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Dynapac F1250CS, Application, Operation & Maintenance

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Dynapac F1250CS Application, Operation & Maintenance Download Page 253

F 10 1

F 10

Maintenance

1

Notes regarding safety

Danger due to changes at the vehicle

Structural chances to the vehicle make the operating 
licence null and void and can cause severe to fatal injuries!

- Only use original spare parts and approved accessories.
- After maintenance and repair work, ensure that any dis-

mantled protective and safety devices are all completely 
fitted again.

- Comply with all further information in these instructions 

and in the safety manual.

Danger due to incorrect vehicle maintenance

Incorrectly performed maintenance and repair work can 
cause severe or fatal injuries!

- Ensure that maintenance and repair work is always only 

carried out by trained, specialist staff.

- All maintenance, repair and cleaning work should only 

be carried out with the engine turned off. Remove igni-
tion key and main switch.

- Affix a sign "Do not start" to the vehicle.
- Perform a visual inspection and check all functions 

every day.

- Proceed with all maintenance tasks according to the 

maintenance schedule.

- Proceed with expert inspection every twelve months.
- Eliminate all ascertained faults straight away.
- Do not restart the vehicle until all ascertained faults have 

been eliminated.

- Failure to comply with the prescribed inspection and 

maintenance work renders the operating licence null 
and void!

- Comply with all further information in these instructions 

and in the safety manual.

DANGER

DANGER

Summary of Contents for F1250CS

Page 1: ...OPERATION MAINTENANCE Paver Finisher F1250CS Type 458 01 1019 4812076240 ...

Page 2: ...www dynapac com ...

Page 3: ...rect usage 12 A Correct use and application 1 B Vehicle description 1 1 Application 1 2 Description of assemblies and functions 2 2 1 Vehicle 3 Construction 3 3 Danger zones 6 4 Safety devices 7 5 Technical data standard configuration 9 5 1 Dimensions all dimensions in mm 9 5 2 Permissible approach angle 10 5 3 Weights F1250CS all weights in t 11 5 4 Performance data F1250CS 11 5 5 Travel drive tr...

Page 4: ...e vehicle 2 3 Transportation on low bed trailers 3 3 1 Preparations 4 4 Securing the load 6 4 1 Prepare the low bed trailer 7 4 2 Driving onto the low bed trailer 8 4 3 Lashing equipment 9 Lashing equipment contact surfaces not swept clean and not free of frost ice and snow 9 Lashing equipment contact surfaces swept clean and free of frost ice and snow 10 4 4 Loading 11 4 5 Preparing the vehicle 1...

Page 5: ...layout on the display 2 Display of activated functions 4 1 1 Menu operation procedure for adjusting parameters 5 Selecting and changing an adjustment parameter in a menu 6 2 Menu structure 7 Menu of the Home displays 7 Displays 7 Home functions Quick Settings 8 Particulate Filter Regeneration menu o Engine measured value display 9 Drive engine measured value display 11 Screed Heater adjustment and...

Page 6: ...luid spray o 13 Separator fluid spraying system o 14 Conveyor limit switches 15 Auger limit switches 16 24 volt sockets o 17 USB interface 17 Fire extinguisher o 18 First aid kit o 18 Rotary beacon o 19 D40 12 Mode of operation 1 1 Preparing for operation 1 Required devices and aids 1 Before starting work in the morning or when starting paving 3 Check list for the vehicle operator 3 1 1 Starting t...

Page 7: ...al safety instructions 1 2 Distribution auger 3 2 1 Height adjustment 3 2 2 Auger width extension and material shaft with protective cover Optional equipment 4 3 Push roller crossbar adjustable 6 4 Connecting the automatic levelling system 7 Connecting the slope controller height controller 8 5 Limit switch 9 5 1 Install auger limit switches left and right 9 F10 Maintenance 1 1 Notes regarding saf...

Page 8: ...cooling system 5 12 Engine drive belt 6 15 F6 12 Maintenance hydraulic system 1 1 Maintenance hydraulic system 1 1 1 Maintenance intervals 3 1 2 Maintenance points 5 Hydraulic oil tank 1 5 Suction return flow hydraulic filter 2 7 High pressure filter 3 8 Pump distribution gear 4 9 Bleeder 10 Hydraulic hoses 5 11 Marking hydraulic hoses storage period period of use 13 Auxiliary flow filter 6 14 F7 ...

Page 9: ... in main terminal box operating panel 12 Relays 14 F11 12 Lubricants and operating substances 1 1 Lubricants and operating substances 1 1 1 Capacities 3 2 Operating substance specifications 4 2 1 Notes on diesel fuel 4 2 2 Drive engine TIER III o fuel specification 4 2 3 Drive engine TIER IV o fuel specification 4 2 4 Engine lubricating oil 5 2 5 Cooling system 5 2 6 Hydraulic system 5 2 7 Pump di...

Page 10: ...3 Cleaning optical or acoustic sensors 7 6 Preserving the paver finisher 8 6 1 Shutdowns for up to 6 months 8 6 2 Shutdowns lasting from 6 months to 1 year 8 6 3 Recommissioning the machine 8 7 Operating the vehicle in special climatic conditions or environments 9 8 Environmental protection disposal 10 8 1 Environmental protection 10 8 2 Disposal 10 9 Bolts torques 11 9 1 Standard metric threads s...

Page 11: ...Example Page B 2 is the second page of chapter B These operating instructions cover various vehicle options Make sure that during op eration and maintenance work the description appropriate to the vehicle option is used In the interest of continued development the manufacturer reserves the right to make changes to the vehicle which will not however change the essential features of the type of vehi...

Page 12: ...nsible for compliance with the resulting regulations and measures A The following warnings prohibitive symbols and instructive symbols indicate dangers for persons the vehicle and the environment due to residual risks when operating the vehicle A Failure to observe this information prohibitions and instructions can result in life threatening injuries A The Guidelines for the Correct Use and Applic...

Page 13: ...result in fatal or se vere injuries unless the corresponding actions are taken Caution Indication of a possible danger that result in moderate or mi nor injuries unless the corresponding actions are taken Note Indication of a possible drawback unless the corresponding actions are taken e g unwanted conditions or consequences can occur 1 3 Other supplementary information Other information and impor...

Page 14: ...itched off Warning on dangerous electrical voltage m All maintenance and repair work on the screed s electrical system must always be carried out by an electrician Warning on suspended loads m Never stand under suspended loads Warning on danger of crushing m There is a danger of crushing when certain components are operat ed or certain functions or vehicle movements are carried out Always make sur...

Page 15: ...V 5 Warning on danger of falling Warning on dangers posed by batteries Warning on hazardous or irritating substances Warning on substances which constitute a fire hazard Warning on gas bottles ...

Page 16: ...start engine drive Maintenance and repair work may only be carried out with the diesel engine shut down Spraying with water is prohibited Extinguishing with water is prohibited Unauthorised maintenance is prohibited Only qualified experts may conduct maintenance A Consult the Dynapac Service Department Fire naked flames and smoking are prohibited Do not switch ...

Page 17: ...oggles to protect your eyes Wear suitable head protection Wear suitable hearing protection to protect your hearing Wear suitable safety gloves to protect your hands Wear safety shoes to protect your feet Always wear close fitting work clothing Wear a warning vest to be seen in time to avoid accidents Wear respiratory equipment if breathing air is contaminated ...

Page 18: ... Hydraulic oil Diesel fuel Coolant Cleaning liquids must not get into the soil or sewer system during cleaning maintenance and repair work Substances must be caught stored transported and brought to pro fessional disposal sites in suitable containers Environmentally hazardous substance 1 8 Fire prevention A Locally applicable regulations may require suitable extinguishing agents to be carried on t...

Page 19: ...oc umentation A For example the maintenance instructions of the engine manufac turer m Description depiction applicable when equipped with gas heater m Description depiction applicable when equipped with electric heat er t Used to indicate standard equipment o Used to indicate optional equipment ...

Page 20: ...ecified in the valid regulations and amend ments together with harmonised standards and other valid provisions 3 Guarantee conditions A The guarantee conditions are included in the scope of supply of the machine This contains a complete specification of the valid conditions The guarantee becomes null and void if damage occurrs through malfunctions caused by improper use and incorrect oper ation re...

Page 21: ...ating range of the machine caused by wrong or improper use of the machine defective or missing safety devices use of the machine by untrained uninstructed staff defective or damaged parts incorrect transport of the machine incorrect maintenance or repairs leaking operating substances emission of noise and vibrations impermissible operating substances Existing residual risks can be avoided by compl...

Page 22: ...the machine includes presence in the danger zone of the machine transporting persons leaving the operator s platform while the machine is operating removing protection or safety devices starting and using the machine outside the operator s platform operating the machine with the screed walkway plate hinged up failing to comply with the maintenance instructions omission or incorrect execution of ma...

Page 23: ...he meaning of these operating instructions is defined as any natural or legal person who either uses the paver finisher himself or on whose behalf it is used In special cases e g leasing or renting the user is considered to be the person who in accordance with existing contractual agreements between the owner and the user of the paver finisher is charged with the observance of the operating duties...

Page 24: ...A 2 ...

Page 25: ...plication The DYNAPAC F1250CS paver finisher is a paver finisher with a caterpillar drive which is used for laying bituminous mixed material roll down or lean mixed concrete and unbound mineral aggregates for foundations for paving ...

Page 26: ...ion indicator holder 4 t Caterpillar drive 5 t Levelling cylinder for paving thickness 6 t Paving thickness indicator 7 t Crossbeam 8 t Travel drive of the caterpillar drive 9 t Conveyor 10 t Auger 11 t Screed 12 t Operator s platform 13 t Operating panel 14 t Working lights t Standard equipment o Optional equipment 4 11 6 8 7 10 12 13 3 2 5 1 9 14 ...

Page 27: ...trols The following extra equipment option is available o Hydraulic front hopper flap o Material chute hinged material chute o Remote control o Additional headlights warning lamps o Emulsion spraying system o Automatic levelling system o Larger working widths o Alternator for electric heater o Further equipment and upgrade options on request Engine The paver finisher is equipped with a water coole...

Page 28: ... the transport width Material compartment hopper The hopper inlet is equipped with a conveyor sys tem that empties the hopper and transfers the material to the auger The hopper can hold approx 5 0 t To facilitate emptying and achieve even material transfer each of the lateral covers of the hopper can be hydraulically folded in With the asymmetrical hopper o a hopper wall can be extended to enlarge...

Page 29: ...system always operates in conjunction with the levelling cylinders on the opposite side By adjusting the height of the traction point of the crossbeam the paving thickness of the material or the laying height of the screed can be controlled Actuation occurs electrohydraulically on both sides and can be controlled manually by means of toggle switches or automatically by means of an electronic grade...

Page 30: ...le operator and the screed personnel are allowed on the vehicle or in the danger zone The vehicle operator and screed per sonnel must keep to the respective driver s seats Make sure that there is no one in the danger zone before switching the vehicle on or starting it moving The vehicle operator must ensure that no one is in the danger zone Sound the horn before driving away Comply with all furthe...

Page 31: ...B 7 4 Safety devices 4 5 6 8 2 3 11 9 2 10 1 7 ...

Page 32: ...e function of these devices at regular intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation 1 Hopper transport safeguard 2 Screed transport safeguard 3 Main switch 4 Travel drive safety switch 5 Emergency stop button 6 Horn 7 Ignition key 8 Lights 9 Rotary beacon 10 Screed warning light 11 Covers lateral flaps coverings ...

Page 33: ...B 9 5 Technical data standard configuration 5 1 Dimensions all dimensions in mm 4784 1367 1790 2818 937 200 3916 1605 1465 1380 2017 1432 420 2761 590 4372 1137 2476 ...

Page 34: ...B 10 5 2 Permissible approach angle max 14 max 12 8 ...

Page 35: ...screed V2400TV V2400TV E Approx 6 94 Approx 6 94 With filled hopper additionally max approx 5 0 Screed used Basic width without cut off shoes Minimum paving width with cut off shoe Fully variable hydr adjustment up to Maximum paving widths with extension parts V2400TV 1 20 0 30 2 40 3 10 m V2400TV E 1 20 0 30 2 40 3 10 m Transport speed 0 3 3 km h Operating speed 0 27 m min Paving height 150 250 m...

Page 36: ...ngine Performance 50 KW 68 PS at 2200 rpm Fuel consumption full load Fuel consumption 2 3 load 14 1 l h 9 4 l h Fuel tank capacity See chapter F Make type Deutz TD 2 9 L4 Version 4 cylinder diesel engine Performance 50 KW 68 PS at 2200 rpm Fuel consumption full load Fuel consumption 2 3 load 14 1 l h 9 4 l h Fuel tank capacity See chapter F Make type Deutz TD 2 9 L4 Version 4 cylinder diesel engin...

Page 37: ...20 mm Conveyor operation Automatic by means of mechanical limit switches Augers Ø 320 mm Drive Left and right auger separately controllable Hydrostatic central drive continuously controllable Conveying volume controller Fully automatic via configurable switching points Auger height adjustment continuously mechanical 150mm Auger extension With extension parts see auger extension chart On board volt...

Page 38: ...400 2483 5Mhz Transmitter frequency band E Transmitter frequency range 2400 2483 5Mhz Number of transmitter channels 2 Transmitter power consumption 30mA Receiver frequency range 2400 2483 5Mhz Rechargeable battery voltage 3 6V Rechargeable battery capacity 2Ah Battery charger 10 30V DC ...

Page 39: ...er of injuries Never remove any warnings or information signs from the vehicle Damaged or lost warning or information signs must be replaced immediately Make yourself familiar with the meaning and position of the warning and information signs Comply with all further information in these instructions and in the safety manual CAUTION ...

Page 40: ...B 16 8 6 3 5 7 41 14 10 20 15 19 3 6 8 14 18 17 16 21 13 11 5 4 14 12 1 40 2 42 o 10 9 9 ...

Page 41: ...B 17 xxxxxxxxxxxxxxxxx 32 30 31 ...

Page 42: ...move the ignition key before performing any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause severe to fatal injuries Switch the engine off and remove the ignition key 3 Warning Danger of crushing Crushing points can cause severe or fatal injuries Maintain a safe distance from the danger area 4 Warning Hot surface Risk of burning Hot surf...

Page 43: ...re to fatal injuries The traction system brake must be released before towing Always observe the operating instructions 8 Warning Danger from running engine If the drive engine is left running this can cause severe to fatal injuries Never open the engine hood while the engine is running 9 Warning remote controlled vehicle The remote controlled vehicle can cause severe to fatal injuries Maintain a ...

Page 44: ...ling point 11 Diesel fuel sulphur level 15 ppm Position of the filling point specification 12 Lifting point Lifting the machine is only permitted at these lifting points 13 Main battery switch Position of the main battery switch 14 Lashing point Lashing the machine is only permitted at these points 15 Hydraulic oil Position of the filling point ...

Page 45: ...ngine oil drainage point Position of the drainage point 18 Gear oil drainage point Position of the drainage point 19 Gearbox oil Position of the filling and control point 20 Hydraulic oil drainage point Position of the drainage point 21 Fuel drainage point Position of the drainage point ...

Page 46: ...B 22 6 3 CE marking No Pictogram Meaning 30 CE sound output level ...

Page 47: ...B 23 6 4 Instructive symbols prohibitive symbols warning symbols No Pictogram Meaning 40 Wear ear protectors 41 Warning on dangers posed by batteries 42 Do not spray the area or component with water ...

Page 48: ...iption 1 Vehicle designation 2 Designation type 3 Year of construction 4 Serial number product identification number PIN 5 Operating weight incl all extension parts in kg 6 Maximum permitted total weight in kg 7 Maximum permitted axle load kg axle 1 8 Maximum permitted axle load kg axle 2 9 Maximum permitted axle load kg axle 3 10 Rated performance in kW 1 2 4 5 7 9 3 6 10 8 ...

Page 49: ...B 25 6 6 Explanation of 17 digit PIN serial number A Manufacturer B Family Model C Code letter F Serial number 10002014JHG002076 A B C F ...

Page 50: ...ne type plate 1 is affixed on top of the engine The type plate states the engine type serial number and engine data Please state the engine number of the engine when ordering spare parts A See also operating instructions for the engine 1 ...

Page 51: ...als used for paving and may even rise above 85 dB A If no ear protectors are used hearing can be impaired The noise emission level of the paver finisher was measured under free field condi tions according to the EN 500 6 draft dated March 1997 and ISO 4872 Sound pressure level at the operator s position at the height of the head LAF 86 0dB A Sound capacity level LWA 104 0dB A ...

Page 52: ...ents of the EMC Directive 2004 108 EC Interference emission according to DIN EN 13309 35 dB μV m for frequencies of 30 MHz 1GHz measured at a distance of 10 m 45 db μV m for frequencies of 30 MHz 1 GHz measured at a distance of 10 m Interference immunity against electrostatic discharge ESD according to DIN EN 13309 The paver finisher did not show any discernible reactions to contact discharges of ...

Page 53: ...ermany gas bottles must not be transported on the paver finisher or on the screed Disconnect the gas bottles from the gas system and protect them with their caps Use a separate vehicle to transport them When loading via ramps there is a risk that the machine will slip tilt or overturn Drive carefully Keep people away from the danger area Additional stipulations for transportation on public roads m...

Page 54: ...t as banksmen by the company and who can be expected to reliably perform the tasks assigned to them High visibility clothing must be worn The banksman and vehicle driver must have made themselves familiar with the dimensions of the vehicle and the transportation vehicle Directions are given by radio or with hand signals The banksman and vehicle driver must have agreed together beyond any doubt on ...

Page 55: ...sideration when selecting the attachment and loading equipment Danger due to vehicle loading Loading or unloading the vehicle onto or from another vehi cle poses a potential risk of accident Vehicles can tip over on driving onto the low bed trailer and cause severe to fatal injuries The transportation vehicle must always meet the requirements for transportation and be designed for this Ensure that...

Page 56: ...ections with the related screw caps m Move the auger to the uppermost position to avoid collisions m Swivel the holder of the height controller on the left and right side of the machine into the front position and secure properly f When screed is operated with the optional gas heating system Remove the gas bottle for the screed heater system Close main shut off valve and bottle valve Turn off the ...

Page 57: ... hopper lids Insert hopper transport safeguards Lift the screed Insert the transportation safeguards of the screed Fully extend the levelling cylinder Retract the screed parts until the screed matches the basic width of the paver finisher ...

Page 58: ...transport vehicle m If the contact surfaces are not swept clean and are not free of frost ice and snow the low loader must have the required number of lashing points with a lashing strength of LC 4 000 daN m If the contact surfaces are swept clean and are free of frost ice and snow the low loader must have the required number of lashing points with a lashing strength of LC 2 000 daN m The total he...

Page 59: ...C 10 12 7 4 1 Prepare the low bed trailer m The floor of the loading space must always be undamaged free of oil and mud dry residual moisture is permitted without accumulations of water and swept clean ...

Page 60: ...C 10 12 8 4 2 Driving onto the low bed trailer f Make sure that there are no persons in the danger area during loading Use the work gear and low engine speeds to drive onto the low bed trailer ...

Page 61: ...oad rating m Always tighten the lashing chains and straps hand tight 100 150 daN m Lashing equipment must be checked by the user for any signs of damage before use On detecting any signs of damage that affect safety the lashing equipment must be withdrawn from further use Lashing equipment contact surfaces not swept clean and not free of frost ice and snow Lashing chain permissible lashing force L...

Page 62: ... 12 10 Lashing equipment contact surfaces swept clean and free of frost ice and snow Lashing chain permissible lashing force LC 2 000 daN Lashing straps permissible lashing force LC 2 000 daN Non slip mats ...

Page 63: ...ng In some vehicles the kingpin load is too low so that the load has to be positioned fur ther to the back of the vehicle A Always heed the details regarding load distribution stipulated for the vehicle together with the centre of gravity of the paver finisher B A 770 510 B ...

Page 64: ...wing prepara tions must be carried out Position the non slip mats under the screed across the whole width of the vehicle 1 and lower the screed Switch off the paver finisher Attach and secure the protective hood 2 to the operating panel Convert control platform 3 in transportation position if necessary 1 2 3 ...

Page 65: ...e load 5 1 Securing in direction of travel m Diagonal lashing secures the paver finisher at the front using the lashing points on the paver finisher and on the low load trailer The lashing equipment must be installed as shown ...

Page 66: ...es swept clean and free of frost ice and snow The lashing angles should be ß between 15 30 and a between 9 50 m Contact surfaces not swept clean and not free of frost ice and snow The lashing angles should be ß between 17 50 and a between 5 45 ...

Page 67: ...curing opposite direction of travel m Diagonal lashing secures the paver finisher at the front using the lashing points on the paver finisher and on the low load trailer The lashing equipment must be installed as shown ...

Page 68: ...es swept clean and free of frost ice and snow The lashing angles should be ß between 20 55 and a between 5 65 m Contact surfaces not swept clean and not free of frost ice and snow The lashing angles should be ß between 17 55 and a between 5 45 ...

Page 69: ...ngine Lift the screed to the transportation position Drive from the trailer at a low engine revs speed Park the paver finisher in a secure spot lower the screed and switch off the engine Remove the key and or cover the operating panel with the protective hood and se cure it ...

Page 70: ...ng or loose parts from finisher and screed see also operating instructions for the screed Store these parts in a safe place f When screed is operated with the optional gas heating system Remove the gas bottle for the screed heater system Close main shut off valve and bottle valve Turn off the bottle valve and remove the gas bottle from the screed Transport the gas bottle on a second vehicle adheri...

Page 71: ... hopper lids Insert hopper transport safeguards Lift the screed Insert the transportation safeguards of the screed Fully extend the levelling cylinder Retract the screed parts until the screed matches the basic width of the paver finisher ...

Page 72: ...ety switch A The safety switch must always be pressed when the drive lever is moved out of the neutral position Otherwise the travel drive is blocked Swivel the drive lever to maximum f The vehicle already advances slightly on deflecting the drive lever Adjust required vehicle speed with the preselector To stop the vehicle swivel the drive lever to the middle setting and set the preselec tor to ze...

Page 73: ...ity is dependent on the screed which is mounted Danger from suspended loads Crane and or lifted vehicle can tip when lifted and cause injuries The vehicle may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further inform...

Page 74: ...any attachments and extension parts from the paver finisher and the screed until the basic width has been attained Take off all protruding or loose parts and the gas bottles of the screed heater see chapters E and D Attach lifting gear to the four attachment points 1 2 m The max permissible attachment point load is Attachment point 1 138 kN Attachment point 2 91 kN m The permissible load applies i...

Page 75: ...must be actuated to be able to tow the machine Pressure for releasing the traction system brakes is built up with the hand pump The drive engine is switched off Push knob 2 into the valve body While pumping next step check that the knob remains in the pressed position Actuate lever 3 of hand pump until sufficient pressure has been built up and traction system brakes have been released m On complet...

Page 76: ...ghten the lock nut 7 to a torque of 22 Nm m On completion of the towing process re store the initial status Attach the tow bar to the coupling 9 located in the bumper A Now carefully and slowly tow the paver finisher out of the construction area m Only ever tow the shortest distance to the means of transport or the next park ing possibility m The max permissible towing speed is 10 m min In hazardo...

Page 77: ... be secured in such a way that unauthorised persons or playing children cannot dam age the vehicle Pull off the ignition key and the main switch 1 and take it with you do not hide them somewhere on the machine Protect the operating panel with the dust cover 2 and lock it Store loose parts and accessories in a safe place 1 2 ...

Page 78: ...face for the hydraulic lift f Make sure that the hydraulic lift is securely and correctly positioned f The hydraulic lift is only intended to lift a load and not as a support Work should only be performed to and under raised vehicles when they have been secured and cor rectly supported to prevent them from tilling over and rolling or sliding away f Roller type jacks must not be moved when under lo...

Page 79: ...vehicle while it is being lifted f All raising and lowering work must be carried out uniformly with all hydraulic lifts in use Always check and observe horizontal alignment of the load f Always carry out raising and lowering work with several people together with an ad ditional person monitoring progress f Only positions 1 and 2 in the left and right side of the vehicle are permissible lifting poi...

Page 80: ...C 10 12 28 ...

Page 81: ... to life Always make sure during work that no one is endangered by the vehicle Ensure that all protective covers and hoods are fitted and secured accordingly Immediately rectify damage which as been ascertained Operation must not be continued when the vehicle is defective Do not let any persons ride on the paver finisher or the screed Remove obstacles from the road and the work area Always try to ...

Page 82: ...g or conveying vehicle parts Rotating or conveying vehicle parts can cause severe to fatal injuries Do not enter the danger zone Do not reach into rotating or conveying parts Only wear close fitting clothing Comply with the warning and information signs on the vehicle Stop the engine and remove the ignition key for any main tenance work Comply with all further information in these instructions and...

Page 83: ... that can pose a hazard when the diesel engine starts up conveying function of auger and conveyor prevent the engine from starting when set to MANUAL To be able to use the functions in the MANUAL operating mode they must be switched off and then to MANUAL to release them ...

Page 84: ...D 10 12 4 15 16 18 13 19 12 17 14 11 10 10 ...

Page 85: ...ing if drive lever is extended Min setting Idling speed Max position Nominal speed A For paving select the rated speed reduce the speed for transportation A The automatic speed control keeps the set speed con stant even under a load 13 Straight ahead travel synchronisation Using this potentiometer both chains can be synchronised for straight ahead travel while driving Set the steering to position ...

Page 86: ...D 10 12 6 15 16 18 13 19 12 17 11 10 10 14 ...

Page 87: ... vibration Levelling as well as increasing the vehicle speed as far as it will go A Before pushing the drive lever out the safety switch must be pressed to release the travel drive Otherwise the travel drive is blocked A Use the preselector to set the maximum speed f The vehicle speed cannot be reduced to 0 with the preselector The vehicle advances slightly with deflect ed drive lever even if the ...

Page 88: ...D 10 12 8 15 16 18 13 19 12 17 11 10 10 14 ...

Page 89: ...y with deflect ed drive lever even if the travel drive preselector is set to zero 18 Steering potentiometer The steering wheel movement is transferred electrohydraulically A For precise adjustments position 0 straight ahead see the straight ahead travel synchronisation For turning on the spot see switch Turning on the spot 19 Horn Press in the case of emergencies and to indicate when the ve hicle ...

Page 90: ...D 10 12 10 22 21 20 ...

Page 91: ...utton function Upper switch position Close right hopper lid Lower switch position Open right hopper lid f On actuation heed danger zones of moving parts of the vehicle 22 Open close asymmetrical hopper o Pushbutton function Upper switch position Close hopper side Lower switch position Open hopper side f On actuation heed danger zones of moving parts of the vehicle A Depending on the vehicle config...

Page 92: ...D 10 12 12 25 24 ...

Page 93: ...f screed Right switch position Retract left half of screed f On actuation heed danger zones of moving parts of the vehicle 25 Retract extend right screed Pushbutton function Left switch position Retract right half of screed Right switch position Extend right half of screed f On actuation heed danger zones of moving parts of the vehicle ...

Page 94: ...D 10 12 14 27 26 ...

Page 95: ...capacity with out material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 27 Right auger Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The conveying func tion of the right half of the auger is switched on when the drive lever is swivelled out and is con tinuously controlled via the material limit switches Operating mode OF...

Page 96: ...D 10 12 16 29 28 ...

Page 97: ...e function can be triggered in all modes of the auger f On actuation heed danger zones of moving parts of the vehicle 29 Reversing switch Right auger Pushbutton function Left switch position The conveying direction of the right half of the auger can be reversed in order to slightly reverse paving material for example A The function can be triggered in all modes of the auger f On actuation heed dan...

Page 98: ...D 10 12 18 31 ...

Page 99: ...rief description 31 Transfer amount controller Auger conveyor Joint continual adjustment of the auger and conveyor speed A The transfer amount must be matched to the existing paving situation Adjustment is possible during operation ...

Page 100: ...D 10 12 20 32 33 ...

Page 101: ...tion of the conveyor is switched on con stantly without material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 33 Reversing switch Conveyor Pushbutton function Upper switch position The conveying direction of the conveyor can be re versed in order to slightly reverse paving material for example which may be present in the material tunnel A The funct...

Page 102: ...D 10 12 22 34 ...

Page 103: ...set to automatic conveyor and auger are switched on A The engaged function is shown in the display of the ve hicle as activated A Once the set material height is reached at the limit switches the conveying functions are switched off A When the vehicle is restarted the function is switched OFF f On actuation heed danger zones of moving parts of the vehicle 35 Not used ...

Page 104: ...D 10 12 24 36 ...

Page 105: ...ocked in position Lower switch position Lower screed floating position Screed is lowered and released in the floating position when the drive le ver is swivelled out A To prevent the screed from lowering during an interme diate stop drive lever in centre position the screed is hydraulically held in position via relief pressure and the counter pressure of the material m Check whether the screed tra...

Page 106: ...D 10 12 26 34 34a ...

Page 107: ...er is switched on when the drive lever is swivelled out Operating mode OFF The screed tamper is switched off Operating mode MANUAL The screed tamper is switched on constantly 34a Tamper speed regulator o Continually adjustable tamper speed setting A The tamper frequency number of strokes per minute is set fully variable using the rotary regulator ...

Page 108: ...D 10 12 28 35 35a ...

Page 109: ...is switched on when the drive lever is swivelled out Operating mode OFF Screed vibration is switched off Operating mode MANUAL Screed vibration is switched on constantly 35a Vibration speed regulator o Continually adjustable vibration speed setting A The vibration frequency number of strokes per minute is set fully variable using the rotary regulator ...

Page 110: ...D 10 12 30 36 38 37 ...

Page 111: ...hbutton function Upper switch position Retract left levelling cylinder Lower switch position Extend left levelling cylinder A The AUTO and OFF mode are overriden when actuated f On actuation heed danger zones of moving parts of the vehicle 38 Retract extend right levelling cylinder Pushbutton function Upper switch position Retract right levelling cylinder Lower switch position Extend right levelli...

Page 112: ...D 10 12 32 39 ...

Page 113: ...cater pillar chains run in opposite directions when the steering potentiometer is turned Steeringpotentiometerturnedtotheleft vehicleturns to the left Steering potentiometer turned to the right vehicle turns to the right A The function can only be activated when the button is pressed and held and the steering potentiometer is in the neutral position A The turning speed of the vehicle changes in pr...

Page 114: ...D 10 12 34 41 40 43 42 ...

Page 115: ...e the radio connection can be established between the radio re mote control and the vehicle m In the Radio remote control operating mode the con trol elements Steering potentiometer Drive lever Travel drive preselector on the main operating panel has no function Intervention can only be carried out via the radio remote control 42 Rotary beacon ON OFF o Detent switch function Upper switch position ...

Page 116: ...D 10 12 36 44 ...

Page 117: ...gnation Brief description 44 Release travel drive Pushbutton function Upper switch position Release travel drive for 2 seconds A The drive lever must be operated in this period of time otherwise the travel drive is blocked ...

Page 118: ...D 10 12 38 45 ...

Page 119: ...eater system ON Lower switch position Screed heater system OFF A The automatic temperature control of the screed heater system is carried out with activation A Gas heating o This opens the non return valves for the gas supply to the burners and activates the electron ic ignition system and the flame monitoring system ...

Page 120: ...D 10 12 40 46 ...

Page 121: ...41 Item Designation Brief description 46 Display Input and display terminal for showing various vehicle param eters activation of functions etc A To operate the display see the corresponding part of this manual ...

Page 122: ...D 10 12 42 Electric heating element o 50 51 52 53 ...

Page 123: ...ator lamp shows that the alternator is switched on by the activated screed heating system 52 Indicator lamp Heating A The indicator lamp is active as soon as the screed heat ing system is switched on by the automatic control sys tem heating process 53 Test key for moni toring of insulation indicator lamp for insulation faults A See the section Insulation monitoring in the screed op erating instruc...

Page 124: ...D 10 12 44 Gas heating element o 62 60 61 63 ...

Page 125: ...ame monitoring function in the corre sponding Operating Instructions for the screed A Please comply with further instructions for the screed heater function and operation in the corresponding Operating Instructions for the screed Item Designation Brief description 60 Malfunction display Left middle section malfunction display red 61 Malfunction display Left extendable part malfunction display red ...

Page 126: ...D 10 12 46 3 Remote control A Depending on the side of the machine left right the function switches only control the corresponding function on the particular side of the machine ...

Page 127: ...g the external levelling system to the left of the vehicle A When not needed close the socket with the corre sponding protective cap 83 Socket Right levelling system For connecting the external levelling system to the right of the vehicle A When not needed close the socket with the corre sponding protective cap 84 Vandalism protection facility Lock the vandalism protection facility at the end of w...

Page 128: ...D 10 12 48 90 91 92 93 94 ...

Page 129: ...ft right Operating mode AUTO OFF MANUAL Detent switch function Left switch position Operating mode AUTO The conveying function of the left right half of the auger is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switches Switch position central Operating mode OFF The conveying function of the left right half of the auger is switched off Rig...

Page 130: ...D 10 12 50 90 91 92 93 94 ...

Page 131: ...n Brief description 94 Retract extend left right screed Pushbutton function Switch position in the corresponding direction extend or retract left right screed half f On actuation heed danger zones of moving parts of the vehicle ...

Page 132: ...ote control When operating the vehicle with the radio remote control the operator must always have a clear view of the vehicle Before starting up check the radio remote control for any signs of damage and test all functions Immediately shut down a defective radio remote control The radio remote control may only be repaired by the manufacturer or skilled workers authorised by the manufacturer The r...

Page 133: ...n the radio remote control main operating panel or remote control can be carried out by all control units m A radio link must be established before beginning work for operation with the radio remove control See the section Establish radio link ...

Page 134: ...ravel drive and the operating functions of the vehicle are switched off The switch off is signalled as an error message in the vehicle display and with an LED 111 Procedure after a safety shut off Reduce the angle of inclination of the radio remote control Move the drive lever 103 in the neutral position Turn the key switch 100 to Position II Reset to acknowledge the error message The LED 111 goes...

Page 135: ...d If there continues to be no radio link the travel drive and the operating functions of the vehicle are switched off after 3 seconds The switch off is signalled as an error message in the vehicle display and with an LED 111 The LED 110 goes out Procedure after a safety shut off Re enter the reception area with the radio remote control Move the drive lever 103 in the neutral position Turn the key ...

Page 136: ...D 10 12 56 4 3 Establish radio link 100 110 41 14 ...

Page 137: ... Travel drive preselector on the main operating panel have no function Intervention can only be carried out via the radio remote control Insert the key switch 100 in position 0 turn it to Position I to switch on the radio remote control and establish the radio link Radio link established short beep A The LED indicator lamp 110 signals the established radio link Radio link failed continuous beep Tu...

Page 138: ...external battery charger Slide the lock 1 on the power supply unit forward and pull the plug 2 up ward out of the power supply unit Fit the country specific plug on the power supply unit Insert the rechargeable battery of the remote control in the battery charger Connect the power supply unit of the battery charger to a power source A The two light emitting diodes on the bat tery charger and on th...

Page 139: ...e switched off Turn the On Off switch 1 to Posi tion 0 and pull it out Press in the rechargeable battery 2 toward the front and remove it down ward out of the battery compartment Insert the replacement rechargeable battery in the battery compartment and lock it in place If necessary establish a radio link with the vehicle see the section Establish radio link 1 2 ...

Page 140: ...D 10 12 60 4 5 Control elements of radio remote control 101 100 ...

Page 141: ...d radio link Radio link failed continuous beep Turn key switch to Position II Reset if no radio link could be established and repeat the linking attempt in Position I Turn the key switch to Position 0 to end the radio link and to switch off the radio remote control A Pull off the key switch after the end of work 101 Release travel drive Pushbutton function When actuated Release travel drive for 2 ...

Page 142: ...D 10 12 62 102 103 ...

Page 143: ...ions connected on the main operating panel and on the remote controls are activated Conveyor auger Tamper vibration Levelling as well as increasing the vehicle speed as far as it will go A Before deflecting the drive lever the safety switch Re lease travel drive 101 must be operated Otherwise the travel drive is blocked A Use the preselector to set the maximum speed f The vehicle speed cannot be r...

Page 144: ...D 10 12 64 106 104 105 109 110 111 107 108 ...

Page 145: ...imum speed that can be reached when the drive lever is at its stop A The scale approximately matches the speed in m min during paving f The vehicle speed cannot be reduced to 0 with the preselector The vehicle advances slightly with deflect ed drive lever even if the travel drive preselector is set to zero 106 Horn Press in the case of emergencies and to indicate when the ve hicle starts to move A...

Page 146: ...D 10 12 66 106 104 105 109 110 111 107 108 ...

Page 147: ... LED red green Radio remote control connected battery weak LED red Radio remote control connected battery heavily discharged LED OFF Radio remote control OFF battery may be completely discharged 110 LED indicator lamp Radio link green A Confirms an established radio link between the radio re mote control and the receiver of the vehicle 111 LED indicator lamp Error message red A Indicates that an e...

Page 148: ...D 10 12 68 112 113 114 115 116 ...

Page 149: ...ated and released at the new paving location 113 Raise lower screed Lower screed floating position Pushbutton detent switch function Button switching position at top Lift the screed After end of operation Screed is hydraulically blocked in position Locked switch position at bottom Lower screed floating position Screed is lowered and released in the floating position when the drive le ver is deflec...

Page 150: ...D 10 12 70 112 113 114 115 116 ...

Page 151: ...ected on the main operating panel is overridden Switch position central Operating mode OFF The conveying function of the left half of the auger is switched off or is controlled via the connected AUTO function on the main oper ating panel Lower switch position Reverse operating mode The conveying direction of the left half of the auger is reversed in order for ex ample to transport back paving mate...

Page 152: ...D 10 12 72 112 113 114 115 116 ...

Page 153: ...ted on the main operating panel is overridden Switch position central Operating mode OFF The conveying function of the right half of the auger is switched off or is controlled via the connected AUTO function on the main oper ating panel Lower switch position Reverse operating mode The conveying direction of the right half of the auger is reversed in order for ex ample to transport back paving mate...

Page 154: ...D 10 12 74 112 113 114 115 116 ...

Page 155: ...d on the main operating panel is overridden Switch position central Operating mode OFF The conveying function of the conveyor is switched off or is controlled via the con nected AUTO function on the main operating panel Lower switch position Reverse operating mode The conveying direction of the conveyor is reversed in order for example to slightly reverse conveying of paving material A The reversi...

Page 156: ...D 10 12 76 121 122 123 124 117 118 119 120 ...

Page 157: ...t material height is reached at the limit switches the conveying functions are switched off f On actuation heed danger zones of moving parts of the vehicle 118 Open close asymmetrical hopper o Pushbutton function Upper switch position Close hopper side Lower switch position Open hopper side f On actuation heed danger zones of moving parts of the vehicle A Depending on the vehicle configuration the...

Page 158: ...D 10 12 78 121 122 123 124 117 118 119 120 ...

Page 159: ...position Retract right levelling cylinder Lower switch position Extend right levelling cylinder A The AUTO and OFF operating modes switched on the main operating panel or remote control are overrid den when operated f On actuation heed danger zones of moving parts of the vehicle 121 Open close left hopper Pushbutton function Upper switch position Close left hopper lid Lower switch position Open le...

Page 160: ...D 10 12 80 121 122 123 124 117 118 119 120 ...

Page 161: ...f screed Right switch position Retract left half of screed f On actuation heed danger zones of moving parts of the vehicle 124 Retract extend right screed Pushbutton function Left switch position Retract right half of screed Right switch position Extend right half of screed f On actuation heed danger zones of moving parts of the vehicle ...

Page 162: ...or radio remote control defective Have checked by and if necessary renewed by an expert Emergency stop button actuated or defective Pull out emergency stop button Have checked by and if necessary renewed by an expert Engine dies without recognisable reason Rechargeable battery discharged or defective Charge battery replace if necessary Antenna defective Have checked by and if necessary renewed by ...

Page 163: ...D 24 12 1 D 24 12 Operating the display ...

Page 164: ...igned in the display area A1 A For orientation the corresponding symbol shows an opened menu in the status line B A To confirm an active opened menu the colour of the cor responding symbol changes from pale to dark grey B Display area for status warning and error messages Existing warnings or error messages are displayed B A A1 ...

Page 165: ...n the section Symbols for status warning and error messages Colour code Explanation RED error message Reports a serious fault that must be checked and rec tified immediately YELLOW warning message Reports a current condition that needs to be observed or rectified at short notice to ensure correct working BLUE GREEN status message Confirms an activated function ...

Page 166: ...on and off The function is activated when the corresponding symbol 1 appears blue A Some functions switched on with the operating panel are shown for confirmation in the display area A The function is activated when the corresponding symbol appears blue 2 Main function switch on radio remote control activated 3 Filling function activated 1 A 2 3 ...

Page 167: ...e The Home menu is open in the display Press button A to open the screed heater menu Press the plus minus button B C to activate the selected parameter to be adjusted A A blue frame appears around the temperature parameter Press the plus minus button B C until the desired temperature is displayed B A 2 C ...

Page 168: ...e appears in the area which is activated for the adjustment Press button A until the blue frame is around the required adjustment parameter Press button B to activate the selected parameter to be adjusted Press buttons C D until the desired value is displayed Press button B to accept the set value Press button A to accept the set value 6 A B C D ...

Page 169: ...plays Displays 1 Speed Paving tortoise Driving hare 2 Fuel gauge 3 Actual temperature of the screen heater C F A The display shows the average temperature of all screed sections 4 Actual diesel engine speed n min 5 Time of day hh mm AM PM 1 2 3 4 5 ...

Page 170: ...symbol appears blue 1 Conveyor switch off function A With the function activated the conveyor switch off is only carried out with when both conveyor switches are operated simultaneously If the function is deactivated the conveyor switch off is carried out by operating a limit switch 2 Fill vehicle for paving process function A The functions are activated by operating the corresponding switch on th...

Page 171: ...iggering necessary particulate filter regeneration A Necessary regeneration is indicated by the regeneration warning sign 1a A Please heed the notes in the Terminal error messages section A When the function is activated the HEST warning sign 1b comes on permanently and the regeneration warning sign 1a flashes HEST High Exhaust System Temperature A Particulate filter regeneration takes about 30 45...

Page 172: ... from particulate filter regeneration Improper particulate filter regeneration can cause severe to fatal injuries Keep the outlet of the exhaust pipe out of the reach of peo ple and of objects that can burn melt or explode There may not be any people or objects within a radius of 0 6 m of the exhaust outlet There may not be any objects or substances that can burn melt or explode within a radius of...

Page 173: ...lay A The menu for filter regeneration is only displayed for vehicles with corresponding ex haust gas aftertreatment 3 Engine coolant temperature C F 4 Engine operating hours h 5 On board voltage V Call up the following menus 6 Home menu 3 4 5 6 ...

Page 174: ...d heater temperature display and adjustment parameters 2 Average actual temperature of all screed sections C F A Direct adjustment of the nominal temperature by pressing the plus minus buttons 3 4 A Setting range 50 200 C A When the heater is switched on and off the colour of the screed symbol changes 5 yellow ON Call up the following menus 6 Home menu 2 1 3 4 6 5 5 ...

Page 175: ...vehicle warning messages Open detailed display Vehicle Warning Messages 2 1 3 Number of engine error messages Open detailed display Engine Error Messages 3 1 A Possibly notify customer service of the system error number displayed on your paver finisher the customer service department will then discuss with you how to proceed Call up the following menus 5 Info menu 6 Home menu 1 2 2 1 1 2 1 3 1 5 6...

Page 176: ...sages in a table 1 Error code 2 Error description 3 Parameters see Bodas error list A If present the following page of the list is shown after a few seconds in each case Call up the following menus 4 Vehicle Warning Messages menu 5 Engine Error Messages menu 6 Info menu 7 Home menu 4 5 6 7 1 2 3 ...

Page 177: ...ble 1 Error code 2 Error description 3 Parameters see Bodas error list A If present the following page of the list is shown after a few seconds in each case Call up the following menus 4 Error Messages With Travel Drive Stop menu 5 Engine Error Messages menu 6 Info menu 7 Home menu 4 5 6 7 1 2 3 ...

Page 178: ... error frequency A All error messages can be identified in the section Drive engine error codes A If present the following page of the list is shown after a few seconds in each case Call up the following menus 4 Error Messages With Travel Drive Stop menu 5 Vehicle Warning Messages menu 6 Info menu 7 Home menu 4 5 6 7 1 2 3 ...

Page 179: ...ation 1 Software version of the vehicle 2 Software version of the display A If consultation with Technical Support is required for your vehicle always specify the software version Call up the following menus 4 Error Messages With Travel Drive Stop menu 5 Vehicle Warning Messages menu 6 Engine Error Messages menu 7 Home menu 4 5 6 7 1 2 ...

Page 180: ...min min 1 2 24hrs PM AM 2 Selection System Language English German 3 Selection Units of measurement Metric Imperial US Monitor brightness display and adjustment parameters 4 1 Daytime light 4 2 Nighttime light A Setting range 10 100 Open the following sub menus Call up the following menus 5 Home menu 5 1 1 3 1 2 2 4 1 4 2 ...

Page 181: ...ashes Urgent maintenance level II Particular filter regeneration must be carried out as soon as possible The engine output may be automatically reduced under certain circumstances Indicator lamp flashes indicator lamp Engine malfunction is on permanently Urgent mainte nance level III Particulate filter regeneration is vitally necessary to avoid subsequent damage and repairs The engine output is au...

Page 182: ... pipe out of the reach of people and of objects that can burn melt or explode f There may not be any people or objects with in a radius of 0 6 m of the exhaust outlet f There may not be any objects or substances that can burn melt or explode within a radius of 1 5 m petrol wood paper plastic tex tiles pressurised cylinders hydraulic lines A In an emergency turn the engine off so that no more exhau...

Page 183: ...of fault the vehicle can temporarily continue to be operated or in the case of serious faults should be shut down immediately to prevent further damage from occurring Each fault should be rectified as soon as possible A An error code query can be shown in the corresponding menu of the display A Lights up for a few seconds once the ignition has been switched on for checking purposes Hydraulic oil t...

Page 184: ...t temperature The engine temperature is too high m The engine performance will be throttled down automatically Driving mode remains possible Stop the paver finisher drive lever to the cen tre position let the engine cool down while idling Determine the cause and rectify if nec essary refer to Malfunctions section After cooling down to normal temperature the engine will run with full performance ag...

Page 185: ...ble errors see engine s oper ating instructions A This error is displayed together with Error Message Emergency mode active Vehicle error The control unit reports one or several malfunc tions that cause the vehicle to shut down It may be possible to continue operating the vehicle in the emergency mode A Error details can be viewed in the Error Memory display menu Master display communication error...

Page 186: ...D 24 12 24 2 1 Drive engine error codes A If a fault is detected on the engine this is shown by the corresponding indication 1 in the display 1 ...

Page 187: ...coding A If present the following page of the list is shown after a few seconds in each case m It may be possible to continue operating the vehicle depending on the severity of the error The error should however be remedied quickly to prevent further damage A Engine malfunctions result in the engine stopping automatically to prevent further damage ...

Page 188: ...D 24 12 26 Example ...

Page 189: ...ary engine shut down Display SPN 157 FMI 3 OC 1 Cause Cable break on sensor for rail pressure Effect Engine shut down Frequency Fault occurs for the 1st time m Notify customer service of the error number displayed on your paver finisher the cus tomer service department will then discuss the further procedure with you ...

Page 190: ...4 12 28 3 Menu structure of the setting and display menus The following illustration shows the menu structure and serves to simplify operation and the procedure in the case of various settings and displays ...

Page 191: ...es a risk of falling from the vehicle which can cause severe to fatal injuries The operator must be at the intended driver s seat during operation Never jump onto or off a moving vehicle Keep accessible surfaces free of any soiling e g operat ing substances to avoid the risk of slipping Use the steps provided and hold onto the handrail with both hands Comply with all further information in these i...

Page 192: ...m protection facility 1 on the operating panel and secure with the corresponding lock The vandalism protection facility can be kept in bracket 2 during op eration The storage space 3 can be used to store the on board tool kit operating instructions and other attachments Keep the storage space closed after work has been completed 3 1 2 ...

Page 193: ...screw the stop screws 1 and re move the handrail 2 Unscrew the detent pin 3 on the un derside of the running board Swivel the running board upward and secure it in the top position with the detent pin 4 Turn the handrail 2 by 180 and guide it into both tubes 5 and secure it with the corresponding stop screws 6 2 3 3 1 6 5 180 4 ...

Page 194: ...isher f Ensure that nobody or nothing is in the danger area f Only adjust the operating position whilst the vehicle is stationary Danger from damaged or missing operating instructions Failure to comply with the operating instructions can cause severe to fatal injuries Familiarise yourself with the contents of the operating instructions Always keep the operating instructions in the intended place o...

Page 195: ...D 30 12 5 Fuse box The terminal box which contains all fus es and relays etc is located beneath the operating panel A An assignment plan for fuses and relays can be found in chapter F8 ...

Page 196: ...ng to the in structions see section Starting the paver finisher external starting starting aid Main battery switch The main battery switch separates the current circuit from the battery to the main fuse A For the assignment of all fuses see chapter F To interrupt the battery s current cir cuit turn the key pin 1 to the left and pull it out A Do not lose the key pin as in this case the paver finish...

Page 197: ...pen dan ger during transportation Crossbeam lock mechanical A The crossbeam locks must additionally be engaged on both sides of the vehicle prior to transportation with the screed lifted f Transportation with an unsecured screed leads to a risk of accidents Lift the screed On both sides of the paver finisher slide the crossbeam lock beneath the crossbeams using the lever 1 place the lever in the d...

Page 198: ...paving situations the same paving thickness should be set on both sides of the vehicle Paving thickness indicator at top One scale each A on which the cur rently set paving thickness can be read off is located on the left and right on the upper side of the engine hood The coloured marking B shows the paving thickness A In normal paving situations the same paving thickness should be set on both sid...

Page 199: ...tlights 2 at the front and rear of the vehicle f Always align the working lights to avoid dazzling the operating personnel or oth er road users LED working light magnetic foot o The working lights are fitted in any position on the machine using the magnetic foot Connect the lead with the 24V sockets 2 on the vehicle f Always align the working lights to avoid dazzling the operating personnel or oth...

Page 200: ...the ratchet lever 2 Set the desired height by alternatingly actuating the left and right ratchets A The current height can be read on both auger height indicators A Observe the notes on adjusting the au ger height in the chapter Set up and modification Auger height displays A scale 1 on which the currently set auger height can be read off is located on the left and right sides of the ladder A Disp...

Page 201: ...er m Use of the sensor rod increases the basic width of the paver finisher f If the sensor rod or sensor rod extension are used ensure that there is no one in the vehicle s danger area A The sensor rod is adjusted when the vehicle is positioned with its set working width on the paving route and the reference marking running parallel to the paving route has been set up Adjusting the sensor rod The ...

Page 202: ...g nuts 4 the end section of the sensor rod 5 can be set to the desired length the angle can additionally be changed by swivelling on the joint 6 A The chain 7 can be used as a guide m Tighten all assembly parts properly after setting up ...

Page 203: ...sphalt with a separator emulsion m Only use approved separator emulsion in the spray 1 Build up pressure by actuating the pump lever 2 The pressure is indicated on the ma nometer 3 Actuate the manual valve 4 to spray f Do not spray into open flame or on hot surface Danger of explosion 2 1 3 4 ...

Page 204: ...use Pull the hose 1 out of the device until a click is audible When released the hose automatically engages here The hose is automatically retracted into the guide after pulling and dis charging again Actuate the manual valve 2 to spray f Do not spray into open flame or on hot surface Danger of explosion A The function is switched on and off at the vehicle operating panel If the system is not in u...

Page 205: ...the screw 3 and move the paddle 4 until the required switch ing point is reached Retighten screw 3 properly or Loosen the housing 5 and turn the switching cam 6 on the shaft until the required switching point is reached Loosen the stud bolt 7 to do this After adjusting retighten all mounting parts properly close housing 1 2 6 3 4 5 7 ...

Page 206: ...rs 3 to ensure that they are not damaged on extending and retracting the screed Align the ultrasound sensor 3 towards the mixed materials in front of the auger The sound waves should impact on the mixed materials at right angles Adjust the deactivation point with the de sired material height by regulating the potentiometer 4 Repeat these tasks everyday before starting work A Always keep the sensor...

Page 207: ...an be con nected here for example 24V socket A Voltage is present when the main switch is switched on USB interface There is a USB interface 2 on the right side of the operating panel console Here for example devices with a corresponding connection can be charged A Voltage is present when the main switch is switched on 1 2 ...

Page 208: ...nnel must be fa miliarised with operation of the fire extin guisher 2 A Observe the inspection interval for the fire extinguisher First aid kit o f Any dressings that have been used must be replaced immediately A Heed the expiry date of the first aid kit 2 1 ...

Page 209: ...rotary beacon onto the plug in contact and secure with a clamping bolt 1 Extend the rotary beacon with tube 2 to the desired height and secure with the clamping bolt 3 Activate the function on the operating panel as necessary A The rotary beacon is easy to remove and should be stored securely at the end of work 1 3 2 ...

Page 210: ...D 30 12 20 ...

Page 211: ...on parts Diesel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector Two filled propane gas bottles Shovel and broom Scraper spatula for cleaning the auger and the hopper infeed area Parts that may become necessary for extending the auger Parts that may become necessary for extending the screed Percentage spirit level levelling rail 4 m long Levelling wire Per...

Page 212: ...lighting must be provided when working at night Comply with all further information in these instructions and in the safety manual Danger of falling from the vehicle Entering and leaving the vehicle and the driver s seat dur ing operation poses a risk of falling from the vehicle which can cause severe to fatal injuries The operator must be at the intended driver s seat during operation Never jump ...

Page 213: ...ves must stop immediately Steering The paver finisher must immediately fol low every steering wheel movement in a precise manner Check straight ahead travel Horn On the operating panel on both remote controls Briefly press the horn button Horn signal must sound Lights Switch on with the ignition key walk around the paver finisher to check and switch off again Screed warning light With the ignition...

Page 214: ...pper transport safeguard When the hopper is closed it must be possible to insert the safety chain between the two hopper lids Other facilities Engine panels Lateral flaps Check that the hoods and flaps are securely seated Accessories First aid box Equipment must be present on the vehicle A Always observe the local regulations Check How ...

Page 215: ...D 40 12 5 1 5 2 5 5 4 6 3 9 7 8 ...

Page 216: ...annot be started if the indicator lamps are on Start inhibit 4 Emergency stop button 5 pressed Error message 6 drive lever 1 swivelled out Engine error with stop 7 engine error with start inhibit Turn ignition key 3 to position 1 and wait for the preheat check 8 o to go off Press the starting button 9 to start the engine Do not let the starter run permanently for more than 20 seconds then allow fo...

Page 217: ...D 40 12 7 1 5 2 5 5 4 6 3 9 7 8 ...

Page 218: ...the positive terminal A of the starting aid battery to the posi tive terminal B of the vehicle battery Then connect the negative terminal C of the starting aid battery to the ground of the discharged vehi cle e g to the engine block or to a bolt D on the vehicle frame f Do not connect the starting aid cable to the negative terminal of the discharged battery Danger of explosion m Lay the starting a...

Page 219: ...reak of one minute A If the engine does not start and the Error message 6 indicator lamp flashes then the electronic engine control system has activated the start inhibit To deactivate the start inhibit turn the system off with the ignition key 3 for approx 30 s If the engine still has not started after two attempts ascertain the cause If the engine starts up disconnect the starting aid cable agai...

Page 220: ...D 40 12 10 5 4 5 5 1 2 3 ...

Page 221: ...by switching on a conveying function Switch off the engine and determine the fault if the lamp does not go out For further possible malfunctions refer to the section Malfunctions Oil pressure indicator lamp for the diesel engine 2 Must go out after starting m If the lamp does not go out or lights up during operation Switch off the engine check the engine oil level For other possible errors see eng...

Page 222: ...D 40 12 12 6 2 1 3 4 4 4 5 5 5 7 ...

Page 223: ... levelling cylinders with the switch 4 Use switch 5 to adjust the screed to the basic width of the paver finisher m Lift the auger if necessary A The engine cannot be started with the drive lever 6 swivelled out To be able to start the travel drive the drive lever must first be returned to the centre position A Before pushing the drive lever 6 out the safety switch 7 must be pressed to re lease th...

Page 224: ...D 40 12 14 4 6 2 6 6 1 3 5 ...

Page 225: ...g carefully tilt the drive lever 4 forward or backward according to the drive direction desired Adjust the speed with the preselector 2 Carry out steering movements by actuating the steering potentiometer 5 f In emergency situations press the emergency stop button 6 To stop set the preselector 2 to 0 and move the drive lever 4 into its centre position A The safety switch must always be pressed whe...

Page 226: ...screed auger push roller with a separator fluid m Do not use diesel fuel as it dissolves the bitumen prohibited in Germany Screed heater Switch on the screed heater approx 15 30 minutes depending on the ambient tem perature before paving begins Warming up prevents the material from sticking to the screed plates ...

Page 227: ...12 17 Direction marks To ensure straight paving a direction mark must be present or established road edge chalk lines or similar Pull the direction indicator out of the bumper arrow and adjust it accordingly ...

Page 228: ...D 40 12 18 2 2 1 2 3 4 ...

Page 229: ...onveyor limit switches with the vehicle turned off until sufficient material is conveyed in front of the screed Filling function A The filling function can additionally be used to convey the material in front of the screed at the start of paving Set the switches for the auger 2 and the conveyor 3 to the AUTO operating mode Actuate switch 4 The engine speed is increased the conveying functions conv...

Page 230: ...D 40 12 20 1 3 8 8 2 13 4 5 6 7 8 9 12 11 10 ...

Page 231: ...y Check the area of the caterpillar chains as uneven ground is levelled by the screed The caterpillar chains act as reference points for the layer thickness The basic setting of the screed must be corrected when the actual layer thickness de viates significantly from the values indicated by the scales see the operating instruc tions for the screed A The basic setting is for asphalt material Item S...

Page 232: ...e way Uniform material transport and distribution or supply to the screed may require cor rections to settings of the material switches for conveyor and auger A See the section Malfunctions when paver functions fail Quality of the layer Paving thickness Slope Evenness in the driving direction and at right angles to it check with 4 m levelling rod Surface structure texture behind the screed A See s...

Page 233: ...D 40 12 23 1 2 3 4 5 ...

Page 234: ...e an edge like the end of a layer Set the drive lever 1 to the centre position During longer breaks e g lunch break Set the drive lever 1 to the centre position and the speed adjuster 2 to minimum Switch off screed heater 3 Switch off drive engine 4 and switch off ignition 5 When the screed is operated with the optional gas heating system o close the valves of the bottles A The screed must be heat...

Page 235: ...D 40 12 25 1 2 4 4 16 3 9 7 6 4 5 8 11 11 10 12 13 14 11 10 10 17 15 ...

Page 236: ...s 6 to OFF Switch off screed heater 13 Switch the working and warning lights 14 to OFF Switch off the drive engine 15 Read and check the operating hour meter 16 to determine whether maintenance work must be performed see chapter F Switch off the ignition 17 Close the main shut off valves and the bottle valves for the screed gas heating sys tem o Remove the levelling units and stow them away in the...

Page 237: ...long waves change in the material temperature demixing roller has stopped on the hot material roller has turned or roller speed has been changed too fast incorrect operation of the roller incorrectly prepared foundation truck brake is applied too tight long standstill times between loads grade control reference line is not suitable incorrect installation of the grade control limit switch is not co...

Page 238: ...slow screed extendable parts are incorrectly installed cold screed bottom plates are worn or warped screed does not work in the floating position paver finisher speed is too high auger is overloaded changing material pressure against the screed Marks in the surface truck hits too much against the finisher while aligning to the finisher too much play in the mechanical screed link suspension truck b...

Page 239: ...the suction line of the pump Seal or replace the connections Tighten or replace the hose clamps Oil filter is soiled Clean the filter if necessary replace the filter Conveyor or augers run too slowly Hydraulic oil level in the tank is too low Top up oil Power supply is interrupted Check fuses and cables replace if necessary Switch is defective Replace the switch One of the pressure limit ing valve...

Page 240: ...ease the speed Hydraulic oil level is too low Top up oil Leak in the suction line Tighten the connections Flow rate regulator defective Replace Leaking seals of the hydraulic cylinder Replace Control valve is defective Replace Power supply interrupted Check fuse and cables replace if necessary ...

Page 241: ...place if necessary Crossbeams cannot be lifted or lowered Switch on the remote con trol is set to Auto Set the switch to Manual Power supply is interrupted Check fuse and cables replace if necessary Switch on the operating panel defective Replace Excess pressure valve defective Replace Flow rate regulator defective Replace Seals defective Replace Crossbeams lower inadvertently Control valves defec...

Page 242: ...he servo unit Insufficient supply pressure Check and adjust if necessary Check the suction filter replace the supply pump and the filter if necessary Drive shaft of hydraulic pumps or engines broken Replace pump or engine Irregular engine speed engine stop function does not work Fuel level too low Check the fuel level refill fuel if necessary Fuse engine speed con trol defective Replace fuse strip...

Page 243: ...lever into centre position and turn preselector controller to zero remove ignition key and battery main switch Protect lifted vehicle parts e g screed or hopper against lowering by means of mechanical safeguards Replace parts or have them replaced as stipulated f When connecting or disconnecting hydraulic hoses and when working on the hydrau lic system hot hydraulic fluid may spurt out at high pre...

Page 244: ...nd void and can cause severe to fatal injuries Only use original spare parts and approved accessories After maintenance and repair work ensure that any dis mantled protective and safety devices are all completely fitted again Comply with all further information in these instructions and in the safety manual DANGER ...

Page 245: ...of the screed material overflow When operating with larger working widths demixing and traction problems may occur Auger too low Not enough material that can be precompacted by the auger Irregularities resulting from this cannot be completely compensated by the screed wavy surface In addition increased auger segment wear occurs Loosen the 4 mounting screws 2 Set the ratchet direction lever 3 to th...

Page 246: ...additional auger segment 1 is fitted to the auger shaft Assembly Remove outermost screw connection 2 from the basic auger Remove plug 3 Fit the auger extension 1 to the corresponding side Fit screw connection 2 Fit plugs 3 to the auger extension The relevant material shaft must be fitted to each auger extension 1 6 2 3 4 5 ...

Page 247: ...d bracket on the basic unit and secure with the rod 5 and the corresponding splint pin For larger paving widths Remove original shaft 4 Fit extension shaft 6 Secure original shaft 4 to extension shaft 6 m Switch off engine and secure the device before carrying out any work on equipment ...

Page 248: ...Hopper with front flap Close hopper halves and remove cover 3 Dismantle retaining pin 4 using a suitable bolt extractor Bring the push roller crossbar into the front rear position A Shift the push roller crossbar at the towing eye 5 or use a suitable assembly lever in its guide left and right to push it into the corresponding position Put the retaining pin 4 correctly back into the intended positi...

Page 249: ...e and one for the left side A The automatic levelling system can be suspended in the opened vandalism protec tion facility in guide 1 Connect the coiled cable of the left and right hand automatic levelling system with the corresponding sockets 2 on the remote controls A Always seal unused sockets or plugs with the corresponding protective caps 2 1 ...

Page 250: ...ets 5 of the automatic levelling system Slope controller to left automatic level ling system socket 6 Slope controller to right automatic lev elling system socket 7 Connect the height controller 4 to the automatic levelling system on the cor responding side of the vehicle A If the connections are confused the automatic levelling system works in reverse m Route the supply lines so as to rule out an...

Page 251: ...ct the left or right sensor s con nection cable to the intended remote control bracket sockets A The connection cables are connected to the relevant sockets on the remote con trol bracket Adjust the deactivation point with the desired material height by regulating the potentiometer 4 A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving materi...

Page 252: ...E 10 12 10 ...

Page 253: ...s Ensure that maintenance and repair work is always only carried out by trained specialist staff All maintenance repair and cleaning work should only be carried out with the engine turned off Remove igni tion key and main switch Affix a sign Do not start to the vehicle Perform a visual inspection and check all functions every day Proceed with all maintenance tasks according to the maintenance sche...

Page 254: ...aces Surfaces including those behind covering parts together with combustion fuels from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the vehicle Only perform maintenance and repair work after the vehicle has cooled down Comply with all further information in these instructions and in the safety manual Danger due to electric...

Page 255: ...F 2 12 1 F 2 12 Maintenance overview 1 Maintenance overview 8 12 4 12 5 12 3 12 7 12 6 12 11 12 100 ...

Page 256: ...e necessary after operating hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F3 12 q q Auger F4 12 q q q Engine F5 12 q q q q q q Hydraulic system F6 12 q q q q q q q Drive units F7 12 q q q q q q q Electrical system F8 12 q q q q q q Checking shutdown F100 q q q Maintenance required q ...

Page 257: ...F 3 12 1 F 3 12 Maintenance conveyor 1 Maintenance conveyor ...

Page 258: ...e may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including tho...

Page 259: ...Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Conveyor chain Check tension q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Replace conveyor conveyor drive wear parts Maintenance q Maintenance during the running in period g ...

Page 260: ...nce When the conveyor chain is tensioned correctly there is a sag of approx 50mm between the upper edge of the chain and the crossmember A m The conveyor chains should not be too tight or too slack An excessively taut chain can cause the chain to be stopped or to break when material falls into the space between the chain and the sprocket An excessively slack chain may catch on protruding objects a...

Page 261: ...cross beam Dismantle the locking plates C of the adjusting screws Adjust the chain tension using the adjusting screw B Increase chain tension turn clockwise Reduce chain tension turn counterclockwise m Adjust the chain tension evenly at both adjusting screws Remount the locking plates C again properly B C C B ...

Page 262: ...s lengthened to such an extent that it can no longer be retightened m Chain links must not be removed to shorten the chain Incorrectly dividing the chains would lead to destruction of the drive wheels A Your Dynapac customer service will be happy to provide support during mainte nance repair and the replacement of wearing parts A ...

Page 263: ...f the system is no longer sealed or there are holes in the parts m The conveyor chain is not offered pro tection by worn cover m Check the following wear parts in the conveyor drive section and replace if necessary Conveyor chain reversing roller Conveyor drive chain sprocket A Your Dynapac customer service will be happy to provide support during mainte nance repair and the replacement of wearing ...

Page 264: ...F 3 12 8 ...

Page 265: ...F 4 12 1 F 4 12 Maintenance auger assembly 1 Maintenance auger assembly ...

Page 266: ...remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion gases from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the vehicle Only perform maintenance and repair w...

Page 267: ... Auger drive chains Adjust tension q Auger drive chains Replace chains and chain sprockets 2 q Auger box Check grease fill q Auger box Top up grease q Auger box Change grease 3 q Seals and sealing rings Check wear q Seals and sealing rings Replace seals 4 q Auger segments Check wear q Auger segments Replace auger segments Maintenance q Maintenance during the running in period g ...

Page 268: ...h augers to the right and left In this case movement clear ance C at the augers outer circumference should be 3 4 mm f Risk of injury due to sharp edged parts To re tension the chains Release the mounting screws A Set the chain tension correctly using the threaded pins B Retighten the bolts A C B A ...

Page 269: ...uger shaft or drive are worn The chains A have lengthened to such an extent that they can no longer be retightened m Chains and chain sprockets must al ways be replaced in sets A Your Dynapac customer service will be happy to provide support during mainte nance repair and the replacement of wearing parts A B B ...

Page 270: ...ntity and quality a film of grease ad heres to the full length of both chains B Top up with grease if necessary Reinstall cover A Change grease A The grease should be changed regularly when proceeding with wear related change of the chains and chain sprockets After dismantling the worn parts clean the auger box on the inside Once all parts have been mounted fill with new grease then fit cover A A ...

Page 271: ...After reaching operating temperature check the gearbox for leaks m In case of visible leaks e g between the flange surfaces A of the drive auger shaft B or at the side cover C re placement of the seals and sealing rings is necessary A C B ...

Page 272: ...duced and the blades B have to be replaced A Remove the bolts C washers D nuts E and auger blade B f Risk of injury due to sharp edged parts m Auger blades must be installed play free the contact surfaces must be dirt free Install the new auger blade B re place the bolts C washers D and nuts E if necessary A B C E D ...

Page 273: ...y 1 Maintenance engine assembly m As well as this maintenance manual always also pay close attention to the mainte nance manual provided by the engine manufacturer All maintenance work and serv ice intervals itemised here are binding in nature ...

Page 274: ...remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion gases from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the vehicle Only perform maintenance and repair w...

Page 275: ...ean the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel system Fuel filter drain the water separator q Engine fuel system Replace fuel pre filter q Engine fuel system Replace fuel filter q Engine fuel system Bleed fuel system Maintenance q Maintenance during...

Page 276: ...r filter Exchange air filter insert 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system Top up coolant q Engine cooling system Check coolant concentration q Engine cooling system Adjust coolant concentration q Engine cooling system Change coolant Maintenance q Maintenanceduringtherunn...

Page 277: ...10 50 100 250 500 annually 1000 annually 2000 every 2 years If necessary 6 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q q Engine drive belt Replace drive belt Maintenance q Maintenance during the running in period g ...

Page 278: ...t run dry and time consuming venting bleeding can therefore be avoided For filling with fuel Open lateral flap Remove cover A Fill in fuel through the filling port until the required fill lever is achieved Replace the cover A Clean the tank and system Unscrew the drain plugs B of the tank and drain about 1 l fuel into a col lection pan When returning the screw make sure to use a new seal A B ...

Page 279: ...heck the oil level when the finisher is in a horizontal position A The dipstick is located at the front end of the engine m Too much oil in engine damages gas kets too little oil results in overheating and engine destruction For filling in the oil Remove cover B Fill up oil to correct level Return cover B Use dipstick to check level again A B ...

Page 280: ...he correct mark on the dipstick A Changing the oil filter A The new filter is inserted during an oil change once the used oil has been drained out A The oil filter is located at the front end of the engine Loosen the filter D using a filter wrench or filter strap and unscrew Clean the contact surface Apply light coating of oil to the gasket on the new filter and fill filter with oil before install...

Page 281: ...in the collecting vessel at regular in tervals or in response to an error mes sage from the engine control unit Put a suitable drip pan underneath Disconnect the electrical connection cable connection Loosen drain plug C Drain off liquid until pure diesel fuel emerges Tighten the drain plug C again Restore the electrical connection ca ble connection A B A C D ...

Page 282: ...lectric fuel feed pump Do not attempt to start the ve hicle while the fuel system is being bled to ensure that no error message is generated Ignition ON A The electronic fuel feed pump switches on for 20 seconds to bleed the fuel system and build up the necessary fuel pressure A Wait until the electric fuel feed pump is switched off by the control unit Ignition OFF A Repeat at least twice until th...

Page 283: ... the filter selected A Filter maintenance becomes necessary if Maintenance interval or Engine electronics service indicator Open the air filter lid Pull out the filter cartridge D and the safety cartridge E A Clean the filter cartridge D and replace after one year at the latest Blow out with dry pressure air max 5 bar from inside out or tap it in case of emer gency only A Do not damage cartridge w...

Page 284: ...nti corrosion agent is available 25 C f When hot the system is under pressure When it is opened there is danger of scalding The fluid level must be up to the centre of the sight glass C A The filler neck is accessed via the serv ice flap A on top of the vehicle A If necessary fill in a sufficient amount of coolant through the open port B of the compensating tank C A B ...

Page 285: ... A on the radiator and let the coolant drain completely Reinstall the drain screw A and tight en properly Fill in coolant through the filling open ing B on the compensation tank until the coolant level rises to the centre of the sight glass C m The air is only able to escape completely from the cooling system once the engine has reached its operating temperature at least 90 C Check the fluid level...

Page 286: ...ssary remove leaves dust or sand from the radiator A Observe engine s operating instructions Check coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentration if necessary A Observe engine s operating instructions ...

Page 287: ...l transverse cracks in the belt are acceptable m In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces belt re placement is necessary A Observe engine s operating instructions Replace drive belt A Observe engine s operating instructions ...

Page 288: ...F 5 12 16 ...

Page 289: ...F 6 12 1 F 6 12 Maintenance hydraulic system 1 Maintenance hydraulic system ...

Page 290: ...Secure the vehicle to prevent it being switched on again Consult a doctor immediately if injured Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion gases from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the ...

Page 291: ...vel q Hydraulic oil tank Top up with oil q Hydraulic oil tank Change oil and clean q Hydraulic oil tank Change ventilation filter dipstick 2 q Hydraulic oil tank Check maintenance indicator q q Hydraulic oil tank Change and vent the suction re turn flow hydraulic filter 3 g g q q High pressure filter Replace filter element Maintenance q Maintenanceduringtherunning inperiod g ...

Page 292: ...up oil g q Pump distribution gear Change oil q Pump distribution gear Check bleeder q Pump distribution gear Clean bleeder 5 g q Hydraulic hoses Visual inspection g q Hydraulic system Leak test q Hydraulic system Retighten screw connections q q Hydraulic hoses Replace hoses 6 q q Auxiliary flow filter Replace filter element o Maintenance q Maintenance during the running in period g ...

Page 293: ... marking Screw in the dipstick B again m Use only the recommended hydraulic oils see section Recommended hy draulic oils A When filling for the first time all hydraulic cylinders should be extended retracted at least 2x for ventilation To change oil To drain the hydraulic oil unscrew the drain plug D at the bottom of the tank Collect the oil in a container using a funnel When returning the screw m...

Page 294: ... 12 6 m When changing the hydraulic oil also change the filter Ventilation filter A The ventilation filter is integrated in the dipstick The dipstick must be replaced according to the maintenance interval ...

Page 295: ... filter head and take out of the engine compartment together with the filter housing A To avoid impurities do not let the filter cartridge fall back into the housing again Remove the filter cartridge E Empty and clean the filter housing B clean the sealing faces in the filter head Replace the O ring F on the filter housing Insert new filter cartridge and fill filter housing with oil up to the top ...

Page 296: ...o collect the draining oil Remove the screw in neck with strain er element D Shake any remaining oil out of the housing E into a vessel for used oil then clean the filter housing with cleaning solvent Check that the O ring F at the screw in neck is in perfect condition replace if necessary Push the screw in neck with strainer element D carefully into the hous ing E and screw in as far as it will g...

Page 297: ... glass A Screw in the filler screw B again m Make sure to clean the screw and the vi cinity of the drain bore Oil change Place the end of the oil drain port hose C in the collection container Remove the screw cap with a wrench and allow the oil to drain completely Replace the screw cap and tighten properly Fill in the oil of specified quality through the filling port on the gearbox B until the oil...

Page 298: ...F 6 12 10 Bleeder The functioning of the bleeder A must be ensured If soiling has occurred the bleeder should be cleaned A ...

Page 299: ...ring pinched or buckled points leaks damage or deformation to the hose fittings affecting the sealing function replace ments are not necessary for minor damage to the surface hose coming away from the fitting corrosion of the fitting with a detrimental effect on function and strength failure to comply with the installation requirements period of use has exceeded 6 years Here it is the date of manu...

Page 300: ...tening of the hoses prevents them from chafing on components or on each other components with sharp edges must be covered when installing hydraulic hoses bending radii are not smaller than the permitted values When hydraulic hoses are connected to moving parts the length of the hose must be dimensioned to ensure that the bending radii are not smaller than the permitted smallest values right across...

Page 301: ...noth er and always ensure that they are at the correct pressure In individual cases the period of use can be stipulated according to experience and may differ from the following general indications When producing the hose pipe the hose purchased by the meter should not be more than four years old The period of use of a hose pipe should not exceed six years including any possi ble storage period Th...

Page 302: ...n the filter then close the non return valve again Replace filter element B and sealing ring C Turn filter element clockwise with the help of carrier straps and at the same time raise it slightly Wait for a moment until the oil has escaped downwards then remove the filter element Check inlet and outlet in filter housing D As required top up hydraulic oil level in filter housing then screw down the...

Page 303: ...F 7 12 1 F 7 12 Maintenance drive unit 1 Maintenance drive unit ...

Page 304: ...e may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including tho...

Page 305: ... 500 1000 annually 2000 every 2 years If necessary 1 q Chain tension Check q Chain tension Adjust q Chains Relieve 2 q Bottom plates Check wear q Bottom plates Replace 3 q Rollers Check for leaks q Rollers Check wear q Rollers Replace Maintenance q Maintenanceduringtherunning inperiod g ...

Page 306: ...10 50 100 250 500 1000 annually 2000 every 2 years If necessary 4 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality Maintenance q Maintenance during the running in period g ...

Page 307: ...lves significant safety measures and should only be carried out by a specialist workshop A Your Dynapac customer service will be happy to provide support during maintenance repair and the replacement of wearing parts Danger from pretensioned springs Incorrectly performed maintenance and repair work can cause severe to fatal injuries Always observe the maintenance instructions Do not perform any un...

Page 308: ...y increasing wear levels m If the chains are tensioned too tightly this increases wear on the idler wheel and drive unit mounting and also increases wear on track bolts and bushes Checking adjusting chain tension grease tensioners The chain tension is adjusted with grease tensioners The filling connections A are located behind the lateral flaps on the left and right x A 2 0 m m B ...

Page 309: ... nipple tool box onto the grease gun Refill the chain tensioner with grease at the filler connection A then re move the grease gun Check the chain tension once again as described above A If the tension is too high see section Relieving the chain A Repeat this procedure on both drive units Relieving the chain f The grease in the tensioning element is under pressure Carefully and slowly un screw the...

Page 310: ...e the bottom plate with the front edge A over the chain links bolt eye B Lubricate the threads and the contact surfaces beneath the bolt heads with a thin film of oil or grease Insert the bolts C into the holes and screw them into the nuts D a few turns Tighten the bolts without applying sig nificant torque Tighten the bolts to the required torque 98 5 Nm m Check that each bolt has attained the fu...

Page 311: ...erve the safety measures when rais ing and securing loads Remove the defective roller Install the new roller using new as sembly parts Tighten the bolts without applying sig nificant torque Tighten the bolts diagonally to the re quired torque Tighten to the following torques Rollers A 83 Nm m Check that each bolt has attained the full tightening torque Lower the track chassis and tension the cater...

Page 312: ...r bore at A until the oil level has reached the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at oper ating temperature m Ensure that no dirt or foreign bodies are able to enter the gear Turn the conveyor chain sprocket so that the drain plug B is located at the bottom Unscrew and remove the drain plug B and filler screw A and drain off ...

Page 313: ...F 8 12 1 F 8 12 Maintenance electrical system 1 Maintenance electrical system ...

Page 314: ...o not remove any protective safeguards Never spray water on electric or electronic components Maintenance work to the electric system should only be carried out by trained specialist staff When equipped with electric screed heater check the insulation monitoring every day according to the instructions Comply with all further information in these instructions and in the safety manual Danger from ba...

Page 315: ...or Insulation monitoring check elec tric system is functioning o q Alternator Visual check for pollution or damage Check the cooling air openings for pollution or clogging clean if necessary o q Check the drive belts for damage and replace them as required o g q Drive belts check tension adjust if necessary o q Replace drive belts o 3 q Electrical fuses Maintenance q Maintenanceduringtherunning in...

Page 316: ... batteries without plugs A If the starting capacity is insufficient check and possible recharge the batteries A Regularly check the charge of the battery and recharge if necessary m A maintenance free battery must be recharged slowly with a special battery charger Do not use conventional chargers as these can damage the battery Heed the corre sponding operating instructions m The battery terminal ...

Page 317: ...nd after recharging a battery always check the electrolyte level in every cell if this needs to be topped up only use distilled water m When recharging batteries every cell must be opened i e plugs and or covers must be removed m Only use commercially available automatic battery chargers according to the manu facturer s instructions A Preferably use the slow recharging procedure and adjust the cha...

Page 318: ...heating system with button 1 Press test button 2 The indicator lamp integrated into the test button signals insulation fault Press reset button 3 for at least 3 sec to delete the simulated fault The indicator lamp goes out f If the insulation fault indicator lamp already indicates a fault before pressing the test button or if no fault is indicated during the simulation indicator lamp OFF at first ...

Page 319: ... the safety precautions and safety regulations when operating the electric screed heating system leads to a risk of electric shock Danger to life All maintenance and repair work on the screed s electrical system may be car ried out by a specialist electrician only ...

Page 320: ...ng the alternator m The alternator must be regularly checked for excessive dirt and must be cleaned if necessary The air intake 1 must be kept free of dirt m Cleaning with a high pressure cleaner is not permissible 1 ...

Page 321: ...on measuring instru ments are available Mechanical tension measuring instrument A Article number 4753200045 Electronic tension measuring instrument B Article number 4812034810 A Comply with instructions for checking tension in the manual of the tension measuring instrument Check the belt in the area of the cutout 1 on the belt guard New belt Used belt min max min max 679 N 728 N 582 N 631 N 171 Hz...

Page 322: ...n is adjusted on the belt Properly tighten the lock nuts of the clamping lock A Replacing belt Remove the belt guard B Reduce the belt tension on the clamp ing lock A so that the belt can be re moved from the pulleys Mount the new belt and adjust tension correctly Install the belt guard B A Always replace the belts in sets A B ...

Page 323: ...F 8 12 11 2 Electrical fuses 2 1 Main fuses 1 Main fuses A F A 1 1 Main fuse 50 1 2 Main fuse 30 1 4 Preheating ignition system 100 A ...

Page 324: ...etrical hopper 7 5 F6 Raise lower screed 7 5 F7 Travel drive steering engine speed horn 7 5 F8 Spare 10 F9 Engine control unit A2 7 5 F10 Auger 7 5 F11 Display GPS module emergency stop 10 F12 Conveyor limit switch 7 5 F13 Control unit A1 5 F14 Levelling 7 5 F15 Screed 10 F16 24V socket 15 F17 GPS module D 10 F18 Screed heater 10 F19 Warning lights 10 F20 Control unit A1 30 F21 Horn 10 B ...

Page 325: ...2 30 F24 GPS module 2 F25 Diesel pump 10 F26 Ignition 7 5 F27 Control unit A1 10 F28 Rear working light auger lighting operating panel lighting 15 F29 Front working lights 10 F30 Diagnosis for engine control unit A2 2 F31 Diagnosis for control unit A1 2 ...

Page 326: ...art stop C K3 Screed heater C K4 Control unit A1 C K5 Levelling C K6 Engine start stop C K7 Horn C K30 Preheating ignition system C K31 Diesel pump C K13 Conveyor C K14 Left auger C K15 Right auger C K30 Pre heating D K31 Fuel pump D K32 Neutral shifting D C D ...

Page 327: ...alities of well known brands m Use only clean containers inside and outside for pouring oil or fuel in A Note capacities see section Capacities m Incorrect oil or lubricant levels promote rapid wear and cause the paver finisher to fail m Never mix synthetic oils with mineral oils m Please heed the equipment related fuel specification requirements ...

Page 328: ...F 11 12 2 7 1 5 6 6 4 2 8 3 ...

Page 329: ...ne cooling system Cooling liquid 14 0 litres 3 Fuel tank Diesel fuel 50 0 litres 4 Hydraulic oil reservoir Hydraulic oil 70 0 litres 5 Pump distribution gear Gearbox oil 1 7 litres 6 Planetary gear drive unit Gearbox oil approx 1 6 litres 0 8 l per side 7 Auger box Liquid grease 3 0 kg 8 Separator fluid tank Separator emulsion 14 0 litres Batteries Distilled water ...

Page 330: ... at http www deutz com 2 3 Drive engine TIER IV o fuel specification m Low sulphur diesel fuel is prescribed for correct operation of the exhaust gas treat ment system The maximum sulphur level must not exceed 15 ppm If low sulphur diesel fuel is not used the prescribed exhaust values cannot be met and damage will be caused to the engine and to the exhaust gas treatment system Permissible diesel f...

Page 331: ...y gear A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Engine oil 200 Dynapac AGIP Chevron Petronas Finke Coolant 200 Antifreeze Special Extended Life Coolant Antifreeze G12 Aviaticon Finkofreeze P12 Dynapac AGIP Chevron Caltex Fuchs Mobil Shell Finke Hydraulic 100 Rando HDZ 46 Rando HDZ 46 Tellus Oil S2 V46 Tellus S2 VX46 Aviaticon HV 46 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gea...

Page 332: ...lt Guard 20L 4812215842 Belt Guard 208L 4812215846 Belt Guard 1000L 4812216094 Caution Possible subsequent damage from not approved separator emulsion Considerable damage can be caused to the vehicle by using separator emulsions and other cleaning agents not approved by the factory without prior consultation The use of separator emulsions and cleaning agents that are not approved makes the vehicle...

Page 333: ... When changing from mineral oil pressure fluids to biodegradable pressure fluids please contact our factory advisory service Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 Shell Naturelle HF E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 Finke Aviaticon HY HE 46 ...

Page 334: ...F 11 12 8 ...

Page 335: ...F 100 1 F 100 Checking shutdown 1 Tests checks cleaning shutdown and disposal ...

Page 336: ... 500 1000 annually 2000 every 2 years If necessary 1 q General visual inspection 2 regularly Check that the bolts and nuts fit firmly 3 q q Inspection by an expert 4 q Cleaning q Cleaning sensors 5 q Preserving the paver finisher Maintenance q Maintenance during the running in period g ...

Page 337: ... they fit firmly retighten them if necessary A The spare parts catalogue states the special torques at the corresponding parts A For the necessary standard torques please refer to the section Bolts torques Caution Possible damage to or destruction of parts Self locking nuts must always be replaced after removal Special torques not mentioned in this manual are stated at the corresponding place in t...

Page 338: ...screed and optional gas or electric system must be checked by a trained specialist when required according to the operating conditions and the nature of application however at least once a year check that they are all in good operational condition ...

Page 339: ...l lube points acc to specification Clean the vehicle with water after laying mineral aggregates lean mixed concrete etc m Do not spray bearing points electrical or electronic components with water Remove residual paving material m After cleaning work with the high pres sure cleaner grease all lube points acc to specification f Danger of slipping Ensure that all steps and ladders are free of grease...

Page 340: ...eying parts Only wear close fitting clothing Comply with the warning and information signs on the vehicle Stop the engine and remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion gases from the engine or screed heater can be very hot...

Page 341: ...F 100 7 5 3 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions m Daily cleaning with a dry lint free cloth ...

Page 342: ...oved batteries every 2 months Protect all bare metal components e g piston rods on hydraulic cylinders with a suitable corrosion inhibitor If it is not possible to park the vehicle is an enclosed building or under cover it must be covered with a suitable size of tarpaulin In all cases seal all air intake and ex haust apertures with plastic film and adhesive tape 6 2 Shutdowns lasting from 6 months...

Page 343: ... impaired Corresponding preventive treatment must be applied to the machine This should be repeated at appropriate intervals when necessary All possible harmful influences must be taken into consideration This includes high salt content in the air near the coast together with the use of de icing agents on the roads or strong UV radiation The vehicle should be treated with corrosion and surface pro...

Page 344: ...nd spare parts and after the vehicle has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oily or greasy parts hydraulic hoses lube pipes etc must be treated separately A Electric devices accessories and packaging should be recycled in an environment friendly manner A Always dispose of drain...

Page 345: ... 1 6 4 1 6 7 7 1 9 M6 8 2 1 12 3 14 3 7 8 1 9 11 2 7 13 3 3 M8 20 5 28 7 1 34 8 19 4 7 26 6 6 31 7 9 M10 41 10 57 14 70 17 37 9 52 13 62 16 M12 73 18 97 24 120 30 63 16 89 22 107 27 M14 115 29 154 39 195 45 100 25 141 35 169 42 M16 185 46 243 61 315 75 156 39 219 55 263 66 M18 238 60 335 84 402 100 215 54 302 76 363 91 M20 335 84 474 119 600 150 304 76 427 107 513 128 M22 462 116 650 162 759 190 4...

Page 346: ... 5 M8x1 21 7 5 4 30 6 7 6 36 7 9 2 19 5 4 9 27 4 6 8 32 8 8 2 M10x1 25 42 1 10 5 59 2 15 71 17 8 37 7 9 4 53 13 63 6 15 9 M12x1 25 75 7 18 9 106 2 26 127 31 9 67 2 16 8 94 5 24 113 28 3 M14x1 5 119 29 7 167 42 200 50 1 106 26 149 37 178 44 6 M16x1 5 183 45 6 257 64 308 77 162 40 227 57 273 68 2 M18x1 5 267 66 8 376 94 451 112 7 236 59 331 83 398 99 4 M20x1 5 373 93 2 524 131 629 157 3 328 82 461 1...

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Page 348: ...www dynapac com ...

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