP45DX

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.

DRP45DX

B-SYM-1068

B-HAT-0003

Checks prior to start up – Checking the engine oil level

5.3 Checking the engine oil level

NOTICE! Danger of engine damage!

– +Use only oil of the permitted specification

Chapter 8.3.1 „Engine oil“ on page 65.

Fig. 23

Fig. 24

Protective equipment:

orking clothes

Safety shoes

Protective gloves

1. Clean the area around the oil dipstick.

2. Pull out the dipstick and wipe it clean with a lint-free, clean

cloth.

3. Insert the dipstick and pull it out again to check the oil level.

The oil level must be between the “MIN” and “MAX”

marks.

4. NOTICE!

Danger of engine damage!

– Do not fill in too much engine oil.

If the oil level is too low, top up oil to the “MAX” mark.

5. Push the dipstick in.

DRP45DX

B-SYM-1069

B-692-0019

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. 25

even damage of the engine. If necessary, fill in fuel through a screen filter.

– Use only fuel of the permitted specification

Chapter 8.3.2 „Fuel“ on page 65.

Fig. 26

Protective equipment:

orking clothes

Safety shoes

Protective gloves

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.

4. Close the cap.

DRP45DX

B-SYM-1073

B-834-0042

Checks prior to start up – Checking the rubber buffers

5.5 Checking the rubber buffers

Fig. 27

Fig. 28

Protective equipment:

Park the machine safely Ä Chapter 6.4 „Parking the machine

Working clothes

Safety shoes

Protective gloves

in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Check all rubber buffers for tight fit, cracks and tear-offs.

4. Replace damaged rubber buffers immediately.

DRP45DX

6 Operation

Operation

DRP45DX

Operation – Folding down the steering rod

6.1 Folding down the steering rod

1. Pull the locking pawl lever (2) and fold down the steering rod.

The steering rod can swing freely

2. Adjust the steering rod with the height adjustment (1) to the

required height.

Fig. 29

DRP45DX

6.2 Starting the engine

B-692-0023

B-692-0241

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. 30

Protective equipment:

Hearing protection

orking clothes

Safety shoes

1. Set the throttle lever to position “MIN”.

2. Set the handle to position “0”.

Fig. 31

DRP45DX

B-ELE-0070

B-ELE-0072

Operation – Starting the engine

Fig. 32

Fig. 33

3. Turn the ignition key to position “I”.

The warning buzzer sounds.

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! 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.

The warning buzzer stops.

NOTICE! Danger of engine damage!

– Warm up engine for a short while

before starting work. Do not operate the engine immediately under full load.

DRP45DX

6.3 Operation

B-692-0022

B-692-0242

Operation – Operation

Operate the machine only with the steering rod folded down.

Use only the steering rod to steer the machine.

Guide the machine so that your hands do not hit against solid objects.

Keep feet clear of the vibrating base plate.

CAUTION! Danger of injury caused by uncontrolled

machine movement!

– Always hold on to a running machine.

Always keep an eye on a running machine.

–

Fig. 34

Protective equipment:

Hearing protection

orking clothes

Safety shoes

1. Make sure that nobody is in the danger zone.

2. NOTICE!

The centrifugal clutch may be damaged!

– Operate the machine only with full

throttle.

Set the throttle lever to “MAX” position.

3. Shift the handle forwards.

The machines vibrates forward with a speed which corre-

sponds with the travel lever position.

Fig. 35

DRP45DX

B-692-0243

B-692-0241

B-692-0023

B-692-0026

Operation – Operation

Fig. 36

4. CAUTION!

Danger of injury caused by the crushing of body parts!

– When reversing, steer the machine from

the side using the steering handle.

Pull the handle back.

The machines vibrates backwards with a speed which

corresponds with the handle position.

5. Move the handle back to position “0”.

The machine stops and vibrates on the spot.

Fig. 37

Fig. 38

Help if the machine gets stuck

6. For short work interruptions you should always return the

throttle lever to “MIN” position (idle speed).

Vibration is switched off.

7. For short work interruptions you should always park the

machine in secured condition

Chapter 6.4 „Parking the

machine in secured condition“ on page 55.

1. Keep shifting the throttle lever between “MIN” and “MAX”

positions.

At the same time use the steering rod to pull the machine right and left, until it comes free.

Fig. 39

DRP45DX

Operation – Parking the machine in secured condition

6.4 Parking the machine in secured condition

1. Park the machine on level and firm ground.

2. Set the throttle lever to “MIN” position (idle speed).

ibration is shut down.

Fig. 40

3. 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. 41

Fig. 42

Set the throttle lever to position “Stop”.

The engine is shut down.

The warning buzzer sounds.

4. Turn the ignition key to position “0” and pull it out.

The warning buzzer stops.

DRP45DX

Operation – Parking the machine in secured condition

DRP45DX

Loading/transporting the machine

7 Loading/transporting the machine

DRP45DX

B-692-0062

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:

orking clothes

Safety shoes

Protective gloves

Chapter 2 „Tech-

Fig. 43

Park the machine safely in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Make sure that the protection hood is fastened correctly

Chapter 8.2.1.2 „Closing the protection

hood“ on page 64.

4. Move the steering rod to an upright position and engage the

locking pawl lever

Chapter 6.4 „Parking the machine

DRP45DX

B-692-0246

Fig. 44

Loading/transporting the machine – Loading the machine

5. Attach the lifting tackle to the designated lifting eye (1).

6. 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.

DRP45DX

B-692-0064

B-692-0244

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:

1. Pull the lashing belts crosswise over the marked lashing

point (1).

orking clothes

Safety shoes

Protective gloves

Fig. 45

Fig. 46

2. Lash the machine securely to the transport vehicle as shown.

DRP45DX

8 Maintenance

Maintenance

DRP45DX

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 work“ on page 33.

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

Chapter 3.4 „Han-

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.

DRP45DX

B-692-0203

B-692-0204

Maintenance – Preparations / concluding work

8.2 Preparations / concluding work

Certain maintenance tasks require preparations and concluding activities.

This includes maintenance doors as well as securing certain components.

After this work close all maintenance flaps and doors again and return all components to their operating condition.

8.2.1 Opening / closing the protection hood

8.2.1.1 Opening the protection hood

e.g. opening and closing maintenance flaps and

Fig. 47

Protective equipment:

1. Remove the rear screws (2) on both sides of the machine.

2. Put the screws (2) and the matching washers to the side.

3. Loosen the front screws (1) on both sides.

4. Fold the protection hood forward.

5. Secure the protection hood against accidental closing.

For this tighten the screw (1) on both sides.

orking clothes

Protective gloves

Fig. 48

DRP45DX

B-692-0204

B-692-0205

Maintenance – Preparations / concluding work

8.2.1.2 Closing the protection hood

o fasten the protection hood, use only the prescribed original

T screws.

Always screw in and tighten all screws and their washers.

Protective equipment:

1. Loosen the screw (1) on both sides.

2. Close the protection hood.

Fig. 49

orking clothes

Protective gloves

Fig. 50

3. T

ighten the screw (1) on both sides.

4. Screw in screws (2) and washers on both sides and tighten

them.

DRP45DX

8.3 Fuels and lubricants

Maintenance – Fuels and lubricants

8.3.1

8.3.1.1 Oil quality

8.3.1.2

Engine oil

Oil viscosity

Use only low-ash engine oils (Low SAPS) according to the following specifications:

n ACEA E7 n ACEA E9 n API CJ-4

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. 51: Oil viscosity diagram

8.3.1.3 Oil change intervals

8.3.2 Fuel

8.3.2.1

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 D 975, grade no. 1-D S15 and 2-D S15 n BS 2869 A1/A2

In order to fulfil national emission regulations, the legally required fuels must be used (

e.g. sulphur content).

DRP45DX

Maintenance – Fuels and lubricants

8.3.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging because of paraf

At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are available for Arctic climates.

8.3.2.3 Storage

Even traces of zinc, lead and copper can cause deposits in the injection nozzles, especially in modern Common-Rail injection systems.

Zinc and lead coatings in refuelling systems and fuel lines are not permitted.

Copper containing materials (copper lines, brass items) should be avoided, because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system.

fin separation.

NOTICE! Danger of engine damage!

– The admixture of petroleum and the addition of

“flow enhancing additives” (fuel additives) is not permitted.

8.3.3

Oil for exciter shaft housing

Use only engine oils according to the following specifications:

n API CI-4 or higher quality

Avoid mixing engine oils.

8.3.4 Mineral oil based hydraulic oil

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.

NOTICE! Components may get damaged!

– Do not use low-ash engine oils for the exciter

shaft housing.

DRP45DX

Maintenance – Fuels and lubricants

The viscosity index must be at least 150 (observe information of manufacturer).

DRP45DX

Maintenance – List of fuels and lubricants

8.4 List of fuels and lubricants

Assembly group Fuel or lubricant Filling quantity

Summer Winter Observe the level

mark!

Engine oil SAE 10W-40

Specification:

Fuel Diesel Winter diesel fuel 5.0 l

Specification:

Exciter shaft housing as engine oil 0.4 l

Steering rod Hydraulic oil (ISO), HV 32

Specification:

Chapter 8.3.1 „Engine oil“ on page 65

SAE 15W-40

SAE 10W-30

SAE 30 SAE 10W

Chapter 8.3.2 „Fuel“ on page 65

Chapter 8.3.4 „Mineral oil based

hydraulic oil“ on page 66

1.5 l

(0.4 gal us)

(1.3 gal us)

(0.1

1 gal us)

0.4 l

(0.1

1 gal us)

DRP45DX

8.5 Running-in instructions

Maintenance – Running-in instructions

8.5.1

General

8.5.2 After 25 operating hours

The following maintenance work must be performed when running in new machines or overhauled engines.

1. Change the engine oil.

Check the valve clearance, adjust if necessary

8.9.2 „Checking, adjusting the valve clearance“ on page 77.

3. Check engine and machine for leaks.

4. Retighten the fastening screws on air filter

attachments.

5. Retighten the bolted connections on the machine.

Check the V belt“ on page 93.

Check the oil level in the exciter shaft housing

8.11.4 „Checking the oil level in the exciter housing“ on page 94.

-belt

Chapter 8.11.3 „Servicing the V-

Chapter

, exhaust and other

Chapter

DRP45DX

Maintenance – Maintenance Table

8.6 Maintenance Table

No. Maintenance works Page

Weekly

8.7.1 Checking, cleaning the air filter 71

8.7.2 Checking and cleaning the water separator 72

Semi-annually

8.8.1 Battery service 74

Annually / every 250 operating hours

8.9.1 Replacing the V-belt 75

8.9.2 Checking, adjusting the valve clearance 77

8.9.3 Changing the engine oil and cleaning the oil filter 79

8.9.4 Replacing the fuel filter 81

8.9.5 Replacing the air filter 82

8.9.6 Changing the oil in the exciter housing 83

8.9.7 Checking the hydraulic oil level 85

8.9.8 Replacing the starter rope 87

8.9.9 Lubricating the machine 89

Every 2 years / every 500 operating hours

8.10.1 Changing the hydraulic oil 90

As required

8.11.1 Cleaning the machine 92

8.11.2 Cleaning the cooling fins and the cooling air intake openings 92

8.11.3 Servicing the V-belt 93

8.11.4 Checking the oil level in the exciter housing 94

8.11.5 Measures prior to extended shut-down period 94

DRP45DX

8.7 Weekly

B-SYM-1074

B-HAT-0006

Maintenance – Weekly

8.7.1

Fig. 52

Fig. 53

Checking, cleaning the air filter

Protective equipment:

2. Allow the engine to cool down.

3. Remove the cap (3).

4. Unscrew the knurled nut (2) and pull out the air filter (1).

5. Clean the cover

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.

Park the machine safely in secured condition“ on page 55.

NOTICE! Danger of engine damage!

– Prevent dirt from getting into the air

–

orking clothes

Safety shoes

Protective gloves

Safety goggles

Chapter 6.4 „Parking the machine

intake opening. Do not clean the air filter housing with

compressed air.

Clean the filter housing with a clean, lint-free cloth.

DRP45DX

B-GEN-0042

B-HAT-0006

B-SYM-1075

Maintenance – Weekly

Fig. 54

7. CAUTION!

Danger of eye injuries caused by particles flying around!

– Wear your personal protective equipment

(safety gloves, protective working clothes, goggles).

Blow the air filter out with dry compressed air (max. 5 bar (73 psi)

) from inside to outside by moving the gun up and

down inside the element, until it is free of dust.

8. Examine the air filter with a torch for cracks and holes.

9. Replace the air filter if it is damaged.

10. Insert the air filter (1) carefully into the filter housing and

fasten it with the knurled nut (2).

11. NOTICE!

Danger of engine damage!

– Ensure correct fit of air filter cover and

seal.

Fig. 55

8.7.2

Fig. 56

Close the cap (3).

Checking and cleaning the water separator

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely

After taking the engine into operation you should check for signs of water and dirt initially every day.

DRP45DX

B-HAT-0005

Maintenance – Weekly

Fig. 57

Protective equipment:

Park the machine safely

orking clothes

Safety shoes

Protective gloves

Chapter 6.4 „Parking the machine

in secured condition“ on page 55.

2. Place the transparent container under the drain plug.

3. Loosen the drain plug and collect escaping fluid.

4. Drain the fuel of

f until there is no water left.

5. Screw the drain plug tightly back in. Ensure leak tightness.

6. Dispose of collected fluid in line with environmental regula-

tions.

DRP45DX

B-SYM-1077

B-692-0066

Maintenance – Semi-annually

8.8 Semi-annually

8.8.1

Fig. 58

Fig. 59

Battery service

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 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!

Protective equipment:

Park the machine safely in secured condition“ on page 55.

2. Remove the bracket (1) of the battery

3. Remove the battery (3) and the vibration damping mats (2, 4,

5, 6).

4. Check the condition of the vibration insulation mats, replace if

necessary

5. Clean the outside of the battery

6. Clean battery poles and pole clamps and grease them with

pole grease (V

7. On serviceable batteries check the acid level, if necessary

top up to the filling mark with distilled water

8. Install battery and vibration insulation mats.

9. Install the bracket of the battery

aseline).

orking clothes

Safety shoes

Protective gloves

Safety goggles

Chapter 6.4 „Parking the machine

, if

DRP45DX

B-692-0206

B-692-0208

Maintenance – Annually / every 250 operating hours

8.9 Annually / every 250 operating hours

8.9.1

Fig. 60

Replacing the V-belt

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Unscrew the V

4. Unscrew the guard (1).

-belt guard (1).

orking clothes

Protective gloves

Chapter 6.4

Fig. 61

Fig. 62

5. Unscrew the V

6. Replace the V

7. If necessary

removed.

8. Fasten the V

DRP45DX

-belt pulley (1).

-belt (3).

, reassemble the spacers (2) that may have been

-belt pulley, tightening torque: 35 Nm (26 ft·lbf).

B-692-0206

Maintenance – Annually / every 250 operating hours

9. Check the centre distance (x) between the centrifugal clutch

(1) and the V-belt pulley (2).

Nominal value: 384 ± 1 mm

If the centre distance is incorrect, contact our customer service.

Fig. 63

Fig. 64

Fig. 65

10. Fasten the guard (1), tightening torque:

11. Fasten the V

-belt guard (1).

15 Nm (11 ft·lbf).

8.9.1.1 Checking the frequency of the base plate

Keep feet and hands clear of the vibrating base plate.

DRP45DX

CAUTION! Danger of injury caused by uncontrolled

machine movement!

– Always hold on to a running machine. – Always keep an eye on a running machine.

Maintenance – Annually / every 250 operating hours

Protective equipment:

Special tool:

1. Park the machine on a rubber mat.

Start the engine engine“ on page 51.

3. Run the machine at maximum speed for one minute.

4. Check the base plate’

instrument (e.g. Sirometer).

Nominal value:

data“ on page 11

Park the machine safely in secured condition“ on page 55.

6. If frequency incorrect:

n Check the engine speed. n Check the V n If necessary, contact our customer service.

-belt.

orking clothes

Hearing protection

Safety shoes

Sirometer

Chapter 6.2 „Starting the

s frequency with a suitable measuring

Chapter 2 „Technical

Chapter 6.4 „Parking the machine

8.9.2 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.

Preparations

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Let the engine to cool down to ambient temperature.

orking clothes

Protective gloves

Chapter 6.4

DRP45DX

Maintenance – Annually / every 250 operating hours

3. Remove the air filter cover (2).

4. Disassemble the covering (1).

Fig. 66

5. Unscrew the fastening screws (1).

6. Remove the valve cover (2) with gasket.

Fig. 67

Checking the valve clearance

Fig. 68

Valve clearance:

Intake valve (IN) 0.20 mm (0.008 in)

Exhaust valve (EX) 0.20 mm (0.008 in)

1. Crank the engine, until the exhaust valve (EX) is fully open.

2. Check the valve clearance on the intake valve (IN) with a

feeler gauge (1), adjust if necessary

3. Crank the engine further

4. Check the valve clearance on the exhaust valve, adjust if

necessary

, until the intake valve is fully open.

DRP45DX

Adjusting the valve clearance

Fig. 69

Final work

Maintenance – Annually / every 250 operating hours

1. Loosen screw (3) on the rocker arm.

2. Adjust the hexagon nut (2), until the feeler gauge (1) can be

inserted and pulled out with noticeable resistance after the screw (3) has been tightened.

1. Install the valve cover (2) with a new gasket.

2. T

ighten the fastening screws (1) evenly.

Fig. 70

Fig. 71

8.9.3

3. Assemble covering (1) and air filter cover (2).

4. After a short test run check the valve cover for leaks.

Changing the engine oil and cleaning the oil filter

NOTICE! Danger of engine damage!

– Change the oil only with the engine at oper-

ating temperature.

–

Use only oil of the permitted specification

Chapter 8.3.1 „Engine oil“ on page 65.

– Filling quantity:

lubricants“ on page 68

Chapter 8.4 „List of fuels and

DRP45DX

Maintenance – Annually / every 250 operating hours

Draining off engine oil

Fig. 72

Cleaning the oil filter

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Clean the area around the dipstick and pull the dipstick out.

3. Clean the area around the drain hose.

4. Loosen the hose clamp (1) and route the drain hose to the

outside.

5. WARNING!

Danger of burning on hot components!

– Wear your personal protective equipment

(protective gloves, protective clothing).

–

Avoid touching hot components.

Unscrew the drain plug (2) and collect any oil running out.

6. Clean and screw in the drain plug.

7. Assemble the drain hose with the hose clamp.

8. Loosen the screw (1) for approx. five turns and pull the oil

filter (2) out of the housing.

orking clothes

Protective gloves

Safety goggles

Chapter 6.4

Fig. 73

Fig. 74

9. CAUTION!

Danger of eye injuries caused by particles flying around!

– Wear your personal protective equipment

(safety gloves, protective working clothes, goggles).

Use compressed air to blow the oil filter out from the inside to the outside.

10. Check the seal ring (2) for damage, change if necessary

11. Slightly oil the seal rings (1) and (2).

DRP45DX

Fig. 75

Filling in engine oil

Maintenance – Annually / every 250 operating hours

12. Insert the oil filter (2) into the housing and press it against the

end stop.

13. Before tightening the screw (1) make sure that the tensioning

springs touch the oil filter with both ends.

14. Tighten the screw.

15. Fill in fresh engine oil up to the bottom edge of the filling

opening.

16. After a short test run check the oil level on the dipstick; if nec-

essary

, top up to the top dipstick mark.

Fig. 76

Concluding work

8.9.4 Replacing the fuel filter

17. Check oil filter and drain plug for leaks.

18. Dispose of oil 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:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Clean the area around the tank filler cap.

3. Remove the tank filler cap.

orking clothes

Protective gloves

Chapter 6.4

DRP45DX

Maintenance – Annually / every 250 operating hours

4. Pull the fuel filter out of the tank by the string.

5. Pull the fuel hose (3) off the fuel filter (2).

6. Take the fuel filter out of the bracket (1) and replace it with a

new one.

7. Plug on the fuel line.

8. Insert the fuel filter into the tank.

9. Close the fuel tank tightly.

Fig. 77

8.9.5 Replacing the air filter

Fig. 78

The fuel system is self-bleeding.

10. Dispose of fuel and filter in an environmentally friendly way.

NOTICE! Danger of engine damage!

– Do not start the engine after having removed

the air filter

Protective equipment:

Park the machine in secured condition Ä Chapter 6.4 „Parking the machine in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Remove the cap (3).

4. Unscrew the knurled nut (2) and pull out the air filter (1).

5. Clean the cover.

6. NOTICE!

Danger of engine damage!

– Prevent dirt from getting into the air

–

orking clothes

Protective gloves

intake opening. Do not clean the air filter housing with

compressed air.

Clean the filter housing with a clean, lint-free cloth.

7. Replace the air filter

DRP45DX

Fig. 79

OIL

B-692-0013

Maintenance – Annually / every 250 operating hours

8. Insert the air filter (1) carefully into the filter housing and

fasten it with the knurled nut (2).

9. NOTICE!

Danger of engine damage!

– Ensure correct fit of air filter cover and

seal.

Close the cap (3).

8.9.6

Changing the oil in the exciter housing

NOTICE! Components may get damaged!

– Use only oil of the permitted specification

cants“ on page 68.

– Do not use low-ash engine oils for the exciter

shaft housing.

Protective equipment:

1. Park the machine on level ground.

Park the machine safely in secured condition“ on page 55.

3. Clean the area around the bleeding screw (1) and filling/drain

plug (2).

4. T

5. Unscrew the bleeding screw

6. Unscrew the filling/drain plug and collect any oil running out.

ilt the machine slightly towards the oil drain side and secure

it properly.

Chapter 8.4 „List of fuels and lubri-

orking clothes

Safety shoes

Protective gloves

Chapter 6.4 „Parking the machine

Fig. 80

DRP45DX

B-692-0014

B-692-0015

Maintenance – Annually / every 250 operating hours

7. Tilt the machine to the opposite side and secure it properly.

8. Fill in new oil.

Fig. 81

9. Stand the machine horizontally and check the oil level.

Nominal value: Bottom edge of filling/drain bore.

10. Clean the bleed screw (1) and filling/drain plug (2) and screw

them in with a low-strength sealing agent (e.g. spare parts number: DL 009 700 16).

11. Dispose of oil in line with environmental regulations.

Fig. 82

DRP45DX

Maintenance – Annually / every 250 operating hours

8.9.7 Checking the hydraulic oil level

Fig. 83

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Adjust the steering rod with height adjustment so that the

area with the filler screw is horizontal.

3. Unscrew the filler screw

4. Press the handle forward against the stop and secure it using

suitable means.

orking clothes

Protective gloves

Chapter 6.4

Fig. 84

Fig. 85

Fill in hydraulic oil, bleed the system

5. The oil level must reach the mark on the steering rod head, if

necessary

Mark: approx. 40 mm (1.6 in) below the filler opening

, fill in hydraulic oil.

NOTICE! Components may get damaged!

– Use only oil of the permitted specification.

DRP45DX

Maintenance – Annually / every 250 operating hours

6. Press the handle forward against the stop and secure it using

suitable means.

Fig. 86

7. Place a cloth underneath the bleeding screw to collect

leaking oil.

8. Slacken the bleeding screw

9. W

ait until all air has escaped and then tighten the bleeding

screw.

Fig. 87

Fig. 88

Concluding work

10. Fill in hydraulic oil up to the mark on the steering rod head.

11. Screw in the filler screw

Fig. 89

DRP45DX

Maintenance – Annually / every 250 operating hours

8.9.8 Replacing the starter rope

Fig. 90

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Unscrew the fastening screws (1) and disassemble the recoil

starter (2).

4. Pull the starter rope with the starter handle (1) out com-

pletely

5. Secure the coil (2) against winding up.

6. Loosen the knot (3) in the starter rope and remove the old

starter rope.

7. Carefully turn the coil back, until the recoil spring is relieved.

orking clothes

Protective gloves

Chapter 6.4

Fig. 91

Fig. 92

8. Thread in the new starter rope and fix it with knots on both

ends .

A = 15 mm (0.6 in)

DRP45DX

Maintenance – Annually / every 250 operating hours

9. Pre-tension the coil by approx. 4 rotations in direction of

arrow.

Thereby place the starter rope into the recess in the coil .

Fig. 93

10. CAUTION!

Danger of injury caused by the starter handle hitting against your body!

– Do not let the starter handle hit back.

Slowly guide the starter handle back to initial position .

11. Pull the starter handle to check the function and light move-

ment of the recoil starter

Fig. 94

Fig. 95

12. Assemble the recoil starter (2) with fastening screws (1).

DRP45DX

B-692-0245

B-692-0186

Grease

B-692-0245

Maintenance – Annually / every 250 operating hours

8.9.9 Lubricating the machine

Fig. 96

Protective equipment:

Park the machine safely in secured condition“ on page 55.

2. Unscrew the four fastening screws (1) and remove the cover

(2).

3. NOTICE!

Inadequate lubrication will cause damage to components!

– Use only grease of the permitted specifi-

cation. (Spare parts number of lubrication

grease: DL 009 960 17)

orking clothes

Safety shoes

Protective gloves

Chapter 6.4 „Parking the machine

Fig. 97

Fig. 98

Grease the mechanical parts between the fork head (1), lever (2) and bolt (3).

4. Fasten the cover (2) with four fastening screws, tightening

torque: 10 Nm

(7.5 ft·lbf).

DRP45DX

Maintenance – Every 2 years / every 500 operating hours

8.10 Every 2 years / every 500 operating hours

8.10.1

Fig. 99

Changing the hydraulic oil

Protective equipment:

2. Adjust the steering rod with height adjustment so that the

3. Unscrew the filler screw

4. Press the handle forward against the stop and secure it using

orking clothes

Protective gloves

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

area with the filler screw is horizontal.

suitable means.

Chapter 6.4

Fig. 100

Fig. 101

5. Unscrew the bleeding screw and collect any oil running out.

6. Screw in the bleeding screw

DRP45DX

Fig. 102

Maintenance – Every 2 years / every 500 operating hours

7. NOTICE!

Components may get damaged!

– Use only oil of the permitted specifica-

tion.

Fill in hydraulic oil up to the mark on the steering rod head.

Mark:

approx. 40 mm (1.6 in) below the filler opening

Fig. 103

Fig. 104

8. Slacken the bleeding screw

9. W

10. Fill in hydraulic oil up to the mark on the steering rod head.

ait until all air has escaped and then tighten the bleeding

screw.

Fig. 105

11. Screw in the filler screw

12. Dispose of oil in an environmentally friendly way

DRP45DX

Maintenance – As required

8.11 As required

1.1 Cleaning the machine

8.1

orking clothes

Protective gloves

Fig. 106: Cleaning the machine (example)

Protective equipment:

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. NOTICE!

Electric components can be damaged by water entering into the system!

– Do not guide the water jet directly into the

cooling air openings of the recoil starter into the dry air filter or onto electrical equipment.

Clean the machine from the outside and inside with a water jet.

4. W

arm up the engine for a while to avoid corrosion.

8.11.2 Cleaning the cooling fins and the cooling air intake openings

Chapter 6.4

30 minutes.

Fig. 107

How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions; clean daily if necessary

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Remove dried dirt with a suitable brush from all cooling fins

and cooling air intake openings.

4. CAUTION!

Danger of eye injuries caused by particles flying around!

– Wear your personal protective equipment

(safety gloves, protective working clothes, goggles).

Blow out the cooling fins and cooling air intake openings with compressed air

orking clothes

Protective gloves

Safety goggles

Chapter 6.4

DRP45DX

8.11.3 Servicing the V-belt

Maintenance – As required

5. In case of damp or oily contamination you should consult our

customer service department.

Fig. 108

Protective equipment:

Park the machine in secured condition „Parking the machine in secured condition“ on page 55.

2. Allow the engine to cool down.

3. Unscrew the V

4. Check condition and tension of V

Compression measurement: 10 - 25 mm

(0.59 - 0.98 in).

-belt guard (1).

The V-belt cannot be re-tightened.

orking clothes

Protective gloves

-belt.

Chapter 6.4

Fig. 109

Fig. 110

Replace the V-belt if it is damaged or if the compression

measurement is exceeded belt“ on page 75.

6. Fasten the V

DRP45DX

-belt guard (1).

Chapter 8.9.1 „Replacing the V-

B-692-0015

Maintenance – As required

8.11.4 Checking the oil level in the exciter housing

NOTICE! Components may get damaged!

– Use only oil of the permitted specification

Chapter 8.4 „List of fuels and lubri-

cants“ on page 68.

– Do not use low-ash engine oils for the exciter

shaft housing.

Fig. 111

Protective equipment:

1. Park the machine on level ground.

Park the machine safely in secured condition“ on page 55.

3. Allow the machine to cool down.

4. Clean the area around the bleeding screw (1) and filling/drain

plug (2).

5. Unscrew the bleeding screw

6. Unscrew the filling/drain plug and check the oil level; top up if

necessary

7. Clean the bleed screw and filling/drain plug and screw them

in with a low-strength sealing agent ( DL 009 700 16).

Nominal value: Bottom edge of filling/drain bore.

n n n

8.11.5 Measures prior to extended shut-down period

orking clothes

W Safety shoes Protective gloves

Chapter 6.4 „Parking the machine

e.g. spare parts number:

8.11.5.1 Measures before shutting down

If the machine is shut down for a longer period of time, e.g. winter season, the following work must be carried out:

1. Clean the machine thoroughly

2. Clean the water separator

3. Fill the fuel tank with diesel fuel, to prevent the formation of

4. Change engine oil and oil filter if the oil change had been car-

5. Change the fuel filter

6. After shutting down store the machine under cover in a dry

7. Protect the cooled down engine against dust and moisture.

condensation water in the tank.

ried out more than 300 operating hours ago.

and well ventilated room.

DRP45DX

8.11.5.2 Battery service during prolonged machine downtimes

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).

Maintenance – As required

Protective equipment:

1. Switch of

2. Measure the open-circuit voltage of the battery at regular

intervals (at least 1 x per month).

3. Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging.

4. Switch of clamps.

5. After each charging process allow the battery to rest for one hour before taking it into service.

6. For standstill periods of more than one month you should always disconnect the battery ular open-circuit voltage measurements.

f all consuming devices (e.g. ignition, light).

Reference values: 12.6 V = fully charged; 12.3 V = discharged to 50%.

The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.

f the charging current before removing the charging

orking clothes

Protective gloves

Safety goggles

. Do not forget to perform reg-

8.11.5.3 Measures before restarting

1. Replace the fuel filter.

2. Replace the air filter.

3. Change the engine oil and clean the oil filter.

4. Check cables, hoses and lines for cracks and leaks.

5. Start the engine and run it for 15 to 30 minutes with idle

speed.

DRP45DX

Maintenance – As required

6. Check the oil levels.

7. Clean the machine thoroughly.

DRP45DX

9 Troubleshooting

Troubleshooting

DRP45DX

Troubleshooting – Preliminary remarks

9.1 Preliminary remarks

Malfunctions are frequently caused by incorrect operation of the machine or insuf should therefore thoroughly read these instructions on correct operation and maintenance.

If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact our customer service department.

ficient maintenance. Whenever a fault occurs you

DRP45DX

B-692-0023

Troubleshooting – Starting the engine with the recoil starter

9.2 Starting the engine with the recoil starter

Start the engine with the recoil starter only if the battery is defective, empty or missing.

Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death.

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. 112

Protective equipment:

orking clothes

Hearing protection

Safety shoes

1. Set the throttle lever to position “MIN”.

DRP45DX

B-692-0241

Troubleshooting – Starting the engine with the recoil starter

2. Set the handle to position “0”.

Fig. 113

3. Lightly pull the rope twice with the starter handle, until resistance can be felt (compression pressure).

4. Guide the starter handle back to initial position.

Fig. 114

Fig. 115

CAUTION! Danger of injury caused by uncontrolled

machine movement!

– 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.

6. Manually guide the starter handle back to initial position.

7. If the engine does not start during the first attempt, repeat the

starting process.

NOTICE! Danger of engine damage!

– Warm up engine for a short while before

starting work. Do not operate the engine immediately under full load.

100

DRP45DX

Fayat DYNAPAC DRP45DX Original Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents