Dynapac DTR75D Walk behind twin drum roller Operation & Maintenance Instruction Manual DL820751 PDF

Operating Instruction/Maintenance Instruction Original Operating Instructions

DTR75D Walk behind twin drum roller

S/N 961 925 54 1001> DL8 207 51 EN © 05/2022

WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Always start and operate the engine in a well-ventilated area.

If in an enclosed area, vent the exhaust to the outside.

Do not modify or tamper with the exhaust system.

Do not idle the engine except as necessary.

For more information go to www.P65warnings.ca.gov/diesel.

WARNING: Crude oil, gasoline, diesel fuel and other petroleum products can expose you to chemicals including toluene and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

These exposures can occur in and around oil fields, refineries, chemical plants, transport and storage operations such as pipelines, marine terminals, tank trucks and other facilities and equipment.

For more information go to www.P65Warnings.ca.gov/petroleum.

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Table of contents

Table of contents 1

Introduction............................................................................................ 9 1.1 Foreword....................................................................................... 10 1.2 Machine type plate and engine type plate................................. 12

2

Technical data...................................................................................... 13 2.1 Noise and vibration data.............................................................. 16 2.1.1 Noise data................................................................................... 16 2.1.2 Vibration data.............................................................................. 17

3

Concerning your safety...................................................................... 19 3.1 Basic prerequisites...................................................................... 20 3.1.1 General........................................................................................ 20 3.1.2 Explanation of signal words used................................................ 21 3.1.3 Personal protective equipment.................................................... 22 3.1.4 Intended use................................................................................ 23 3.1.5 Improper use............................................................................... 24 3.1.6 Estimated service life of the machine.......................................... 24 3.2 Definition of responsible persons.............................................. 26 3.2.1 Operating company..................................................................... 26 3.2.2 Expert / qualified person.............................................................. 26 3.2.3 Driver / operator.......................................................................... 27 3.3 Basic safety regulations for safe operation............................... 28 3.3.1 Remaining dangers, remaining risks........................................... 28 3.3.2 Regular safety inspections.......................................................... 28 3.3.3 Modifications and alterations to the machine.............................. 28 3.3.4 Damage, defects, misuse of safety devices................................ 29 3.4 Handling fuels and lubricants..................................................... 30 3.4.1 Preliminary remarks.................................................................... 30 3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel...................................................................... 31 3.4.3 Safety regulations and environmental protection regulations for handling oil.................................................................................. 33 3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil................................................................... 34 3.4.5 Safety regulations and environmental protection regulations for handling battery acid................................................................... 36

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Table of contents 3.5 Loading / transporting the machine........................................... 38 3.6 Start-up procedure....................................................................... 39 3.6.1 Prior to starting up....................................................................... 39 3.6.2 Starting the engine...................................................................... 39 3.7 Work mode.................................................................................... 41 3.7.1 Persons in the danger area......................................................... 41 3.7.2 Operation..................................................................................... 41 3.7.3 Driving up and down slopes........................................................ 41 3.7.4 Working with vibration................................................................. 42 3.7.5 Parking the machine.................................................................... 42 3.8 Refuelling...................................................................................... 43 3.9 Emergency procedures............................................................... 44 3.10 Maintenance work...................................................................... 45 3.10.1 Preliminary remarks.................................................................. 45 3.10.2 Working on hydraulic lines........................................................ 45 3.10.3 Working on the engine.............................................................. 46 3.10.4 Maintenance work on electric components and battery............ 46 3.10.5 Cleaning work............................................................................ 47 3.10.6 Measures for longer shut-down periods.................................... 47 3.10.7 After maintenance work............................................................. 47 3.11 Repair.......................................................................................... 48 3.12 Signage....................................................................................... 49 4

4

Indicators and control elements........................................................ 55 4.1 Machine......................................................................................... 56 4.1.1 Water spraying system................................................................ 56 4.1.2 Operating hour meter.................................................................. 57 4.1.3 Starter switch............................................................................... 57 4.1.4 Warning buzzer for engine oil pressure....................................... 58 4.2 Steering rod.................................................................................. 59 4.2.1 Steering rod locking bolt.............................................................. 60 4.2.2 Travel lever.................................................................................. 60 4.2.3 Throttle lever............................................................................... 60 4.2.4 Reversing protection................................................................... 61 4.2.5 Cleaning rod................................................................................ 61 4.2.6 Vibration lever............................................................................. 61

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Table of contents 4.2.7 Locking pawl lever....................................................................... 62 4.2.8 Height adjustment....................................................................... 62 4.3 Engine........................................................................................... 63 4.3.1 Recoil starter............................................................................... 63 5

Checks prior to start up...................................................................... 65 5.1 Notes on safety............................................................................. 66 5.2 Visual inspections and function tests........................................ 67 5.3 Daily maintenance........................................................................ 68 5.3.1 Checking the engine oil level....................................................... 68 5.3.2 Checking the fuel level; topping up fuel....................................... 69 5.3.3 Checking the hydraulic oil level................................................... 70 5.3.4 Checking the reversing protection............................................... 72 5.3.5 Checking the rubber buffers........................................................ 74 5.3.6 Checking the water level, topping up.......................................... 75

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Operation.............................................................................................. 77 6.1 Folding down and adjusting the steering rod........................... 78 6.2 Starting the engine....................................................................... 80 6.3 Travel mode.................................................................................. 84 6.4 Work mode.................................................................................... 86 6.4.1 Preliminary remarks and safety notes......................................... 86 6.4.2 Working with vibration................................................................. 87 6.5 Switching the water spraying system on/off............................. 89 6.6 Parking the machine in secured condition................................ 90 6.7 Emergency procedures............................................................... 92 6.7.1 Disconnecting the battery............................................................ 92 6.7.2 Deactivating the reversing protection.......................................... 92

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Loading / transporting the machine.................................................. 95 7.1 Loading the machine................................................................... 96 7.2 Lashing the machine to the transport vehicle........................... 98 7.3 Loading by crane.......................................................................... 99 7.4 After transportation.................................................................... 100

8

Maintenance....................................................................................... 101 8.1 Preliminary remarks and safety notes..................................... 102 8.2 Fuels and lubricants.................................................................. 104

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Table of contents 8.2.1 Engine oil................................................................................... 104 8.2.2 Fuel........................................................................................... 105 8.2.3 Oil for exciter shaft housing....................................................... 106 8.2.4 Hydraulic oil............................................................................... 107 8.3 List of fuels and lubricants........................................................ 109 8.4 Running-in instructions............................................................. 110 8.4.1 General information................................................................... 110 8.4.2 After the first 25 operating hours............................................... 110 8.5 Maintenance Table...................................................................... 111 8.6 Weekly......................................................................................... 113 8.6.1 Checking, cleaning the air filter................................................. 113 8.6.2 Checking and cleaning the water separator.............................. 115 8.7 Semi-annually............................................................................. 117 8.7.1 Battery service........................................................................... 117 8.8 Annually...................................................................................... 119 8.8.1 Changing engine oil and oil filter element.................................. 119 8.8.2 Replacing the fuel filter.............................................................. 121 8.8.3 Changing the oil in the exciter housing..................................... 123 8.8.4 Replacing the air filter................................................................ 124 8.8.5 Checking the hydraulic lines...................................................... 125 8.9 Every 2 years / every 500 operating hours.............................. 127 8.9.1 Changing hydraulic oil and hydraulic oil filter............................ 127 8.10 As required............................................................................... 131 8.10.1 Cleaning the water spraying system....................................... 131 8.10.2 Cleaning the scrapers............................................................. 132 8.10.3 Checking/adjusting the scrapers............................................. 133 8.10.4 Cleaning the cooling fins and the cooling air intake openings. 133 8.10.5 Cleaning the machine.............................................................. 134 8.10.6 Measures if there is a risk of frost........................................... 136 8.10.7 Measures prior to extended shut-down period........................ 136 9

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Troubleshooting................................................................................ 141 9.1 Preliminary remarks................................................................... 142 9.2 Starting the engine with jump leads......................................... 143 9.3 Starting the engine with the recoil starter............................... 145 9.4 Fuse assignment........................................................................ 149

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Table of contents 9.4.1 Fuse box.................................................................................... 149 9.4.2 Main fuse................................................................................... 149 9.5 Engine malfunctions.................................................................. 150 10 Disposal.............................................................................................. 153 10.1 Final shut-down of machine.................................................... 154

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Table of contents

8

DTR75D

Introduction

1

Introduction

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9

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 55.

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 77.

Before every start up, carry out all required visual inspections and function tests Ä Chapter 5 ‘Checks prior to start up’ on page 65.

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” Ä Chapter 8 ‘Maintenance’ on page 101.

Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment.

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Introduction – Foreword 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.

The above notes do not constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of Dynapac GmbH. We wish you successful work with your Dynapac machine.

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Introduction – Machine type plate and engine type plate

1.2

Machine type plate and engine type plate Please enter here: Machine type (1):

Made by Designation Nominal Power

Type Operating Mass

Year of Construction

1

Serial-No.

2

Ammerländer Str. 93 D-26203 Wardenburg

Serial number (2):

Made in Germany

B-924-0001

Fig. 1: Machine type plate (example) Please enter here: Engine type (1):

MADE IN ITALY

1 Model s/n

Engine number (2):

rpm Spec.

2 B-KOH-0001

Fig. 2: Engine type plate (example)

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Technical data

2

Technical data

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Technical data Dimensions

B-834-0368

Fig. 3 A

B

C

D

H

500

720

210

400

1100 1700 155

(19.7 (28.3 (8.3) (15.7 (43) ) ) )

H1 (67)

K

L

O

S

W

2030 2130 35

8

650

(6.1) (80)

L1 (84)

(1.4) (0.3) (25.6 )

Dimensions in millimetres (Dimensions in inches) Weights Operating weight Basic weight Average axle load Average static linear load

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740

kg

(1631)

(lbs)

710

kg

(1565)

(lbs)

370

kg

(816)

(lbs)

5.7

kg/cm

(31.9)

(pli)

Technical data Travel characteristics Max. travel speed forward Max. travel speed reverse Max. gradeability without/with vibration (soil and weather dependent)

0 - 5.9

km/h

(0 - 3.7)

(mph)

0 - 2.5

km/h

(0 - 1.6)

(mph)

40/35

%

Drive Engine manufacturer

Kohler

Type

KD15 440

Cooling system

Air

Number of cylinders

1

Rated power ISO 3046

6.3

kW

(8.4)

(hp)

Rated speed

3000

min-1

Drive system

hydrostatic

Driven drums

front + rear

Brakes Service brake

hydrostatic

Parking brake

hydro-mechanical

Exciter system Drive system

hydrostatic

Frequency Amplitude, high

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63

Hz

(3780)

(vpm)

0.5

mm

(0,019)

(in)

15

Technical data – Noise and vibration data Exciter system Amplitude, low Centrifugal force, high Centrifugal force, low

0.25

mm

(0,009)

(in)

25

kN

(5620)

(lbf)

13

kN

(2923)

(lbf)

4.3

l

Filling capacities Fuel (diesel)

(1.1) (gal us) Water

60

l

(15.9) (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 Directive 2003/10/EU n Vibration Protection Directive 2002/44/EU During operation these values may vary because of the prevailing operating conditions.

2.1.1

Noise data

Sound pressure level at the operator's stand

16

LpA = 94 dB(A), determined acc. to ISO 11201 and EN 500.

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Technical data – Noise and vibration data

WARNING! Loss of hearing caused by too high noise burdens!

– Wear your personal protective equipment (ear protection).

Guaranteed sound power level

2.1.2

LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500.

Vibration data

Hand-arm vibration

Vector total of the weighted effective acceleration in three orthogonal directions: Total vibration value ahv = 3.9 m/s2 on crushed rock determined acc. to ISO 5349 and EN 500.

Associated uncertainty K = 0.5 m/s2, determined acc. to EN 12096.

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

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Technical data – Noise and vibration data

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Concerning your safety

3

Concerning your safety

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Concerning your safety – Basic prerequisites

3.1 3.1.1

Basic prerequisites 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.

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Concerning your safety – Basic prerequisites

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.

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.

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Concerning your safety – Basic prerequisites

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.

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Safety shoes

They protect against heavy falling parts and slipping on slippery ground.

Protective gloves

They protect the hands against scrapes, punctures or deeper injuries, irritating and caustic substances and burns.

Safety goggles

They protect the eyes against airborne particles and squirting fluids.

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Concerning your safety – Basic prerequisites Face protection

This protects the face against airborne particles and squirting fluids.

Hard hat

This protects the head against falling parts and injuries.

Hearing protection

This protects against extreme noise.

Fine dust mask

For protection against particulate pollutants.

Respiratory protection This protects the airways against substances or particles.

3.1.4

Intended use This machine is intended for commercial use only.

The 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)

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Concerning your safety – Basic prerequisites Intended use also includes compliance with the specified operating, maintenance and repair measures.

3.1.5

Improper use Dangers may arise with the machine if it is used other than for its intended purpose.

Any hazard caused by improper use is the sole responsibility of the operating company or driver/operator; the manufacturer cannot be held liable.

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).

3.1.6

Estimated service life of the machine If the following general conditions are met, the service life of the machine is usually in the range of several thousand operating hours:

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Concerning your safety – Basic prerequisites n Regular safety inspections by an expert / qualified person n Performance of the prescribed maintenance work within the specified time n Immediate performance of necessary repair work n Exclusive use of original spare parts

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Concerning your safety – Definition of responsible persons

3.2 3.2.1

Definition of responsible persons 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 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.

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Concerning your safety – Definition of responsible persons 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.

3.2.3

Driver / operator 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, n have made himself familiar with the operation of the machine, n be physically and psychologically able to drive and operate the machine.

Persons under the influence of alcohol, medication or drugs are not allowed to operate, service or repair the machine.

Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists.

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Concerning your safety – Basic safety regulations for safe operation

3.3

Basic safety regulations for safe operation

3.3.1

Remaining dangers, remaining risks Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and handling the machine.

Both the machine as well as all other system components comply with the currently valid safety regulations. Nevertheless, remaining risks cannot be ruled out completely, even when using the machine for the purpose it is intended for and following all information given in the operating instructions.

A remaining risk can also not be excluded beyond the actual danger zone of the machine.

Persons remaining in this area must pay particular attention to the machine, so that they can react immediately in case of a possible malfunction, an incident or failure etc.

All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine.

3.3.2

Regular safety inspections Have the machine inspected by an expert / qualified person as required for the conditions the machine is working under, but at least once every year.

3.3.3

Modifications and alterations to the machine Unauthorized changes to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine.

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Concerning your safety – Basic safety regulations for safe operation We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us.

The installation and/or use of such products may have an adverse effect on the active and/or passive safety.

3.3.4

Damage, defects, misuse of safety devices Machines which are not safe to operate or in traffic must be immediately taken out of service and shall not be used, until these deficiencies have been properly rectified.

Safety installations and switches must neither be removed nor must they be made ineffective.

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Concerning your safety – Handling fuels and lubricants

3.4 3.4.1

Handling fuels and lubricants Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants.

Safety data sheets provide valuable information about the following characteristics: n name of substance n possible dangers n composition / information on constituents n first-aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure / personal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n information on transport n legislation n other data

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Concerning your safety – Handling fuels and lubricants

3.4.2

Fig. 4

Safety regulations and environmental protection regulations for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel!

– Do not allow diesel fuel to come into contact with hot components.

– Smoking and open fire are prohibited!

– Wear your personal protective equipment (protective gloves, protective clothing).

CAUTION! Health hazard caused by contact with diesel fuel!

– Wear your personal protective equipment (protective 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. » Continued on the next page

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Concerning your safety – Handling fuels and lubricants

– Immediately bind spilled diesel fuel with an oil-binding agent and dispose of properly.

– Dispose of diesel fuel and fuel filters according to regulations.

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Concerning your safety – Handling fuels and lubricants

3.4.3

Fig. 5

Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil!

– Do not allow oil to come into contact with hot components.

– Smoking and open fire are prohibited!

– Wear your personal protective equipment (protective gloves, protective clothing).

CAUTION! Health hazard caused by contact with oil!

– Wear your personal protective equipment (protective 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 regulations.

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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 hydraulic fluid penetrate the skin, seek medical assistance immediately.

WARNING! Danger of burning by ignited hydraulic oil!

– Do not allow hydraulic oil to come into contact with hot components.

– Smoking and open fire are prohibited!

– Wear your personal protective equipment (protective gloves, protective clothing).

CAUTION! Health hazard caused by contact with hydraulic oil!

– Wear your personal protective equipment (protective gloves, protective clothing).

– Do not inhale any oil vapours.

– Avoid contact.

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Concerning your safety – Handling fuels and lubricants

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 regulations.

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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 (protective 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 mixture!

– Remove the plugs when recharging the battery.

– Ensure adequate ventilation.

– Smoking and open fire are 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 (protective gloves, protective clothing, goggles).

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Concerning your safety – Handling fuels and lubricants

ENVIRONMENT! Battery acid is an environmentally hazardous substance!

– Dispose of battery and battery acid according to regulations.

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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.

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Concerning your safety – Start-up procedure

3.6 3.6.1

Start-up procedure 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 non-functional safety installations.

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Concerning your safety – Start-up procedure Before starting and moving the machine, make sure that there is nobody in the danger zone.

Always keep an eye on the machine when the engine is running and hold it by the steering bow.

Do not inhale exhaust fumes, because they contain toxic substances, which could cause damage to health, unconsciousness or even death.

Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.

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Concerning your safety – Work mode

3.7 3.7.1

Work mode Persons in the danger area Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions.

Give warning signals, if necessary. Stop work immediately if persons remain in the danger zone, despite the warning.

3.7.2

Operation Use only the handles to steer the machine.

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 13.

Drive extremely carefully on gradients and always directly up or down the slope.

DTR75D

41

Concerning your safety – Work mode 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.

B-834-0279

Fig. 8

3.7.4

Wet and loose soil considerably reduces traction of the machine on inclinations and slopes.

Greater danger of accident!

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.

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 unauthorised use.

Mark machines, which could be in the way, with a clearly visible sign.

42

DTR75D

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.

Keep away from ignition and heat sources.

Apply measures against electrostatic charging.

Do not spill any fuel. Collect leaking 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 cover; if , necessary, replace immediately.

DTR75D

43

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.

44

DTR75D

Concerning your safety – Maintenance work

3.10 Maintenance work 3.10.1

Preliminary remarks Always carry out the prescribed maintenance work and maintenance measures on time in order to maintain the safety, operational readiness and long service life of the machine.

The machine must only be serviced by qualified personnel authorised by the operating company.

3.10.2

Working on hydraulic lines Before the hydraulic system can be depressurized, machine parts with hydraulic movement must be safely set down or secured to prevent them from falling.

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.

DTR75D

45

Concerning your safety – Maintenance work 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.

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.

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 and open fire are 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.

46

DTR75D

Concerning your safety – Maintenance work 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

Measures for longer shut-down periods If the machine is taken out of operation for a longer period of time, various conditions must be met and maintenance work must be carried out both before and after shut-down Ä Chapter 8.10.7 ‘Measures prior to extended shut-down period’ on page 136.

It is not necessary to define a maximum storage period if these measures have been performed.

3.10.7

After maintenance work Reassemble all guards and protections.

DTR75D

47

Concerning your safety – Repair

3.11

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.

48

DTR75D

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.

DIESEL 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

F153

S T A R T 1 W O R K 1

2

3

4

5

2

3

4

5

S T O P 1

2

3

4

5

F103

Made by Designation Nominal Power

Type Operating Mass

Year of Construction

Serial-No.

Ammerländer Str. 93 D-26203 Wardenburg

Made in Germany

Hydraulic Oil

B-924-0059

Fig. 9

DTR75D

49

Concerning your safety – Signage Warning sticker - Follow operating instructions

Fig. 10 Warning sticker - Hot surface Information sticker - Filler opening for hydraulic oil Hydraulic Oil

B-DEC-0354

Fig. 11 Instruction sticker - Wear ear defenders

Fig. 12 Information sticker - Guaranteed sound capacity level

Fig. 13

50

DTR75D

Concerning your safety – Signage Information sticker - Disconnecting the battery

B-DEC-0219

Fig. 14 Information sticker - Lashing point

Fig. 15 Information sticker - Lifting point

Fig. 16 Information sticker - fuses

F153

F103

B-DEC-0380

Fig. 17

DTR75D

51

Concerning your safety – Signage Operation sticker - Throttle lever

B-DEC-0359

Fig. 18 Operation sticker - Travel lever

Fig. 19 Operation sticker - Vibration lever

B-DEC-0246

Fig. 20

S T A R T 1 W O R K 1

2

3

4

5

2

3

4

5

S T O P 1

2

3

4

5

n Brief operating instructions n Instruction sticker - Observe operating instructions

B-DEC-0381

Fig. 21

52

DTR75D

Concerning your safety – Signage Maintenance sticker

DIESEL 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

B-DEC-0372

Fig. 22 Machine type plate (example) Made by Designation Nominal Power

Type Operating Mass

Year of Construction

Serial-No.

Ammerländer Str. 93 D-26203 Wardenburg

Made in Germany

B-924-0002

Fig. 23

DTR75D

53

Concerning your safety – Signage

54

DTR75D

Indicators and control elements

4

Indicators and control elements

DTR75D

55

Indicators and control elements – Machine

4.1

Machine 1

2

3

B-834-0346

Fig. 24 1 Water spraying system lever 2 Operating hour meter 3 Starter switch

4.1.1

Water spraying system Position “0”

Water spraying system off

Turn anticlockwise

Water spraying system on

B-016-0006

Fig. 25

56

DTR75D

infinite adjustment of the spraying quantity up to “MAX” position

Indicators and control elements – Machine

4.1.2

Operating hour meter Maintenance work is to be carried out in accordance with the indicated operating hours.

B-GEN-0114

Fig. 26

4.1.3

Starter switch Position “0”

Switch the ignition off Ignition key can be removed

Position “I”

Ignition on

Position “II”

Turn further against spring pressure, the engine starts Turn the ignition key back to position “I” when the engine starts.

Fig. 27

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.

DTR75D

57

Indicators and control elements – Machine

4.1.4

Warning buzzer for engine oil pressure sounds

When starting up: n Starter switch is in position "I" (ignition on).

Must stop after the engine has started.

B-SYM-1217

Fig. 28

During operation: n Low engine oil pressure detected. n Shut down the engine. n Check the engine oil level. n If necessary, perform troubleshooting. n Inform our Customer Service Department.

58

DTR75D

Indicators and control elements – Steering rod

4.2

Steering rod 1

2

3 4

5

8

7

6 B-834-0316

Fig. 29 1 Steering rod locking bolt 2 Travel lever 3 Throttle lever 4 Reversing protection 5 Cleaning rod 6 Vibration lever 7 Locking pawl lever 8 Steering rod height adjustment

DTR75D

59

Indicators and control elements – Steering rod

4.2.1

Steering rod locking bolt

B-016-0005

Fig. 30

4.2.2

Travel lever Shift forward

Forward travel

“Middle” position

Neutral position

Pull back

Reverse travel

B-834-0318

Fig. 31

4.2.3

Throttle lever Position “STOP” Engine off Position “MIN”

Idle speed

Position “MAX” Maximum speed

B-834-0320

Fig. 32

60

DTR75D

Indicators and control elements – Steering rod

4.2.4

Reversing protection actuated

Machine stops Travel lever is disengaged No travel movement possible

release

Reverse travel and forward travel possible

B-834-0321

Fig. 33

4.2.5

Cleaning rod Cleaning rod for cleaning the scrapers.

B-834-0394

Fig. 34

4.2.6

Vibration lever Position “0”

Vibration off

Position “Rear” Maximum vibration , high amplitude Position “Front” Minimum vibration, low amplitude B-834-0322

Fig. 35

DTR75D

61

Indicators and control elements – Steering rod

4.2.7

Locking pawl lever Position “Bottom”

Steering rod swings freely

Position “Top”

Steering rod is locked in position Temporary operation with fixed steering rod, e.g. for work on uneven terrain

B-016-0013

Fig. 36

4.2.8

Height adjustment

B-016-0007

Fig. 37

62

Normal operation

DTR75D

Indicators and control elements – Engine

4.3

Engine

4.3.1

Recoil starter

B-016-0064

Fig. 38

DTR75D

63

Indicators and control elements – Engine

64

DTR75D

Checks prior to start up

5

Checks prior to start up

DTR75D

65

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 protection regulations must be followed when handling fuels and lubricants Ä Chapter 3.4 ‘Handling fuels and lubricants’ on page 30.

WARNING! Danger of injury caused by rotating parts!

– Before starting work on the machine make sure that the engine can not be started.

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

66

DTR75D

Checks prior to start up – Visual inspections and function tests

5.2

Visual inspections and function tests 1. Check the condition of the hydraulic oil tank and hydraulic lines and check for leaks.

2. Check the condition of the fuel tank and fuel lines and for leaks.

3. Check the bolted connections are tight and secure.

4. Check the machine for contamination and damage.

DTR75D

67

Checks prior to start up – Daily maintenance

5.3

Daily maintenance

5.3.1

Checking the engine oil level NOTICE! Danger of engine damage!

– +Use only oil of the permitted specification Ä Chapter 8.2.1 ‘Engine oil’ on page 104.

B-SYM-1068

Fig. 39

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Clean the area around the oil dipstick.

2. Pull the dipstick out, wipe it off with a lintfree, clean cloth and reinsert it to the end stop.

MAX MIN B-LOM-0010

3. Pull the dipstick out again. ð The oil level must be between the “MIN” and “MAX” marks.

Fig. 40 4.

NOTICE! Danger of engine damage!

– Do not overfill with engine oil.

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

B-LOM-0009

5. Insert the dipstick.

Fig. 41

68

DTR75D

Checks prior to start up – Daily maintenance

5.3.2

Checking the fuel level; topping up fuel

B-SYM-1069

Fig. 42

NOTICE! Danger of engine damage!

– Monitor the entire refuelling process.

– Contaminated fuel can cause malfunction or even damage of the engine. If necessary, fill in fuel through a screen filter.

– Use only fuel of the permitted specification Ä Chapter 8.2.2 ‘Fuel’ on page 105.

Protective equipment:

Diesel

n Working clothes n Safety shoes n Protective gloves

1. Clean the area around the filling port.

2. Remove the cap and check the filling level visually.

3. If necessary, fill with fuel through a funnel with screen filter.

4. Close the cap.

B-LOM-0005

Fig. 43

DTR75D

69

Checks prior to start up – Daily maintenance

5.3.3

Checking the hydraulic oil level

B-SYM-1071

Fig. 44

NOTICE! Components may get damaged!

– Check the hydraulic oil level at room temperature (approx. 20 °C (68 °F)).

– 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 8.2.4.1 ‘Hydraulic oil’ on page 107.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Check the oil level in the inspection glass.

Normal level

approx. 1/2 height of inspection glass

Minimum level approx. 1/3 height of inspection glass B-016-0021

Fig. 45 2. Unscrew the covering plate to refill.

3. Clean the area around the filling port.

B-924-0004

Fig. 46

70

DTR75D

Checks prior to start up – Daily maintenance 4. Unscrew the cap and fill in oil through a funnel with screen filter.

HV 32

5. Retighten the cap and covering plate.

B-016-0022

Fig. 47

DTR75D

71

Checks prior to start up – Daily maintenance

5.3.4

Checking the reversing protection

B-SYM-1205

Fig. 48 Prerequisites: n The machine is on level, firm ground. n Sufficient space to the rear without any obstacles.

1. Start the engine Ä Chapter 6.2 ‘Starting the engine’ on page 80.

2.

CAUTION! Danger of injury caused by the crushing of body parts!

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

B-834-0324

Pull the travel lever slowly back. ð The machine drives backwards with a speed which corresponds to the travel lever position.

Fig. 49

3. Push in the reversing protection and check the proper function. ð Make sure the machine brakes until it comes to a standstill.

The travel lever must disengage.

B-834-0321

Fig. 50

4. If this does not work correctly, shut down the machine and notify our Customer Service department.

5. Only operate the machine again after it has been repaired.

72

DTR75D

Checks prior to start up – Daily maintenance 6. Shift the travel lever to neutral position. ð The travel lever is engaged again.

B-834-0325

Fig. 51 7. If the travel lever does not engage in neutral position, pull out the reversing protection if necessary.

8. Park the machine.

B-834-0326

Fig. 52

DTR75D

73

Checks prior to start up – Daily maintenance

5.3.5

Checking the rubber buffers

B-SYM-1073

Fig. 53 Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Check the rubber buffers, left and right, for tight fit, cracks and tear-offs. ð Replace damaged rubber buffers immediately.

B-016-0023

Fig. 54 2. Check the rubber buffers on the steering rod, for tight fit, cracks and tear-offs. ð Replace damaged rubber buffers immediately.

B-834-0327

Fig. 55

74

DTR75D

Checks prior to start up – Daily maintenance

5.3.6

Checking the water level, topping up NOTICE! Dirty or contaminated water can block the boreholes!

– Fill only with clean water.

NOTICE! Components may get damaged by frost!

– Follow the special maintenance instructions in case of frost Ä Chapter 8.10.6 ‘Measures if there is a risk of frost’ on page 136.

Protective equipment:

n Working clothes n Safety shoes

1. Clean the area around the filling port.

Water

2. Remove the cap and check the water supply in the water tank.

3. If necessary, fill in clean water.

4. Close the cap.

B-016-0025

Fig. 56

DTR75D

75

Checks prior to start up – Daily maintenance

76

DTR75D

Operation

6

Operation

DTR75D

77

Operation – Folding down and adjusting the steering rod

6.1

Folding down and adjusting the steering rod

Folding down and adjusting the steering rod 1. Secure the steering rod with one hand.

2. Loosen the locking bolt by turning it and fold down the steering rod.

Do not click the locking pawl lever into position during operation.

The steering rod must be able to swing freely.

B-834-0336

Fig. 57 3. Adjust the steering rod with the height adjustment to the required height.

B-016-0007

Fig. 58

78

DTR75D

Operation – Folding down and adjusting the steering rod Locking the steering rod in position

Click the locking pawl lever into position only for temporary operation with fixed steering rod, e.g. for work on uneven terrain.

4. Turn the locking pawl lever to position “Top” and click it into position. ð The steering rod is locked in position.

B-016-0027

Fig. 59 5. Turn the locking pawl lever to position “Bottom”. ð The steering rod can swing freely.

B-016-0028

Fig. 60

DTR75D

79

Operation – Starting the engine

6.2

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

WARNING! Danger of poisoning by exhaust gases!

– Do not inhale exhaust gases.

– Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.

WARNING! Loss of hearing caused by too high noise burdens!

– Wear your personal protective equipment (ear protection).

Protective equipment:

n Hearing protection

1. Folding down and adjusting the steering rod Ä Chapter 6.1 ‘Folding down and adjusting the steering rod’ on page 78.

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

B-016-0031

Fig. 61

80

DTR75D

Operation – Starting the engine 3. Shift the travel lever to neutral position.

B-834-0325

Fig. 62 4. Shift the vibration lever to position “0”.

B-834-0328

Fig. 63 5. Turn the ignition key to position “I”. ð The warning buzzer sounds.

B-ELE-0081

Fig. 64

DTR75D

81

Operation – Starting the engine 6.

B-ELE-0082

Fig. 65

NOTICE! Components may get damaged!

– Start for a maximum of 30 seconds continuously or start a maximum of three times for 10 seconds. Then let the starter cool down to ambient temperature.

– If the engine has not started after the attempt, determine the cause.

Turn the ignition key to position “II”. ð The starter cranks the engine.

The warning buzzer must stop.

7. If the warning buzzer does not stop after the engine has started: n Shut down the engine. n Check the engine oil level; top up if necessary. n If necessary, contact our Customer Service.

8. 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.

82

DTR75D

Operation – Starting the engine 9. Run the engine warm for approx. 1 to 2 minutes in idle speed.

NOTICE! Danger of engine damage!

– Warm up engine for a short while before starting work.

Do not operate the engine immediately under full load.

DTR75D

83

Operation – Travel mode

6.3

Travel mode Operate the machine only with the steering rod folded down and adjusted to height Ä Chapter 6.1 ‘Folding down and adjusting the steering rod’ on page 78.

Use only the handles to steer the machine.

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

CAUTION! Danger of injury caused by uncontrolled machine movement!

– Always hold on to a running machine.

– Always keep an eye on a running machine.

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

B-016-0030

Fig. 66 Driving forward 2. Shift the travel lever forward. ð The machine drives forward with a speed which corresponds to the travel lever position.

B-834-0323

Fig. 67

84

DTR75D

Operation – Travel mode Driving backwards 3.

CAUTION! Danger of injury caused by the crushing of body parts!

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

B-834-0324

Pull the travel lever back. ð The machine drives backwards with a speed which corresponds to the travel lever position.

Fig. 68

steer the machine 4. Move the travel lever quickly alternating between forward and reverse.

5. At the same time, steer the machine by pushing from the side or pulling the steering rod handles.

B-834-0333

Fig. 69 Stopping the machine 6. Shift the travel lever to neutral position. ð The machine decelerates to a standstill.

B-834-0325

Fig. 70

DTR75D

85

Operation – Work mode

6.4 6.4.1

Work mode Preliminary remarks and safety notes NOTICE! Possible damage to neighbouring buildings!

– 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.

NOTICE! Machine parts may get damaged!

– Do not activate the vibration on hard (frozen, concrete) ground.

Vibration at standstill causes transverse marks: 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.

86

DTR75D

Operation – Work mode

6.4.2

Working with vibration 1. Move the machine forward or back.

NOTICE! Vibration at standstill causes transverse marks!

– Do not switch on vibration with the machine at standstill.

2. Shift the vibration lever to “Front” position. ð Minimum vibration is switched on.

B-834-0329

Fig. 71 3. Shift the vibration lever to “Rear” position. ð Maximum vibration is switched on.

B-834-0330

Fig. 72 4. Shift the vibration lever to position “0”. ð Vibration is switched off after a short time.

B-834-0328

Fig. 73

DTR75D

87

Operation – Work mode 5. For short work interruptions you should always return the throttle lever to “MIN” position (idle speed).

B-016-0032

6. For short work interruptions you should always park the machine in secured condition Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

Fig. 74

88

DTR75D

Operation – Switching the water spraying system on/off

6.5

Switching the water spraying system on/off 1. For switching on, turn the lever out of position “0”.

The spraying quantity can be infinitely adjusted until “MAX” position.

B-016-0006

Fig. 75

2. For switching off, turn the lever to position “0”.

DTR75D

89

Operation – Parking the machine in secured condition

6.6

Parking the machine in secured condition 1. Drive the machine onto level, firm ground.

2. Shift the travel lever to neutral position. ð The machine decelerates to a standstill.

B-834-0325

Fig. 76 3. Set the throttle lever to “MIN” position (idle speed).

B-016-0032

Fig. 77 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.

B-016-0033

Fig. 78

Set the throttle lever to position “STOP”. ð The engine is shut down.

The warning buzzer sounds.

90

DTR75D

Operation – Parking the machine in secured condition 5. Turn the ignition key to position “0” and pull it out. ð The warning buzzer stops.

B-ELE-0080

Fig. 79

DTR75D

91

Operation – Emergency procedures

6.7

Emergency procedures

6.7.1

Disconnecting the battery In event of emergency, e.g. in case of a cable fire, disconnect the battery from the vehicle network.

1. Flip open the cap. ð The pole clamp comes off the minus pole.

2. Remove the pole clamp from the battery and place it aside.

B-834-0339

Fig. 80

6.7.2

Deactivating the reversing protection The reversing protection protects the operator from being crushed between the machine and an obstacle during reverse travel.

If reversing protection is activated, the machine brakes to a standstill.

The travel lever is disengaged by the reversing protection, the machine cannot be moved forward or backward.

92

DTR75D

Operation – Emergency procedures Prerequisites: n Reversing protection has been triggered. n The machine is at a standstill. n The travel lever is disengaged.

1. Step aside from the machine, slightly lift the steering rod for this, if necessary.

2. Shift the vibration lever to position “0”, if necessary. ð Vibration is switched off after a short time.

B-834-0328

Fig. 81 3. Set the throttle lever to “MIN” position (idle speed).

B-016-0032

Fig. 82 4. Shift the travel lever to neutral position. ð The travel lever is engaged again.

B-834-0325

Fig. 83

DTR75D

93

Operation – Emergency procedures 5. If the travel lever does not engage in neutral position, pull out the reversing protection if necessary.

B-834-0326

Fig. 84 6. Shift the travel lever forward.

7. Move the machine forward, away from the obstacle.

B-834-0323

Fig. 85

94

DTR75D

Loading / transporting the machine

7

Loading / transporting the machine

DTR75D

95

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 13.

Protective equipment: 1.

n Working clothes n Safety shoes n Protective gloves

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 onto the transport vehicle.

2. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

96

DTR75D

Loading / transporting the machine – Loading the machine 3. Fold the steering rod up to transport position.

4. Secure the steering rod with one hand and lock it with the locking bolt.

B-834-0335

Fig. 86

DTR75D

97

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 tackle at the lifting points.

Use lifting tackle only in the specified loading direction.

Lifting tackle must not be damaged by machine parts.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Fasten four ratchet straps to the marked lashing points.

2. Lash the machine securely to the transport vehicle.

B-834-0337

Fig. 87

98

DTR75D

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 13.

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.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Fasten the lifting tackle to the intended lifting point.

2.

B-016-0052

Fig. 88

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.

DTR75D

99

Loading / transporting the machine – After transportation

7.4

After transportation 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.

1. Folding down and adjusting the steering rod Ä Chapter 6.1 ‘Folding down and adjusting the steering rod’ on page 78.

2. Start the engine Ä Chapter 6.2 ‘Starting the engine’ on page 80.

3.

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.

100

DTR75D

Maintenance

8

Maintenance

DTR75D

101

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 qualified and authorized personnel.

– Follow the safety regulations for maintenance work Ä Chapter 3.10 ‘Maintenance work’ on page 45.

WARNING! Health hazard caused by fuels and lubricants!

– Safety regulations and environmental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3.4 ‘Handling fuels and lubricants’ on page 30.

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.

102

DTR75D

Maintenance – Preliminary remarks and safety notes 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.

DTR75D

103

Maintenance – Fuels and lubricants

8.2

Fuels and lubricants

8.2.1 8.2.1.1

Engine oil Oil quality The following engine oil specifications are permitted: n API CF or higher quality n ACEA B2-B4 or higher quality n MIL-L-2104 C / MIL-L-46152 D Avoid mixing engine oils.

8.2.1.2

Oil viscosity Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class).

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.

F° -40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104113122 C° -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

SAE 10W SAE 20W SAE 30

* Mineral oil base ** Semi-synthetic base *** Synthetic base

SAE 40 SAE 10W-30 SAE 10W-40 SAE 10W-60 SAE 15W-40* SAE 15W-40** SAE 20W-60** SAE 10W-30*** SAE 5W-30***

B-KOH-0003

Fig. 89

104

DTR75D

Maintenance – Fuels and lubricants

8.2.1.3

Oil change intervals 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.

8.2.2 8.2.2.1

Fuel Fuel quality The following fuel specifications are permitted: n EN 590 n ASTM D975 Grade-No. 1-D and 2-D n BS 2869 A1/A2 In order to fulfil national emission regulations one must strictly use the legally required fuels (e.g. sulphur content).

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.

DTR75D

105

Maintenance – Fuels and lubricants

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 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.

8.2.3

Oil for exciter shaft housing Use only engine oils according to the following specifications: n API CI-4 or higher quality Avoid mixing engine oils.

NOTICE! Components may get damaged!

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

106

DTR75D

Maintenance – Fuels and lubricants

8.2.4 8.2.4.1

Hydraulic oil 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.

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

8.2.4.2

Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil.

The biodegradable hydraulic oil Panolin HLP Synth. 46 or Plantohyd 46 S meets all the requirements of a mineral oil based hydraulic oil according to DIN 51524.

In hydraulic systems filled with biodegradable hydraulic oil, always use the same oil to top up and do not mix oil types.

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.

DTR75D

107

Maintenance – Fuels and lubricants

NOTICE! Danger of damage to the hydraulic system!

– After the changeover check the hydraulic oil filters 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.

108

DTR75D

Maintenance – List of fuels and lubricants

8.3

List of fuels and lubricants

Assembly group

Fuel or lubricant Summer

Engine oil

Winter

Filling quantity Observe the level mark!

SAE 10W-40

1.2 l

Specification: Ä Chapter 8.2.1 ‘Engine oil’ on page 104

(0.3 gal us)

SAE 15W-40 SAE 10W-30 Fuel

Exciter shaft housing

Diesel

Winter diesel fuel

4.3 l

Specification: Ä Chapter 8.2.2 ‘Fuel’ on page 105

(1.1 gal us)

SAE 10W-40

0.25 l

Specification: Ä Chapter 8.2.3 ‘Oil for exciter shaft housing’ on page 106

(0.07 gal us)

Components may get damaged! Do not use low-ash engine oils for the exciter shaft housing.

SAE 15W-40 SAE 10W-30 Hydraulic system

Hydraulic oil (ISO), HV 32

24 l

Specification: Ä Chapter 8.2.4.1 ‘Hydraulic oil’ on page 107

(6.3 gal us)

or ester based biodegradable hydraulic oil Specification: Ä Chapter 8.2.4.2 ‘Biodegradable hydraulic oil’ on page 107

DTR75D

109

Maintenance – Running-in instructions

8.4

Running-in instructions

8.4.1

General information When commissioning new machines, the running-in instructions listed in this chapter must be carried out after the specified operating hours.

The maintenance work listed must be carried out in addition to the regular maintenance intervals.

8.4.2

After the first 25 operating hours 1. Change the engine oil Ä Chapter 8.8.1 ‘Changing engine oil and oil filter element’ on page 119.

2. Check engine and machine for leaks.

3. Retighten the fastening screws on air filter, exhaust and other attachments.

4. Retighten the bolted connections on the machine.

110

DTR75D

Maintenance – Maintenance Table

8.5

Maintenance Table

No.

Maintenance works

Page

Daily maintenance 5.3.1

Checking the engine oil level

68

5.3.2

Checking the fuel level; topping up fuel

69

5.3.3

Checking the hydraulic oil level

70

5.3.4

Checking the reversing protection

72

5.3.5

Checking the rubber buffers

74

5.3.6

Checking the water level, topping up

75

Weekly 8.6.1

Checking, cleaning the air filter

113

8.6.2

Checking and cleaning the water separator

115

Semi-annually 8.7.1

Battery service

117 Annually

8.8.1

Changing engine oil and oil filter element

119

8.8.2

Replacing the fuel filter

121

8.8.3

Changing the oil in the exciter housing

123

8.8.4

Replacing the air filter

124

8.8.5

Checking the hydraulic lines

125

Every 2 years / every 500 operating hours 8.9.1

Changing hydraulic oil and hydraulic oil filter

127

As required 8.10.1

Cleaning the water spraying system

131

8.10.2

Cleaning the scrapers

132

8.10.3

Checking/adjusting the scrapers

133

8.10.4

Cleaning the cooling fins and the cooling air intake openings

133

8.10.5

Cleaning the machine

134

DTR75D

111

Maintenance – Maintenance Table No.

Maintenance works

Page

8.10.6

Measures if there is a risk of frost

136

8.10.7

Measures prior to extended shut-down period

136

112

DTR75D

Maintenance – Weekly

8.6

Weekly

8.6.1

Checking, cleaning the air filter

B-SYM-1074

Fig. 90

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. The air filter must be replaced at the latest after half a year or 500 operating hours respectively.

– 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 element. If in doubt use a new air filter.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves n Safety goggles

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Allow the engine to cool down.

DTR75D

113

Maintenance – Weekly 3. Remove the cover.

B-695-0219

Fig. 91 4. Check the pre-filter in the cover for dirt or blockage, clean if necessary.

B-695-0220

Fig. 92 5. Unscrew the wing nut and remove the air filter.

B-695-0221

Fig. 93 6. Check the seal ring for damage, change if necessary.

7.

B-695-0222

Fig. 94

114

NOTICE! Danger of engine damage!

– Prevent dirt from getting into the air intake opening.

– Do not clean the air filter housing with compressed air.

DTR75D

Maintenance – Weekly Clean the filter housing with a clean, lintfree cloth.

8.

Fig. 95

CAUTION! Danger of eye injuries caused by particles flying around!

– Wear your personal protective equipment (protective gloves, protective clothing, goggles).

Blow the air filter out with dry compressed air (max. 5 bar (73 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust.

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

10. Replace the air filter if it is damaged.

11. Insert the air filter carefully into the filter housing and fasten it with the wing nut.

12.

NOTICE! Danger of engine damage!

– Ensure correct fit of cover and seal.

Close the cap.

8.6.2

Checking and cleaning the water separator

B-SYM-1075

Fig. 96

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.

DTR75D

115

Maintenance – Weekly Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Place the transparent container under the drain plug.

3. Loosen the drain plug and drain the fluid until pure diesel fuel starts to run out.

4. Collect the escaping fluid.

B-LOM-0013

Fig. 97

116

5. Screw the drain plug back on tightly.

Ensure leak tightness.

6. Dispose of collected fluid in line with environmental regulations.

DTR75D

Maintenance – Semi-annually

8.7

Semi-annually

8.7.1

Battery service

B-SYM-1077

Fig. 98

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!

Protective equipment:

n Working clothes n Safety shoes n Protective gloves n Safety goggles

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Remove the holding fixture (1) of the battery.

1

3. Remove the battery (2) and the vibration damping mat (3).

4. Check the condition of the vibration damping mat; replace if necessary.

2 3

Fig. 99

5. Clean the outside of the battery.

B-834-0338

6. Clean the battery poles and terminals and grease them with pole grease (Vaseline).

7. On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.

8. Install battery and vibration damping mat.

DTR75D

117

Maintenance – Semi-annually 9. Install the holding fixture of the battery.

118

DTR75D

Maintenance – Annually

8.8

Annually

8.8.1

Changing engine oil and oil filter element NOTICE! Danger of engine damage!

– Change the oil only with the engine at operating temperature.

– Use only oil of the permitted specification Ä Chapter 8.2.1 ‘Engine oil’ on page 104.

– Filling quantity: Ä Chapter 8.3 ‘List of fuels and lubricants’ on page 109 Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

Draining off engine oil 2. Clean the area around the filling port and remove the cap.

B-LOM-0008

Fig. 100

DTR75D

119

Maintenance – Annually 3. Clean the area around the drain plug.

B-834-0348

Fig. 101

WARNING! Danger of burning on hot components!

– Wear your personal protective equipment (protective 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.

Changing the oil filter

6. Clean the area around the filter cover.

7. Remove the filter cover and pull the oil filter out of the housing.

8. Clean the sealing face on the engine.

9. Insert a new oil filter.

10. Check the seal on the filter cover for damage, replace if necessary.

B-LOM-0007

Fig. 102

11. Attach the filter cover with the seal and tighten it.

Filling in engine oil 12. Fill in fresh engine oil up to the bottom edge of the filling opening.

B-LOM-0009

Fig. 103

120

DTR75D

Maintenance – Annually 13. After a short test run, check the oil level on the dipstick, top up oil if necessary.

14. Close the cap.

MAX MIN B-LOM-0010

Fig. 104 Concluding work

15. Check filter cover and drain plug for leaks.

16. Dispose of the oil and oil filter in an environmentally friendly way.

8.8.2

Replacing the fuel filter NOTICE! Danger of engine damage!

– Ensure strict cleanliness! Thoroughly clean the area around the fuel tank beforehand.

– Never operate the engine after having removed the fuel filter.

Protective equipment:

n Working clothes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Use a suitable vessel to collect running out fuel.

DTR75D

121

Maintenance – Annually 3. Close the fuel line in front of the fuel filter.

4. Clean the area around the fuel filter.

B-LOM-0012

Fig. 105 5. Loosen the hose clamps on the three fuel lines and disconnect the fuel lines.

6. Remove the screw, open the bracket and take off the fuel filter.

7. Replace the fuel filter.

B-LOM-0011

Fig. 106

Observe the installation direction (arrow) when assembling the new fuel filter.

8. Insert the new fuel filter and fasten the bracket with the screw.

9. Attach the fuel lines and fasten them with hose clamps.

10. Open the fuel line.

11. After a short test run check fuel filter and fuel lines for leaks.

The fuel system is selfbleeding.

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

122

DTR75D

Maintenance – Annually

8.8.3

Changing the oil in the exciter housing NOTICE! Components may get damaged!

– Use only oil of the permitted specification Ä Chapter 8.3 ‘List of fuels and lubricants’ on page 109.

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

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine on level ground.

2. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

1

2 B-834-0341

Fig. 107

3. Clean the area around filler screw (1) and drain plug (2).

4. Unscrew the filler screw.

5. Unscrew the drain plug and collect any oil running out.

6. Clean the drain plug and screw it in with a low-strength sealing agent (e.g. spare parts number: DL 009 700 16).

7. Fill in new oil. ð Filling quantity: Ä Chapter 8.3 ‘List of fuels and lubricants’ on page 109 8. Clean the filler screw and screw it in with a low-strength sealing agent (e.g. spare parts number: DL 009 700 16).

B-834-0342

Fig. 108

9. Dispose of oil in line with environmental regulations.

DTR75D

123

Maintenance – Annually

8.8.4

Replacing the air filter NOTICE! Danger of engine damage!

– Do not start the engine after having removed the air filter.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Allow the engine to cool down.

3. Remove the cover.

B-695-0219

Fig. 109 4. Check the pre-filter in the cover for dirt or blockage, clean if necessary.

B-695-0220

Fig. 110

124

DTR75D

Maintenance – Annually 5. Unscrew the wing nut and remove the air filter.

B-695-0221

Fig. 111 6. Replace the seal ring.

7.

B-695-0222

Fig. 112

NOTICE! Danger of engine damage!

– Prevent dirt from getting into the air intake opening.

– Do not clean the air filter housing with compressed air.

Clean the filter housing with a clean, lintfree cloth.

8. Replace the air filter.

9. Insert the air filter carefully into the filter housing and fasten it with the wing nut.

10.

NOTICE! Danger of engine damage!

– Ensure correct fit of cover and seal.

Close the cap.

8.8.5

Checking the hydraulic lines This work must only be performed by an expert / qualified person!

DTR75D

125

Maintenance – Annually 1. Park the machine in secured condition Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Check all hydraulic lines.

Hydraulic hoses must be immediately replaced if: n the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks), n embrittlement of the outer layer or formation of cracks in the hose material, n the hose shows deformation in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose (e.g. layer separation, formation of blisters, crushed spots, buckling), n leaks on hose, socket or fitting, n the hydraulic hose has separated from the fitting, n fittings are damaged or deformed, whereby the function and strength of the hose - fitting connection is impaired, n the fitting shows corrosion that impairs both function and strength, n incorrect installation (squeezing, shearing or chafing points), n paint covered hydraulic hoses (no detection of identifications or cracks), n shelf life and service life exceeded.

3. Replace damaged hydraulic hoses immediately, fasten these properly and avoid chafing.

4. Only operate the machine after it has been repaired.

126

DTR75D

Maintenance – Every 2 years / every 500 operating hours

8.9

Every 2 years / every 500 operating hours

8.9.1

Changing hydraulic oil and hydraulic oil filter NOTICE! Risk of damage!

– Perform the oil change when the hydraulic oil is warm.

– Use only hydraulic oil of the permitted specification Ä Chapter 8.2.4.1 ‘Hydraulic oil’ on page 107.

– Filling quantity: Ä Chapter 8.3 ‘List of fuels and lubricants’ on page 109.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

Draining off hydraulic oil 2. Remove the covering plate.

B-924-0004

Fig. 113

DTR75D

127

Maintenance – Every 2 years / every 500 operating hours 3. Clean the area around the filler opening and remove the cap.

4. Clean the area around the drain plug.

B-834-0311

Fig. 114

WARNING! Danger of burning on hot components!

– Wear your personal protective equipment (protective gloves, protective clothing).

– Avoid touching hot components.

5. Unscrew the drain plug and collect any oil running out.

6. Clean the drain plug and screw it back in with a new seal ring.

Replacing the hydraulic oil filter 7. Unscrew the filter housing.

8. Take out the old filter element and clean the filter housing.

9. Clean the thread on the filter housing.

10. Reassemble the filter housing with a new filter element and a new O-ring.

11. Tighten the filter housing.

B-834-0312

Fig. 115

128

DTR75D

Maintenance – Every 2 years / every 500 operating hours Replacing the suction filter 12. Clean the area around the cover (2).

2

1

13. Remove the screws (1) and take off the cover.

3

14. Remove the suction filter (4) and replace it.

15. Attach the cover with a new seal (3) and fasten the screws.

4 B-834-0217

Fig. 116 15 Nm 9

35 Nm 4

2

8

5

7

6

1

3

16. Tighten the screws crosswise in the correct sequence (1 - 10), tightening torque: 15 Nm (11 ft·lbf).

17. Then retighten the screws in the same sequence, tightening torque: 35 Nm (26 ft·lbf).

10 B-834-0313

Fig. 117 Filling up hydraulic oil

NOTICE! Risk of damage!

– Use only hydraulic oil of the permitted specification Ä Chapter 8.2.4.1 ‘Hydraulic oil’ on page 107.

DTR75D

129

Maintenance – Every 2 years / every 500 operating hours 18. Fill in new hydraulic oil through a funnel with screen filter.

HV 32

19. Check the hydraulic oil level in the inspection glass, top up if necessary. ð Nominal value: Middle of inspection glass B-016-0022

Fig. 118 Concluding work

20. Retighten the cap and covering plate.

21. Check the connections on the hydraulic oil tank and the hydraulic oil filter for leaks.

22. Dispose of the hydraulic oil and hydraulic oil filter in line with environmental regulations.

130

DTR75D

Maintenance – As required

8.10 As required 8.10.1

Cleaning the water spraying system Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Open the water tank cover.

Water

B-016-0025

Fig. 119 3. Open the lever and drain off all water.

B-016-0043

Fig. 120 4. Unscrew the two spray tubes and pull them out of the frame.

5. Flush the water tank out with a strong water jet.

6. Flush spray tubes and water lines.

B-834-0334

Fig. 121

7. Insert the spray tubes and screw them tight.

8. Fill the water tank with clean water and close the cap.

DTR75D

131

Maintenance – As required

8.10.2

Cleaning the scrapers Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Loosen and pull out the cleaning rod.

B-016-0045

Fig. 122 3. Clean the scraper with the cleaning rod.

4. Insert the cleaning rod again and fasten it.

B-016-0046

Fig. 123

132

DTR75D

Maintenance – As required

8.10.3

Checking/adjusting the scrapers Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Check the condition of the front and rear scrapers, as well as both middle scrapers regarding settings and condition; readjust them if necessary.

B-016-0048

Fig. 124 2. To readjust the scrapers, loosen the fastening screws and press the scraper towards the drum. ð Align the scrapers with a distance of approx. 1 mm parallel to the drum.

3. Fasten the fastening screws again.

B-016-0049

Fig. 125

8.10.4

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

DTR75D

133

Maintenance – As required Protective equipment:

n Working clothes n Protective gloves n Safety goggles

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

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 (protective gloves, protective clothing, goggles).

Fig. 126

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

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

8.10.5

Cleaning the machine NOTICE! Danger of engine damage caused by reduced cooling!

– Immediately remove any oil or fuel leaks near fuel tank, cylinders or cooling air intake.

134

DTR75D

Maintenance – As required Protective equipment:

n Working clothes n Safety shoes n Protective gloves n Safety goggles

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Allow the engine to cool down for at least 30 minutes.

3.

WATER AQUA

B-834-0347

Fig. 127

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 air filter, the exhaust outlet, the battery or other electrical equipment.

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

4. Warm up the engine for a while to avoid corrosion.

DTR75D

135

Maintenance – As required

8.10.6

Measures if there is a risk of frost Protective equipment:

n Working clothes n Safety shoes n Protective gloves

1. Park the machine safely Ä Chapter 6.6 ‘Parking the machine in secured condition’ on page 90.

2. Open the water tank cover.

Water

B-016-0025

Fig. 128 3. Open the lever and drain off all water.

4. Close the cover again.

B-016-0043

Fig. 129

8.10.7 8.10.7.1

Measures prior to extended shut-down period 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. If there is a risk of frost, perform appropriate measures Ä Chapter 8.10.6 ‘Measures if there is a risk of frost’ on page 136.

136

DTR75D

Maintenance – As required 3. After shutting down store the machine under cover in a dry and well ventilated room.

4. Spray a thin oil film onto to all lever joints and bearing points without lubrication.

5. Repair damaged paint; preserve bare areas thoroughly with anti-corrosive agent.

6. Clean the water separator.

7. Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank.

8. Change engine oil and oil filter.

9. Change the fuel filter.

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

8.10.7.2

Battery service during prolonged machine downtimes WARNING! Danger of injury caused by exploding gas mixture!

– Remove the plugs when recharging the battery.

– Ensure adequate ventilation.

– Smoking and open fire are 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 (protective gloves, protective clothing, goggles).

DTR75D

137

Maintenance – As required Protective equipment:

n Working clothes n Protective gloves n Safety goggles

1. Switch off all consuming devices (e.g. ignition, light).

2. Measure the open-circuit voltage of the battery at regular intervals (at least 1x per month). ð Reference values: 12.6 V = fully charged; 12.3 V = discharged to 50%.

3. Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform fast charging. ð The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge.

4. Switch off the charging current before removing the charging 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. Do not forget to perform regular open-circuit voltage measurements.

8.10.7.3

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.

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Maintenance – As required 5. Check the service life of hydraulic hoses and replace if necessary.

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

7. Check the oil levels.

8. Clean the machine thoroughly.

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Maintenance – As required

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Troubleshooting

9

Troubleshooting

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Troubleshooting – Preliminary remarks

9.1

Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance.

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

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Troubleshooting – Starting the engine with jump leads

9.2

Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system.

– Bridge the machine only with a 12 Volt auxiliary battery.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves n Hearing protection

1. Remove the cap from the plus pole of the battery.

B-834-0343

Fig. 130 2. Flip open the cap of the pole clamp (minus pole).

B-016-0055

Fig. 131

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Troubleshooting – Starting the engine with jump leads 3. First connect the plus pole of the external battery to the plus pole of the starter battery using the first jump lead.

12 V B-ELE-0027

Fig. 132

4. Next, connect the second jump lead to the minus pole of the energizing external battery and then to the minus pole of the starter battery.

5. Start the engine: Ä Chapter 6.2 ‘Starting the engine’ on page 80.

6. After starting, disconnect the minus poles first and the plus poles after.

7. Fold down the caps or put them on again.

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Troubleshooting – Starting the engine with the recoil starter

9.3

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 burdens!

– Wear your personal protective equipment (ear protection).

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Troubleshooting – Starting the engine with the recoil starter Protective equipment:

n Hearing protection n Safety shoes n Protective gloves

1. Folding down and adjusting the steering rod Ä Chapter 6.1 ‘Folding down and adjusting the steering rod’ on page 78.

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

B-016-0031

Fig. 133 3. Shift the travel lever to neutral position.

B-834-0325

Fig. 134 4. Shift the vibration lever to position “0”.

B-834-0328

Fig. 135

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Troubleshooting – Starting the engine with the recoil starter 5. Turn the ignition key to position “I”.

B-ELE-0081

Fig. 136 6. Pull the rope by the starter handle, until resistance can be felt.

7. Guide the starter handle back to initial position.

B-GEN-0083

Fig. 137 8.

B-GEN-0084

Fig. 138

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.

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

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Troubleshooting – Starting the engine with the recoil starter 10. If the engine does not start during the first attempt, repeat the starting process.

11. Run the engine warm for approx. 1 to 2 minutes in idle speed.

NOTICE! Danger of engine damage!

– Warm up engine for a short while before starting work.

Do not operate the engine immediately under full load.

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Troubleshooting – Fuse assignment

9.4

Fuse assignment

9.4.1

Fuse box

F153 F103 B-834-0345

Fig. 139 Fuse

Amperage

Designation

F153

10 A

Fuse for potential 15

F103

10 A

Fuse for potential 15

9.4.2

Main fuse

B-016-0057

Fig. 140 Fuse

Amperage

Designation

F00

30 A

Main fuse

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Troubleshooting – Engine malfunctions

9.5

Engine malfunctions

Fault

Possible cause

Remedy

The engine is Fuel tank empty hard to start or does not Fuel filter clogged start at all.

Check the fuel level; top up if necessary.

Check the fuel filter; replace if necessary.

Fuel lines leaking

Check the fuel lines.

Incorrect valve clearance

Have it checked by qualified expert personnel.

Wear on cylinder or piston rings

Have it checked by qualified expert personnel.

Injection nozzle out of order

Have it checked by qualified expert personnel.

Engine does Fuel filter clogged by paraffin not start or separation starts poorly Engine oil with wrong SAE at low temper- viscosity class atures.

Insufficiently charged battery

Replace the fuel filter; use winter fuel.

Changing the engine oil Check the battery; charge if necessary.

Engine starts Fuel filter clogged up, but does not run.

Check the fuel filter; replace if necessary.

The starter does not switch on or the engine does not crank.

Main fuse broken

Replace main fuse

Battery or other cables not connected correctly

Check

Battery defective or not charged

Check the battery, charge or replace if necessary.

Starter defective

Replace the starter.

Engine stops. Fuel tank empty

150

Check the fuel level; top up if necessary.

Fuel filter clogged

Replace the fuel filter

Tank ventilation blocked

Ensure sufficient ventilation of the tank.

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Troubleshooting – Engine malfunctions Fault

Possible cause

Remedy

Air in the fuel system

Check the fuel system for air ingress.

Mechanical defect

Have checked by qualified expert personnel.

Engine looses Fuel tank empty power and speed.

Fuel system clogged

Engine loses power and speed; exhaust smoke is black.

Engine overheats.

Check the fuel level; top up if necessary.

Replace the fuel filter

Tank ventilation blocked

Ensure sufficient ventilation of the tank.

Air filter contaminated

Clean; replace if necessary

Air in the fuel system

Check the fuel system for air ingress.

Too much oil in exciter housing.

Drain the oil from the exciter housing.

Air filter contaminated

Clean the air filter, replace if necessary.

Incorrect valve clearance

Have it checked by qualified expert personnel.

Injection nozzle out of order

Have it checked by qualified expert personnel.

Engine oil level too high

Check the engine oil level; drain off engine oil if necessary.

Air filter contaminated

Clean the air filter, replace if necessary.

Lack of cooling air

Clean the cooling fins and the cooling air intake openings.

Check air guide plates and ducts for completeness and good sealing.

Engine runs Hydraulic pump defective with high speed, but no vibration.

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Have it checked by qualified expert personnel.

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Troubleshooting – Engine malfunctions Fault

Possible cause

Remedy

Clutch between engine and hydraulic pump defective

Have it replaced by qualified expert personnel

Engine runs Clutch between engine and with high hydraulic pump defective speed, but no travel movement

Have it replaced by qualified expert personnel

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Disposal

10

Disposal

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Disposal – Final shut-down of machine

10.1 Final shut-down of machine After the machine has reached the end of its service life, the individual components of the machine must be disposed of properly.

Observe national regulations!

Carry out the following work and have the machine dismantled by a state-approved recycling company.

WARNING! Health hazard caused by fuels and lubricants!

– Safety regulations and environmental protection regulations must be followed when handling fuels and lubricants Ä Chapter 3.4 ‘Handling fuels and lubricants’ on page 30.

Protective equipment:

n Working clothes n Safety shoes n Protective gloves n Safety goggles

1. Remove the batteries.

2. Empty the fuel tank.

3. Drain engine oil from engine and exciter housing.

4. Drain off hydraulic oil.

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