Dynapac F1800W Operation & Maintenance Manual Download Page 1

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OPERATION & MAINTENANCE

Paver Finisher
F1800W
Type 912

03-1019

4812076574

Summary of Contents for F1800W

Page 1: ...OPERATION MAINTENANCE Paver Finisher F1800W Type 912 03 1019 4812076574 ...

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

Page 3: ...e incorrect 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 7 4 Safety devices 8 5 Technical data standard configuration 10 5 1 Dimensions all dimensions in mm 10 5 2 Allowed angle of rise and slope 11 5 3 Permissible approach angle 11 5 4 Turning circle 11 5 5 Weights all weigh...

Page 4: ...Vibrations acting on hands and arms 33 7 5 Electromagnetic compatibility EMC 33 C12 18 Transportation 1 1 Safety regulations for transportation 1 2 Directing of the vehicle 2 3 Transportation on low bed trailers 3 3 1 Preparations 3 4 Securing the load 5 4 1 Prepare the low bed trailer 5 4 2 Driving onto the low bed trailer 6 4 3 Lashing equipment 7 4 4 Loading 8 4 5 Preparing the vehicle 9 5 Secu...

Page 5: ...iled display Error Messages With Travel Drive Stop 13 Detailed display Vehicle Warning Messages 14 Detailed display Engine Error Messages 15 Info menu 16 Display of the following information 16 Display set up menu 17 3 Terminal error messages 18 Status warning and error messages symbols 18 3 1 Drive engine error codes 23 4 Menu structure of the setting and display menus 27 D30 18 Operation 1 1 Ope...

Page 6: ... 30 Push roller crossbar adjustable 31 Push roller damping hydraulic o 32 Fire extinguisher o 33 First aid kit o 33 Rotary beacon o 34 Illuminated balloon o 35 Installation and operation 36 Maintenance 37 Replacing the lamp 37 D42 18 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 machine o...

Page 7: ...reed 31 E10 18 Set up and modification 1 1 Special notes on safety 1 2 Distribution auger 3 2 1 Height adjustment 3 2 2 Auger width extension and material shaft with protective cover optional equipment 5 Push roller crossbar adjustable 6 Hopper scraper 7 2 3 Crossbeam guide 8 3 Screed 9 4 Electrical connections 9 5 Limit switch 11 5 1 Auger limit switches left and right mount PLC version 11 5 2 Au...

Page 8: ...11 Engine cooling system 5 12 Engine drive belt 6 14 F60 18 Maintenance hydraulic system 1 1 Maintenance hydraulic system 1 1 1 Maintenance intervals 4 1 2 Points of maintenance 6 Hydraulic oil tank 1 6 Suction return flow hydraulic filter 2 8 Ventilation filter 8 High pressure filter 3 9 High pressure filter 4 10 Pump distribution gear 5 11 Bleeder 12 Hydraulic hoses 6 13 Marking hydraulic hoses ...

Page 9: ...ystem 1 3 Bearing points 2 7 F100 Tests stopping 1 1 Tests checks cleaning stopping 1 1 1 Maintenance intervals 2 2 General visual inspection 3 3 Check that the bolts and nuts fit firmly 3 4 Inspection by an expert 4 5 Cleaning 5 5 1 Cleaning the hopper 6 5 2 Cleaning the conveyor and auger 6 5 3 Cleaning optical or acoustic sensors 7 6 Preserving the paver finisher 8 6 1 Shutdowns for up to 6 mon...

Page 10: ...s 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 distribution gear 5 2 8 Pump distribution gear as of s n 3309 3510 ff 5 2 9 Drive unit planetary gear 6 2 10 Auger box 6 2 11 Grease 6 2 12 Hydraulic oil 7 ...

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: ...ication The Dynapac paver finisher F1800W is a wheeled paver finisher which is used for paving bituminous mixed material roll down or lean mixed concrete track laying bal last and unbound mineral aggregates for foundations for paving ...

Page 26: ...paving thickness 6 t Traction roller 7 t Crossbeam pull bar 8 t Paving thickness indicator 9 t Crossbeam 10 t Travel drive 11 t Auger 12 t Screed 13 t Operator s platform 14 t Operating panel can be moved to either side 15 t Tandem front axle 16 o Protective roof 17 o Working lights 18 o Hydraulic front hopper t Standard equipment o Optional equipment 12 1 2 7 6 9 10 14 13 16 4 11 17 3 15 18 8 5 ...

Page 27: ...ed to all work conditions The operation of the paver finisher is considerably facilitated by the automatic mate rial handling system the independent travel drives and the clearly structured operat ing components and controls The following extra equipment option is available o Automatic levelling slope control system o Hopper with hydraulic front hopper o Protective roof control platform o Emulsion...

Page 28: ...c hoses These oil engines drive the drive wheels via planetary gears The multi stage planetary gear covers the various driving ranges and the braking function Steering system operator s platform The fully hydraulic steering system ensures easy manoeuvrability The small turning radius permits quick and easy manoeuvring The seat consoles left right can be moved beyond the outer edge of the vehicle p...

Page 29: ...ransfer amount is reg ulated fully automatically The drive is reversible Augers The augers are driven and actuated independently from the conveyors The left hand and the right hand half of the auger can be controlled separately The drive system is fully hydraulic The conveying direction can be changed towards the centre or towards the outside This ensures that there is always a sufficient supply o...

Page 30: ...de control system Crossbeams screed lifting device The screed lifting device is used to lift the screed for the paving conditions and during transportation This takes place by hydraulic means by actuating a hydraulic cylinder The crossbeams have a multi stage rapid adjustment for the positioning angle Automatic paving stop The automatic paving stop prevents the formation of any screed marks caused...

Page 31: ...le operator and the screed personnel are allowed on the vehicle or in the danger zone The vehicle operator and screed personnel 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 further...

Page 32: ...B 8 4 Safety devices 10 7 2 11 2 1 9 12 3 10 8 4 5 6 7 ...

Page 33: ...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 Crossbeam lock mechanical 3 Main switch 4 Emergency stop button 5 Horn 6 Ignition key 7 Lights 8 Protective roof latch o 9 Fire extinguisher o 10 Screed warning light o 11 Covers lateral flaps coverings 12 Rotary...

Page 34: ...l data standard configuration 5 1 Dimensions all dimensions in mm A For screed technical data refer to the screed operating instructions R65 5350 5020 1620 2590 2915 3600 3150 3040 1800 1450 260 420 1910 1600 310 310 ...

Page 35: ...on gradient slope lateral inclina tion which is above the specified limit value please consult the customer service de partment for your vehicle 5 3 Permissible approach angle 5 4 Turning circle Internal turning cycle 2 51 m External turning cycle 4 31 m max 15 max 15 max 15 max 15 max 15 max 13 ...

Page 36: ...e screed attachments see the operating instruc tions for the screed Paver finisher without screed approx 8 7 Paver finisher with screed V3500 approx 10 3 With extension parts for max working width additionally max approx 0 52 With filled hopper additionally max approx 10 5 ...

Page 37: ... cut off shoe fully variable hydr adjustment up to Maximum paving widths with extension parts V3500TV 1 75 0 7 3 50 4 1 m Transport speed 0 15 km h Transport speed reversing 0 4 8 km h Operating speed 0 25 m min Paving height 120 200 mm Max grain size 30 mm Theoretical paving performance 350 t h ...

Page 38: ...e Deutz TD 2 9 L4 Version 4 cylinder diesel engine Performance 54 KW 73 PS at 2200 rpm Fuel consumption full load Fuel consumption 2 3 load 14 l h 9 3 l h Fuel tank capacity See chapter F Make type Deutz TD 2 9 L4 Version 4 cylinder diesel engine Performance 54 KW 73 PS at 2200 rpm Fuel consumption full load Fuel consumption 2 3 load 15 3 l h 10 2 l h Fuel tank capacity See chapter F Make type Deu...

Page 39: ...eight centre 520 mm Minimum inlet height outside 605 mm Hopper width outside open 3400 mm Type Dual conveyor belt Width 2 x 350mm Conveyors Left and right auger separately controllable Drive Hydrostatic 0 1 Conveying volume controller Fully automatic via configurable switching points Auger diameter 320 mm Drive Hydrostatic external drive fully variable regardless of conveyor Auger halves can be sw...

Page 40: ...sible temperature ranges Special functions At standstill Screed stop Levelling system Mechanical grade control Optional systems with and without slope control On board voltage 24 V Batteries 2 x 12 V 74Ah Alternator o 12 5 kVA 400V Operation 5 C 45 C Storage 5 C 45 C ...

Page 41: ...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 42: ...B 18 22 21 22 21 22 21 8 52 4 5 72 6 50 2 1 28 29 30 3 33 32 31 3 20 60 12 25 10 26 9 23 6 11 27 24 34 34 ...

Page 43: ...B 19 71 70 40 41 42 xxxxxxxxxxxxxxxxx 51 53 73 ...

Page 44: ...ngine and re move the ignition key before perform ing any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause se vere to fatal injuries Switch the engine off and remove the ignition key 3 Warning Danger of crushing Crushing points can cause severe to fatal injuries Maintain a safe distance from the danger area 4 Warning Hot surface Risk of b...

Page 45: ...arning 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 10 Warning Danger of being pulled in by the belt drive Being pulled in by the belt drive can cause severe injuries to the hands and arms Keep your hands a safe distance away from the danger area 11 Warning danger from improper transpor...

Page 46: ...B 22 No Pictogram Meaning 12 Maintenance for the starter batteries Maintenance work has to be carried out to the starter batteries Comply with the maintenance instructions ...

Page 47: ...s only permitted at these lifting points 22 Lashing point Lashing the machine is only permitted at these points 23 Main battery switch Position of the main battery switch 24 Diesel fuel Position of the filling point 24 Diesel fuel sulphur level 15 ppm Position of the filling point specification 25 Fuel drainage point Position of the drainage point ...

Page 48: ... Position of the drainage point 28 Engine coolant Position of the filling and control point 29 Hydraulic oil Position of the filling point 30 Hydraulic oil level Position of the control point 31 Hydraulic oil drainage point Position of the drainage point 32 Gearbox oil Position of the filling and control point ...

Page 49: ...B 25 6 3 CE marking No Pictogram Meaning 33 Gear oil drainage point Position of the drainage point 34 Tyre air pressure Tyre pressure to be adjusted No Pictogram Meaning 40 CE sound output level ...

Page 50: ...4 Instructive symbols prohibitive symbols warning symbols No Pictogram Meaning 50 Wear ear protectors 51 Do not spray the area or component with water 52 Warning on dangers posed by batteries 53 First aid kit ...

Page 51: ...ammation Avoid contact with the human body also avoid inhaling the vapours and seek medical advice if feeling unwell N Environmentally hazardous sub stance May cause immediate or delayed danger to the eco system when released into the environment Do not release into the sewage system ground or environment depending on hazard potential Comply with special disposal regulations Diesel fuel complies w...

Page 52: ...tation 71 Attention Danger of high voltage in vehicle electrical system Disconnect batteries and electronics dur ing welding work or when charging the batteries or use a service watchdog D978000024 in accordance with the cor responding instruction manual 72 Attention Only use approved radiator anti freeze Never mix different grades of radiator anti freeze Always observe the operating instructions ...

Page 53: ... Designation 1 Paver finisher type 2 Year of construction 3 Operating weight incl all extension parts in kg 4 Maximum permitted total weight in kg 5 Max permissible load on the front axle in kg 6 Max permissible load on the rear axle in kg 7 Maximum permissible axle load of the trailer axle in kg o 8 Rated performance in kW 9 Product identification number PIN 1 3 5 7 9 2 8 4 6 ...

Page 54: ...B 30 6 8 Explanation of 17 digit PIN serial number A Manufacturer B Family Model C Code letter F Serial number 10002014JHG002076 A B C F ...

Page 55: ...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 56: ...f the paver finisher was measured under free field condi tions according to EN 500 6 2006 and ISO 4872 Sound pressure level at the operator s position at the height of the head LAF 87 0 dB A Sound capacity level LWA 104 0 dB A 7 2 Operating conditions during measurement The diesel engine was running at maximum speed The screed was lowered into working position The tamper and the vibrator were runn...

Page 57: ...nts 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 4...

Page 58: ...B 34 ...

Page 59: ...many 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 C...

Page 60: ...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 61: ... be taken into consideration when selecting the attachment and loading equipment 3 1 Preparations Prepare the paver finisher for transportation see chapter D Remove all overlaying or loose parts from finisher and screed see also operating instructions for the screed Store these parts in a safe place m Move the auger to the uppermost position to avoid collisions f When screed is operated with the o...

Page 62: ... the hopper lids Engage both 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 63: ...able for securing loads positive fit force connection diagonal lashing etc in accordance with the specific transport vehicle m The low loader must have the necessary number of lashing points with a lashing strength of LC 4 000 daN m The total height and total width must not exceed the maximum permissible dimensions m The ends of lashing chains and straps must be secured to prevent them working loo...

Page 64: ...C 12 18 6 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 65: ...ermitted lashing force and load 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 chain permissible lashing force LC 4 000 daN Lashing straps permissible lashing force LC 4 ...

Page 66: ...rther to the back of the vehicle Always heed the details regarding load distribution stipulated for the vehicle together with the centre of gravity of the paver finisher If the paver finisher has to be placed in the front section of the low bed trailer for load distribution reasons or on account of the length of the paver finisher ensure that it stands freely ...

Page 67: ...mats under the screed across the whole width of the vehicle 2 and lower the screed Switch off the paver finisher Attach and secure the protective hood 3 to the operating panel Lower the roof and set the retainers 4 properly on both sides see section entitled Protective roof Fold up the walkway plates of the screed and fasten on both sides using lashing straps 5 and the existing retaining pins 6 1 ...

Page 68: ...on the paver finisher and on the low load trailer Fasten the lashing chains as shown m Shackles have to be used To ensure that lashing chains can be fitted securely on the left and on the right a shackle has to be fitted at each of the lashing points 1 provid ed on the paver finisher for the lashing equipment m The lashing angles should be ß between 6 55 and a between 20 65 1 ...

Page 69: ... Fasten lashing chains m Diagonal lashing secures the paver finisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown A Permissible angles see Securing at the front ...

Page 70: ...ntitled Protective roof Start engine 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 71: ...ion Possible collision of parts The following adjustments must be made before lowering the roof Both seat consoles pushed in Backrests and armrests of driver s seats tilted forwards Operating panel in lowest position and locked with the vandalism protection facility Front window closed Engine hood closed NOTE ...

Page 72: ...l the roof has reached the upper or lower limit position Bolt 3 must be inserted in the corresponding hole on both sides of the roof Position 3a Roof raised Position 3b Roof lowered A The bolt must be inserted with the alignment as shown and then swivelled against the roof beam Possibly adjust the position of the roof with the hand pump to insert the bolt Position 3c Roof raised Position 3d Roof l...

Page 73: ...e adjustment lever 4 to the Raise or Lower position Operate the pump lever 1 until the roof has reached the upper or lower limit position Bolt 3 must be inserted in the corresponding hole on both sides of the roof Position 3a Roof raised Position 3b Roof lowered Secure bolt with split pin 3c 1 2 3b 3c 3 4 3a ...

Page 74: ... 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 valves on the bottles and remove the gas bottles from the holder Transport the gas bottle on a second vehicle a...

Page 75: ...e the hopper lids Engage both 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 76: ... Set the fast slow switch to Hare if necessary Turn the preselector to zero 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 preselector to zero ...

Page 77: ...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 78: ... mounted is located in the area of the front edge 3 of the rear wheel Secure vehicle wherever it is parked up Engage the transport safeguards Remove 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 Lower the protective roof 1 2 3 ...

Page 79: ...gear to the four attachment points 1 2 m The max permissible attachment point load at the attachment points is 73 0 kN m The permissible load applies in the vertical direction m Make sure that the paver finisher remains in a horizontal position during transportation ...

Page 80: ...tion sys tem brakes is built up with the hand pump Release lock nut 2 screw threaded dowel 3 into pump as far as possible and secure with lock nut A Insert the pump lever of the roof pump in the opening 4 A From serial number 2281 et seq Push knob 3a into the valve body While pumping next step check that the knob remains in the pressed position Actuate lever 5 of hand pump until sufficient pressur...

Page 81: ...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 82: ... 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 83: ...hem from tilling over and rolling or sliding away f Roller type jacks must not be moved when under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequately dimensioned and be able to take the corresponding weight f There must not be anyone on the vehicle while it is being lifted f All raising and lowering work must be carried out uniformly with all h...

Page 84: ...C 12 18 26 ...

Page 85: ...fe 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 choose...

Page 86: ...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 87: ...ions that can pose a hazard when the diesel engine starts up turning to the side conveying function of auger and conveyor prevent the engine from starting start inhibit when switched on or when set to MANUAL or AUTO These functions must be Straight ahead travel or OFF ...

Page 88: ...D 12 18 4 13 14 17 16 18 15 10 12 11 ...

Page 89: ...st be pulled out again 11 Engine speed adjuster Continuously variable engine speed setting 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 12 Starter drive engine OFF For starting and shutting off the drive engine On ac...

Page 90: ...D 12 18 6 13 14 17 16 18 15 10 12 11 ...

Page 91: ...r on 2 position Screed motion tamper vibration on travel drive on increase speed until the stop is reached 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 travel drive preselector is set to zero A If the engine is started with the drive lever swivelled the travel dri...

Page 92: ...D 12 18 8 13 14 17 16 18 15 10 12 11 ...

Page 93: ... matches the speed in m min during paving m The vehicle must not travel at max transport speed when the hopper is full 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 17 Steering potentiometer The steering wheel movement is transferred electrohydraulically A For precise adj...

Page 94: ...D 12 18 10 21 20 ...

Page 95: ...left hopper lid Lower switch position Open left hopper lid f On actuation heed danger zones of moving parts of the vehicle 21 Open close right hopper Pushbutton 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 ...

Page 96: ...D 12 18 12 23 22 ...

Page 97: ...f screed Right switch position Retract left half of screed f On actuation heed danger zones of moving parts of the vehicle 23 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 98: ...D 12 18 14 25 24 ...

Page 99: ...inder Lower switch position Extend left levelling cylinder f On actuation heed danger zones of moving parts of the vehicle 25 Retract extend right levelling cylinder Pushbutton function Upper switch position Retract right levelling cylinder Lower switch position Extend right levelling cylinder f On actuation heed danger zones of moving parts of the vehicle ...

Page 100: ...D 12 18 16 26 27 ...

Page 101: ...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 Switch position c...

Page 102: ...D 12 18 18 28 29 ...

Page 103: ...den A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 29 Reverse right auger Conveying direction inwards Pushbutton function manually trigger the conveying function conveying direction inwards A For manual triggering the auger function must be switched to AUTO or MANUAL A When triggered the automatic or manual function is overri...

Page 104: ...D 12 18 20 30 31 ...

Page 105: ...very rate without material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 31 Right conveyor Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The conveying func tion of the right conveyor is switched on when the drive lever is swivelled out and is continu ously controlled via the material limit switches Switch position central...

Page 106: ...D 12 18 22 32 33 ...

Page 107: ...den A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 33 Reversing switch Right conveyor Pushbutton function 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 For manual triggering the conveyor function must be switched ...

Page 108: ...D 12 18 24 34 35 ...

Page 109: ...led 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 transport safeguard is inserted f On actuation heed danger zones of moving parts of the vehicle 35 Screed relieving Detent switch function Upper switch position ...

Page 110: ...D 12 18 26 36 37 ...

Page 111: ...switch position AUTO can also be put into operation with the control lever not swivelled by means of the Set up mode button 37 Tamper Operating mode AUTO OFF Detent switch function Upper switch position Operating mode AUTO The screed tamper is switched on when the drive le ver is swivelled out Lower switch position Operating mode OFF The screed tamper is switched off A The function in switch posit...

Page 112: ...D 12 18 28 38 ...

Page 113: ...lically extend the push roller crossbar Switch position central OFF Lower switch position Retracting active by counterpressure A If the push roller crossbar has been pressed into the home position by the counterpressure of the truck tyres it has to be extended again f On actuation heed danger zones of moving parts of the vehicle ...

Page 114: ...D 12 18 30 39 40 41 42 ...

Page 115: ... working lights ON Lower switch position Front working lights OFF f Avoid dazzling other road users 41 Rear working lights ON OFF o Detent switch function Upper switch position Rear working lights ON Lower switch position Rear working lights OFF f Avoid dazzling other road users 42 Rotary beacon ON OFF o Detent switch function Upper switch position Rotary beacon ON Lower switch position Rotary bea...

Page 116: ...D 12 18 32 44 43 ...

Page 117: ...Pushbutton function Lower switch position Not used 44 Raising lowering auger o Pushbutton function For hydraulic adjustment of the auger height Upper switch position Raise auger Lower switch position Lower auger On actuation heed danger zones of moving parts of the vehicle A The height can be read on the scales to the left and the right of the auger crossbeam support Rule of thumb Paving thickness...

Page 118: ...D 12 18 34 45 46 47 ...

Page 119: ...ing process is continued on swivelling the drive lever out A On restarting the function is set to ON A Heed corresponding screen display 46 Set up mode Pushbutton function When the vehicle is stationary this function enables all operating functions which are only activated when the drive lever is swivelled out vehicle driving to be started up A The main function switch must be set to the OFF posit...

Page 120: ...D 12 18 36 47 ...

Page 121: ...unction for the paving process The conveying functions set to automatic conveyor and auger are switched on A Once the set 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 A Heed corresponding screen display ...

Page 122: ...ft right the function switches only control the corresponding function on the particular side of the machine m Important Do not disconnect remote controls with emergency stop button during op eration This causes the paver finisher to be shut down 90 91 92 94 93 95 96 96 ...

Page 123: ...nd to indicate when the ve hicle starts to move A The horn can also be used to communicate acoustical ly with the truck driver for material loading 92 Auger left right Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The conveying func tion of the left right half of the auger is switched on when the drive lever is swivelled out and is continuously controlled via the materi...

Page 124: ...D 12 18 40 90 91 92 94 93 95 96 96 ...

Page 125: ... switch position Operating mode MANUAL height adjustment is carried out using the corresponding function switches on the remote control or operating panel Lower switch position Operating mode AUTO height adjustment is carried out automatically via the connected grade control system 95 Retract extend left right screed Pushbutton function Switch position in the corresponding direction extend or retr...

Page 126: ...D 12 18 42 ...

Page 127: ...D 24 18 1 D 24 18 Operating the display ...

Page 128: ...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 129: ...idual displays can be found in 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 ...

Page 130: ...tions 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 1 Main function switch activated 2 Set up mode activated 3 Filling function activated A 1 2 3 ...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ... 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 136: ...lay A The menu for filter regeneration is only displayed for vehicles with corresponding exhaust 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 137: ...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 If individual screed sections are heated the display is shown accord ingly Example 5a Call up the following menus 6 Home menu 2 1...

Page 138: ...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 139: ...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 140: ...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 141: ... 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 142: ...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 143: ...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 144: ...el 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 automatically reduced Indicato...

Page 145: ... 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 146: ...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 147: ...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 perform ance a...

Page 148: ...ible errors see engine s operating 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 149: ...D 24 18 23 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 150: ...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 151: ...D 24 18 25 Example ...

Page 152: ...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 153: ...4 18 27 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 154: ...D 24 18 28 ...

Page 155: ...alling from the vehicle which can cause severe to fatal injuries During operation the operator must be at the intended driver s seat and be seated properly 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 i...

Page 156: ...on Possible collision of parts The following adjustments must be made before lowering the roof Both seat consoles pushed in Backrests and armrests of driver s seats tilted forwards Operating panel in lowest position and locked with the vandalism protection facility Front window closed Engine hood closed NOTE ...

Page 157: ... the roof has reached the upper or lower limit position Bolt 3 must be inserted in the corresponding hole on both sides of the roof Position 3a Roof raised Position 3b Roof lowered A The bolt must be inserted with the alignment as shown and then swivelled against the roof beam Possibly adjust the position of the roof with the hand pump to insert the bolt Position 3c Roof raised Position 3d Roof lo...

Page 158: ...e adjustment lever 4 to the Raise or Lower position Operate the pump lever 1 until the roof has reached the upper or lower limit position Bolt 3 must be inserted in the corresponding hole on both sides of the roof Position 3a Roof raised Position 3b Roof lowered Secure bolt with split pin 3c 1 2 3b 3c 3 4 3a ...

Page 159: ...D 30 18 5 Control platform telescoping seat consoles 10 B A B 11 6 4 5 2 8 A 9 7 12 ...

Page 160: ...n in one of the intended detent positions Raise lower the operating panel Release clamping lever 6 lift or lower operating panel Tighten clamping lever 6 in required position Steering wheel inclination adjustment o Press latch 7 swivel steering wheel to the required position and allow latch to en gage again A During longer interruptions and after work has been completed cover the operating panel w...

Page 161: ...consoles increase the basic width of the paver finisher f If the seat consoles are moved ensure that there is no one in the danger area f Only adjust the operating position whilst the vehicle is stationary f During transportation in road traffic and when transporting the vehicle on transport ers the seat consoles must be secured in the retracted position Storage space There are lockable storage co...

Page 162: ...handle 3 with the latch pulled 2 To close the front window pull the latch 2 and pull the sliding frame at the handle 3 Risk of crushing hands When closing the spring loaded front window there is a risk of crushing which can cause injuries Do not reach into the danger zone Set the latches correctly Comply with further instructions in the safety manual A B 3 2 4 1 B A CAUTION ...

Page 163: ...ilable to the left and right of the protective roof to protect the driver for example when the seat console is extended Pull the latch 6 and extend the sunshade Set the latches in one of the intended detent positions m The sunshade must be retracted again before lowering the roof and for transport on the low bed trailer Holder for the vandalism protection facility Keep the vandalism protection fac...

Page 164: ...ividually adjusted Raise the button to adjust the inclination The seat surface in clines to the desired position by simultaneously loading or relieving it Armrest inclination 6 The armrest s longitudinal inclination can be adjusted by turning the hand wheel Turning outwards raises the front of the armrest turning inwards lowers it at the front In addition the armrests can be folded up fully Lumbar...

Page 165: ...eat height adjustment 4 The seat height can be individually adjusted Turn the handle in the desired direction to adjust the seat height Backrest adjustment 5 The backrest inclination can be continuously adjusted Turn the handle in the desired direction to adjust Armrest inclination 6 The armrest s longitudinal inclination can be adjusted by turning the hand wheel Turning outwards raises the front ...

Page 166: ...30 18 12 Fuse box The terminal box which contains all fus es and relays etc is located beneath the central control platform floor panel A An assignment plan for fuses and relays can be found in chapter F8 ...

Page 167: ...rding to the instructions see section Starting the paver finisher ex ternal 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 3 to the left and pull it out A Do not lose the key pin as in this case the paver fin...

Page 168: ...ly open dan ger during transportation Screed lock mechanical A The screed locks must additionally be engaged on both sides of the vehicle pri or 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 screed lock beneath the crossbeams using the lever 1 place the lever in the deten...

Page 169: ...the reading position the scale 1 can be raised and lowered again in one of the adjacent locating bores 2 The pointer 3 can be swivelled to differ ent positions using the locking knob 4 m The scale 1 and pointer 3 must be swivelled in completely to transport the machine A In normal paving situations the same paving thickness should be set on both sides of the vehicle 1 2 4 3 ...

Page 170: ...D 30 18 16 Auger lighting o A Two swivelling headlights 1 are located at the back of the vehicle for illuminating the auger compartment They are engaged together with the working lights 1 ...

Page 171: ...D 30 18 17 LED working light o There are two LED spotlights 1 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 1 1 ...

Page 172: ...ckwise lifts the auger Actuate the ratchet lever 2 Set the desired height by alternatingly actuating the left and right ratchets The current height can be read at the scale 3 Hydraulic height adjustment Adjust the required height by pressing the corresponding switch ope rating panel The current height can be read at the scale 4 A Observe the notes on adjusting the au ger height in the chapter Set ...

Page 173: ... 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 sensor rod 1 is locate...

Page 174: ... adjustment to the required length You can also change the angle by swivelling the joint 5 m Tighten all assembly parts properly after setting up m During transportation the sensor rod must be swivelled right back and fixed correctly The max transport width must not be exceeded ...

Page 175: ...n Remove the spray 1 from its bracket 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 On completion of work secure the man ual spray in its bracket with a lock 5 f Do not spray into open flame or on hot surface Danger of explosion 5 2 1 2 2 3 4 ...

Page 176: ... here The hose is automatically retracted into the guide after pulling and dis charging again Actuate button 3 to activate and de activate the pump The indicator lamp 4 lights up when the emulsion pump is running Actuate the manual valve 5 to spray f Do not spray into open flame or on hot surface Danger of explosion A The spraying system is fed by a canister 6 at the vehicle step Check the level a...

Page 177: ...n the rele vant half of the conveyor The conveyors should stop when the material has roughly reached the area below the auger tube A This requires that the auger height has been adjusted correctly see chapter E A In vehicles with a PLC control system the deactivation point is set on the re mote control 1 ...

Page 178: ...nsor s angle After adjusting retighten all mounting parts properly A The connection cables 4 are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed over the full working width A We recommend adjusting the limit switch positions during material distrib...

Page 179: ...o set the sensor height the deacti vation point loosen the star handles 4 and adjust the linkage to the re quired length After adjusting retighten all mounting parts properly A The connection cables are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be convey...

Page 180: ... A socket 1 is located behind the left right seat consoles Additional working lights can be con nected here for example Right seat console 12V socket Left seat console 24V socket A Voltage is present when the main switch is switched on 1 ...

Page 181: ...ap on the oper ator s platform m The pumping interval adjusted in the facto rymustbemodifiedto thepavingsituation A Changing the duration of lubrication and breaks may be necessary when laying mineral or cement bound material mix A The adjustment is carried out in the vehi cle control display for PLC vehicles ...

Page 182: ...the pressure for the screen con trol with paving stop floating stop with relief A Isengagedautomatically with paving stop Pressure adjustment with valve 1 A Lock the valve with the corresponding nut after making the adjustment For pressure indication see mano meter 2 2 1 ...

Page 183: ...arer 1 up and se cure in the uppermost position with a shackle 2 To lower the lane clearer it must be lifted a little and the shackle 2 must be swivelled back A The blade s level above the ground is adjusted with a bolt 4 Caution Possible collision of parts The lane clearer must be adjusted in the lower setting with a few mm clearance between the ground and the blade 3 When driving up inclines loc...

Page 184: ... locks 2 for eccentric adjustment Swivel screed to the desired position using the lever 3 and engage the locking knob again A If the levelling unit is connected to a height controller this has the function of balanc ing out any rapid rise in the screed position The levelling cylinders are extended until the correct height is reached A The change in approach angle can only take place slowly and uni...

Page 185: ...of the crossbar Remove insert plate 4 Remove bolt 5 Move the push roller crossbar as far as it will go to the front rear position A Shift the push roller crossbar at the towing eye or use a suitable assembly lever in its guide left and right to push it into the corresponding position Turn the bolt 5 180 and reinsert in the front or rear position Turn the insert plate 5 180 and reinsert into the gr...

Page 186: ...D 30 18 32 Push roller damping hydraulic o A Push roller damping hydraulically absorbs the shocks between the material truck and paver finisher Activate the function on the operating panel as necessary ...

Page 187: ...nnel must be fa miliarised with operation of the fire extin guisher 1 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 1 1 ...

Page 188: ...d secure with a wing bolt 1 Raise the bracket 2 swivel to the outer position and allow to engage there Slide the rotary beacon with the tube 2 out to the desired height and se cure 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 o 3 2 1 ...

Page 189: ... of bridges and tunnels and the enlarged vehicle width f Always disconnect the power supply before working on the illuminated balloon f Never look directly in the balloon when it is switched on f The illuminated balloon must not be used in the vicinity of highly flammable materials e g petrol and gas a safety distance of at least 1 metre must be maintained from combustible materials 2 3 1 7 6 4 5 ...

Page 190: ...e holding tube 5 and tighten the clamping bolt 6 Close the zip fastener in the balloon skin and smooth away any large wrinkles in the skin Guide the holding tube 5 into the premounted holder 1 and tighten the clamping lever 7 correctly to fix the holding tube Once the illuminated balloon is completely mounted and secured connect the plug 8 of the illuminated balloon in the corresponding switch cab...

Page 191: ...nts to clean the balloon skin Replacing the lamp Disconnect the power cable and open the zip fastener of the skin f Let lamp cool down completely m Always wear the supplied cotton glove to touch the lamp Press the lamp down gently to remove it Insert the new lamp in the socket Close the zip fastener of the balloon skin 9 ...

Page 192: ...D 30 18 38 ...

Page 193: ...arts Diesel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector A full bottle of propane gas o 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 Protect...

Page 194: ...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 195: ...st 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 hazard flasher with vario screeds Wit...

Page 196: ...ecurely seated Screed transport safeguard When the screed is raised before transport make sure that the cross beam lock is fixed correctly Hopper transport safeguard When the hopper is closed before transport the locks must be fixed correctly Protective roof Both locking bolts must be in the provided bore hole Other facilities Engine panels Lateral flaps Check that the hoods and flaps are securely...

Page 197: ...D 42 18 5 1 9 2 5 5 3 4 6 7 8 ...

Page 198: ...e current drain on the battery Turn ignition key 3 to position 1 and wait for the preheat check 8 o to go off A The vehicle cannot 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 Press the starting button 9 to start the engine Do not let the starter run perm...

Page 199: ...D 42 18 7 1 9 2 5 5 3 4 6 7 8 ...

Page 200: ...ehicle battery Then connect the negative ter minal C of the starting aid battery to the ground of the discharged vehicle 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 aid cable so that it can be disconnected once the engine is running Set the drive lever 1...

Page 201: ...the starting button 9 to start the engine Do not let the starter run permanently for more than 20 seconds then allow for a break of one minute A If the engine does not start and the Error message 5 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...

Page 202: ...D 42 18 10 1 2 3 4 5 6 ...

Page 203: ...ngine speed can be increased 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 3 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 ...

Page 204: ...D 42 18 12 2 3 6 5 7 1 ...

Page 205: ...he levelling cylinders with the switch 5 A To extend the levelling cylinders levelling operating mode 6 must be switched to MANUAL on the remote controls Use switch 7 to adjust the screed to the basic width of the paver finisher m Lift the auger if necessary A If the engine is started with the drive lever swivelled the travel drive is blocked To be able to start the travel drive the drive lever mu...

Page 206: ...D 42 18 14 2 2 3 1 6 5 4 ...

Page 207: ...medium speed For driving carefully tilt the drive lever 3 forward or backward according to the drive direction desired Adjust the speed with the preselector 2 If necessary increase the engine speed with the speed controller 4 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...

Page 208: ...eed auger push roller with a separator fluid m Do not use diesel fuel as it dissolves the bitumen prohibited in Germany Screed heater system 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 209: ...arks To ensure straight paving a direction mark must be present or established road edge chalk lines or similar Slide the operating panel to the de sired side and secure it Adjust direction of travel indicator on the bumper ...

Page 210: ...D 42 18 18 A 1 3 2 4 ...

Page 211: ...just the con veyor 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 auto Actuate switch 4 The engine speed is increased the conveying functions conveyor and...

Page 212: ...D 42 18 20 1 2 5 6 7 4 11 10 3 12 9 8 ...

Page 213: ...ive wheels as the screed tends to level an uneven ground The reference points for the layer thickness are the caterpillar chains or drive wheels 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 Travelling di...

Page 214: ...in the 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 height 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...

Page 215: ...D 42 18 23 3 1 2 ...

Page 216: ...ed out A To prevent the screed from lowering during an intermediate stop drive lever in centre position the screed is hydraulically held in position via relief pressure and the coun ter pressure of the material m Check whether the screed transport safeguard is inserted Setting pressure for screed control with paving stop relieving A Pressure adjustments can only be made while the diesel engine is ...

Page 217: ...D 42 18 25 1 2 3 ...

Page 218: ...r empty and create an edge like the end of a layer Set the drive lever 1 to the centre position During extended interruptions e g lunch break Set the drive lever 1 to the centre position and the speed adjuster 2 to minimum Switch the screed heater system off Turn the engine off with switch 3 With a screed with gas heating system o close the bottle valves A The screed must be heated up to the corre...

Page 219: ...D 42 18 27 1 3 14 2 15 5 8 4 9 7 6 5 4 11 10 12 13 16 ...

Page 220: ...system off See screed operating instructions Switch the working and warning lights 13 to OFF Read and check the operating hour meter 14 to determine whether maintenance work must be performed see chapter F Turn the engine off with switch 15 Remove the ignition key 16 in position 0 o Close main shut off valve and bottle valve of the screed gas heating system Remove the levelling units and stow them...

Page 221: ...ce 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...

Page 222: ...ow screed extendable parts are incorrectly installed cold screed bottom plates are worn or warped screed is not operated 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 223: ...n 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 interrupted Check fuses and cables replace if necessary Switch is defective Replace the switch One of the pressure limit ing valves...

Page 224: ...cannot be lifted Oil pressure too low Increase the oil pressure Leaking seal Replace Screed relieving or charg ing is switched on Switch must be in the centre position Power supply interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote control is set to Auto Set the switch to Manual Power supply interrupted Check fuse and cables replace i...

Page 225: ...e 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 226: ...D 42 18 34 ...

Page 227: ...ver 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 press...

Page 228: ...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 229: ...incorrect height setting can result in the following problems during paving Auger too high Too much material in front 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 ...

Page 230: ...wise or anti clockwise direction Adjust the required height by actuating the ratchet 2 The current height can be read at the scale 3 Hydraulic height adjustment Adjust the required height by pressing the corresponding switch operating panel The current height can be read at the scale 4 ...

Page 231: ...ditional 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 4 6 3 5 1 2 6 4 ...

Page 232: ...f the crossbar Remove insert plate 4 Remove bolt 5 Move the push roller crossbar as far as it will go to the front rear position A Shift the push roller crossbar at the towing eye or use a suitable assembly lever in its guide left and right to push it into the corresponding position Turn the bolt 5 180 and reinsert in the front or rear position Turn the insert plate 5 180 and reinsert into the gro...

Page 233: ...e hopper scrapers 1 must be adjusted on both hopper lids Loosen the mounting screws 2 Set a gap of 6 mm across the whole length of the scraper Retighten the mounting screws 2 properly f Risk of injury due to sharp edged parts Wear suitable safety gloves to protect your hands 1 2 ...

Page 234: ... the vehicle must be adjusted to the prevailing paving conditions e g positive or negative crowning etc Remove screws 2 Move guide plate to the required size basic setting 25mm Retighten the mounting screws 2 properly f Risk of injury due to sharp edged parts Wear suitable safety gloves to protect your hands 1 2 ...

Page 235: ...tructions cover all work required for mounting setting up and extending the screed 4 Electrical connections Prepare or make the following electrical connections when the mechanical compo nents have been mounted and set up 1 2 5 3 6 7 8 4a 4 2a 3 ...

Page 236: ... to install the cables Install the cables to rule out the risk of any damage to the cables m If the side shield is not connected the socket 4 has to be connected with the bridge plug 4a Other connection possibilities Auger limit switches 5 Grade control system 6 External levelling system 7 24 volt consumers e g additional lighting A When using an external levelling system this must be logged in us...

Page 237: ...cure with a clamping lever 4 Connect the left or right sensor s con nection cable 5 to the intended re mote control bracket sockets A The connection cables are connected to the relevant sockets on the remote control bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed over the full working width A We recommen...

Page 238: ...oosen the star handles 4 and adjust the linkage to the re quired length After adjusting retighten all mounting parts properly A The connection cables are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed over the full working width A We recommend adj...

Page 239: ...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 240: ...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 241: ...F 21 18 1 F 21 18 Maintenance review 1 Maintenance review 83 18 90 100 50 18 60 18 40 18 71 18 30 18 ...

Page 242: ...ating hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F31 18 q q q Auger F40 18 q q q q q Engine F50 18 q q q q q q Hydraulic system F60 18 q q q q q q q Wheel chassis F71 18 q q q q q q Electrical system F83 18 q q q q q q q Lubrication points F90 q q q q Checking stopping F100 q q q Maintenance required q ...

Page 243: ...F 30 18 1 F 30 18 Maintenance conveyor 1 Maintenance conveyor ...

Page 244: ...e and transport close both hopper lids and fit the correspond ing hopper transport safeguards When the vehicle is parked and during maintenance and transport raise the screen and fit the corresponding screed transport safeguards Ensure that opened hoods and covering parts are locked properly Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces in...

Page 245: ...ars If necessary 1 q Conveyor chain Check tightness q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Conveyor drive drive chains Check chain tightness q Conveyor drive drive chains Adjust chain tightness 3 q Replace conveyor deflectors conveyor plates Maintenance q Maintenanceduringtherunning inperiod g ...

Page 246: ...n material falls into the space be tween the chain and the sprocket An excessively slack chain may catch on protruding objects and be destroyed Adjustment of chain tension A One adjusting screw is located on both halves of the conveyor for adjusting the chain tension A The adjusting screws are located at the reversal behind the crossbeam A A special wrench for the lock nut A is included in the sco...

Page 247: ...ctly dividing the chains would de stroy the drive wheels m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyor deflectors Conveyor plates Deflector plates Conveyor chain reversing rollers Conveyor drive chain sprockets A Your Dynapac customer service will be happy to provide support during maintenance repair and t...

Page 248: ...hain in the oblong hole of the chain guard If the tension has been set properly the chain must be able to move freely approx 10 15 mm To re tension the chains Unfasten mounting screws B and lock nut C slightly Adjust the required chain tension us ing the tensioning screw C Retighten fastening bolts B and lock nuts C correctly B D C 10mm A ...

Page 249: ...r deflectors with new bolts A At the latest the conveyor plates B must be replaced when the wear limit of 5 mm in the rear area beneath the chain has been reached m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyor deflectors Conveyor plates Deflector plates Conveyor chain reversing rollers Conveyor drive chain ...

Page 250: ...F 30 18 8 ...

Page 251: ...F 40 18 1 F 40 18Maintenance auger assembly 1 Maintenance auger assembly ...

Page 252: ...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 253: ...s Check tension q Auger drive chains Adjust tension q Augur drive chains Replace chains and chain sockets 2 q Augur box Check grease fill q Augur box Top up with grease q Augur box Change grease 3 q Seals and sealing rings Check wear q Seals and sealing rings Replace seals 4 q Outer auger bearing Lubricate Maintenance q Maintenance during the running in period g ...

Page 254: ...500 1000 annually 2000 every 2 years 5000 If necessary 5 g g Outer bearing bolts Check tightening q Outer bearing bolts Tighten to correct torque 6 q Auger blade Check wear q Auger blade Replace auger blade Maintenance q Maintenance during the running in period g ...

Page 255: ...rn both 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 Adjust chain tension with the adjusting screws B Retighten the bolts A C A B ...

Page 256: ...auger 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 257: ...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 258: ... 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 259: ...ially greasing the outer bearing points in or der to improve ventilation on greasing The outer rings must be properly se cured again after greasing A New bearings must be filled with 60 strokes of grease using a grease gun Mounting screws outer augur bearing Check tightening 5 m Following the running in period the tightening torques of the outer auger bearing mounting screws must be checked Tighte...

Page 260: ...duced and the blades B have to be replaced 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 D E B ...

Page 261: ...ly 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 262: ...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 263: ...Clean 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 Maintenancedurin...

Page 264: ... filter Replaceair filter cartridge 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 Maintenance during the r...

Page 265: ...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 266: ...ystem cannot run dry and time consuming venting bleeding can therefore be avoided For filling with fuel 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 267: ...check the oil level when the finisher is in a horizontal position A The sensor rod 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 with oil Remove cover B Fill up oil to correct level Return cover B Use dipstick to check level again B A ...

Page 268: ...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 Use the maintenance flap for access Loosen the filter D using a filter wrench or filter strap and unscrew Collect escaping lubricating oil Clean the sealing face of the filter car rier with a clean lint free cloth Slightly lubricate the seal of the new filter before insta...

Page 269: ...ain 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 ...

Page 270: ...electric 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 t...

Page 271: ...f 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 ...

Page 272: ...stem is under pressure When opening there is a danger of scalding m Use only approved coolants A Observe the instructions in the chapter entitled Operating substances Remove the drain screw B on the ra diator and let the coolant drain com pletely Reinstall the drain screw B and tight en properly Fill in coolant through the filling open ing A on the compensation tank until the coolant level rises t...

Page 273: ...sary remove leaves dust or sand from the radiator A Observe engine s operating instructions Checking coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentration if necessary A Observe engine s operating instructions ...

Page 274: ...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 275: ...F 60 18 1 F 60 18 Maintenance hydraulic system 1 Maintenance hydraulic system ...

Page 276: ...k 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 th...

Page 277: ...on key before any maintenance work Secure the vehicle to prevent it being switched on again Let the hydraulic oil cool down A After depressurising begin slowly and carefully when opening the threaded connections in the hy draulic lines Continue to loosen the threaded connections with caution in order to notice possible dangers resulting from any still remaining pressure in the hydraulic fluid here...

Page 278: ... tank Change oil and clean q Hydraulic oil tank Change ventilation filter 2 q Hydraulic oil tank Check maintenance indicator q q Hydraulic oil tank Change and vent the suction re turn flow hydraulic filter 3 q High pressure filter Check maintenance indicator q q High pressure filter Replace filter element 4 g g q q High pressure filter mesh filter Replace filter element o Maintenance q Maintenance...

Page 279: ...up oil g q Pump distribution gear Change oil q Pump distribution gear Check bleeder q Pump distribution gear Clean bleeder 6 g q Hydraulic hoses Visual inspection g q Hydraulic system Leak test q Hydraulic system Retighten screw connections q q Hydraulic hoses Replace hoses 7 q q Auxiliary flow filter Replace filter element o Maintenance q Maintenance during the running in period g ...

Page 280: ... the side of the tank For filling with oil Remove cap B Fill in oil through the filler opening until the oil level rises to the centre of the sight glass A 5 mm Screw cap B on again A Regularly remove dust and pollution from the oil tank vent integrated in the cover B Clean the surfaces of the oil cooler m Use only the recommended hydraulic oils see section Recommended hy draulic oils A When filli...

Page 281: ...on the oil drainage hose F opens the valve to let the oil drain out Place the end of the hose in the col lecting vessel and let the oil drain completely Unscrew the drainage hose and return the screw cap A The oil should be changed when at operating temperature m When changing the hydraulic oil also change the filter Ventilation filter A The ventilation filter is integrated in the cover B The cove...

Page 282: ... the sealing surfaces and O rings with clean operating fluid Fill the opened filter housing with hy draulic oil up to approx 2 cm below the top edge If the oil level drops replenish oil again A Slow oil level reduction of approx 1 cm min is normal If the oil level remains stable slowly insert the assembled unit with new filter element into the housing position the cover A and screw hand tight m En...

Page 283: ...ter cartridge Clean the filter housing Insert the new filter cartridge Replace the seal ring of the filter housing Turn on the filter housing by hand and tighten it using a wrench Start trial operation and check the tightness of the filter A Replace the seal ring whenever the filter cartridge is replaced A After replacing the filter element the red mark in the maintenance indicator A automatically...

Page 284: ...rench A Put a vessel underneath to 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 housing E ...

Page 285: ... 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 286: ...F 60 18 12 Bleeder The functioning of the bleeder A must be ensured If soiling has occurred the bleeder should be cleaned A ...

Page 287: ...ering 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 man...

Page 288: ...stening 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 acros...

Page 289: ...anoth 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 T...

Page 290: ...in 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 hous ing D As required top up hydraulic oil level in filter housing then screw down t...

Page 291: ...F 71 18 1 F 71 18 Maintenance travel drive steering 1 Maintenance travel drive steering ...

Page 292: ...e and transport close both hopper lids and fit the correspond ing hopper transport safeguards When the vehicle is parked and during maintenance and transport raise the screen and fit the corresponding screed transport safeguards Ensure that opened hoods and covering parts are locked properly Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces in...

Page 293: ...nce point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 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 Maintenanceduringtherunning inperiod g ...

Page 294: ...ce tyres q Drive wheels Check air pressure q Drive wheels Adjust air pressure g Drive wheels Check wheel nuts q Drive wheels Tighten wheel nuts 3 q Lubricating points Lubricate king pins q Lubricating points Lubricate steering q Lubricating points Lubricate floating axle q Lubricating points Lubricate wheel bearings o Maintenance q Maintenanceduringtherunning inperiod g ...

Page 295: ...e oil level has reached the lower edge of the inspection hole Check gaskets on both screws and re place if necessary Tighten the inspection bolt A and fill er screw B back in again 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 conveyor chain sprocket so that drain plug A is in the 6 o clock position Pla...

Page 296: ...wheels 2 Check tyres replace tyres Check the tyres on a daily basis for signs of damage cracks or blister for mation Regularly check compliance with the minimum profile depth m Replace damaged or worn tyres immediately ...

Page 297: ... have been secured and correctly sup ported to prevent them from tilling over and rolling or sliding away f The jack must only be used on smooth firm ground f Roller type jacks must not be moved when under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequately dimensioned and be able to take the corresponding weight f There must not be anyone on th...

Page 298: ...he raised wheel as a safeguard Place another wooden block under the machine frame at point 2 m The wooden block must support the vehicle frame at the side wall and rear wall Remove the wooden block under the raised wheel and gently lower the vehicle onto the remaining wooden block 2 Dismantle the wheel nuts and remove the wheel A Reassemble in reverse order 1 2 ...

Page 299: ...Check the tyre pressure in cold condi tion A slight increase in tyre pressure during operation is normal and there is no need to relieve pressure f Only ever set the tyre pressure using a self regulating filler connection Never stand directly in front of the tyres when filling them with air f Please comply with the safety instructions for checking and adjusting the air pressure A Bear in mind that...

Page 300: ...ts tighten wheel nuts A Following wheel replacement check the wheel nuts after the running in time Check tighten all wheel nuts using a torque wrench as shown A Adjust the torque to 288 Nm 11 3 13 9 1 12 4 14 6 2 5 7 15 10 8 16 ...

Page 301: ... does not apply for ve hicles with central lubrication system Wheel bearings o A The lube nipples A are accessible through a hole in the wheel rim A The number of lube nipples depends on whether the vehicle is equipped with without front wheel drive 5x A ...

Page 302: ...F 71 18 12 ...

Page 303: ...F 83 18 1 F 83 18 Maintenance electrical system 1 Maintenance electrical system ...

Page 304: ...Do 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 b...

Page 305: ... 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 g q Alternator Check the drive belts for damage replace if necessary o g q Alternator Drive belts check tension adjust if necessary o q Alternator Replace drive belts o 3 q Electrical fuses Maintenance q Maintenancedurin...

Page 306: ... free of corrosion oxide and protected with a special grade of terminal grease m When removing the batteries always first remove the negative terminal en suring that the battery terminals cannot be short circuited A Keep the battery surfaces clean and dry use only a damp or antistatic cloth for cleaning m Do not open batteries without plugs A If the starting capacity is insufficient check and poss...

Page 307: ...n 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 charge current accord ing to the following rule of thumb Battery capa...

Page 308: ...the function of the insulation monitor not whether an insula tion error has occurred on the heating sections or consumers Start the paver finisher s drive engine Switch heating system switch 1 to ON 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 1 3 2 ...

Page 309: ...creed or with connected external equipment f The screed and equipment must be checked or repaired by a specialist electri cian Only then may work again be undertaken with the screed and equipment f Danger from electric voltage f Non adherence to the safety precautions and safety regulations when operating the electric screed heating system leads to a risk of electric shock Danger to life All maint...

Page 310: ...arried out If the indicator lamp goes out the switches of the heating system and external equipment can be switched back to ON one after another until a message again appears and the system is shut down The equipment found to be faulty must be removed or must not be engaged and the reset button must be pressed for at least 3 seconds to delete the fault A Operation may now be continued without the ...

Page 311: ...ing 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 312: ...ons for checking tightness in the pretention measuring instrument instructions A A pretention measuring instrument can be ordered under Article No 4753200045 If necessary adjust the belt tension Unfasten lock nut A from the clamp ing lock Adjust belt tension to the correct val ues by turning the clamping lock B Tighten the lock nut A again A Further instructions for checking of ten sion see descri...

Page 313: ...8 11 Replacing belt Unfasten lock nut A from the clamping lock Turn and open clamping lock B until belts C can be replaced A Pre tension the newly fitted belts using clamping lock B Check adjust belt tension ...

Page 314: ...F 83 18 12 2 Electrical fuses 2 1 Main fuses Main fuses A F A 1 1 Main fuse 50 1 2 Main fuse 30 1 4 Preheating ignition system 100 A ...

Page 315: ...d 10 F2 Screed 10 F3 Screed 10 F4 Starter 5 F6 Auger light 10 F7 Monitoring unit 10 F8 Monitoring unit 5 F10 Central lubrication 5 F12 Conveyor auger 7 5 F13 24V socket left 10 F16 24V socket right 10 F17 Power supply A1 master 5 F19 12V socket 10 F20 Rotary beacon 7 5 B ...

Page 316: ...ition 2 F28 Instrument panel illumination 10 F29 Steering potentiometer preselection potentiometer GPS module 3 F30 Reverse buzzer 5 F31 Central lubrication 5 F32 Power supply A1 master 5 F35 Protective roof rear light 10 F36 Protective roof front light 10 F37 Interface engine diagnosis A2 2 F38 Interface engine diagnosis A1 2 ...

Page 317: ...Emergency stop K5 Front working lights K6 Rear working lights K7 Auger working light K8 Horn K10 Right conveyor K11 Left conveyor K12 Left auger K13 Right auger K14 Levelling left K15 Levelling right K16 Rotary beacon K20 Reverse buzzer K21 Central lubrication K22 Operating functions lock K26 Fuel pump K27 Engine pre heating function C ...

Page 318: ...F 83 18 16 ...

Page 319: ...0 18Maintenance lubricating points 1 Maintenance lubricating points A The information on the lubricating points for the various assemblies is assigned to the specific maintenance descriptions and must be read there ...

Page 320: ...Item Interval Maintenance point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Check lubricant tank fill level o q Top up lubricant tank o q Bleed central lubrication system o q Check pressure limiting valve o q Check flow of lubricant at the consumer o 2 q Bearing points Maintenance q Maintenance during the running in period g ...

Page 321: ...ring operation f Risk of injury due to escaping lubricant as the system operates at high pressures f Ensure that the diesel engine cannot be started when working on the system f Observe safety regulations for handling hydraulic systems m Ensure maximum cleanliness when working on the central lubrication system The following assemblies lubricating points can be automatically supplied with grease by...

Page 322: ...N mark A on the tank Top up lubricant tank A filler hose B is located on the lubricant tank A for filling purposes Connect the grease gun C included with the scope of supply to the filler hose B and fill the lubricant tank A up to the MAX mark Alternatively the lubricant tank can be filled with a standard grease gun at the lu bricating nipple D A When the lubricant tank is completely empty the pum...

Page 323: ... lubricant has emerged Check all connections and lines for leaks Check pressure limiting valve m If lubricant emerges at the pressure lim iting valve A this indicates a malfunc tion in the system The consumers are no longer adequate ly supplied with lubricant Disconnect all distribution lines B leading from the distributor C to the consumers in succession If lubricant emerges from one of the disco...

Page 324: ...move the lubrication line A and install a normal lubricating nipple B Connect the grease gun C included in the scope of supply to the lubricat ing nipple B Operate the grease gun until the lu bricant visibly emerges Rectify any faults in the flow of lubricant Reinstall the lubrication lines Check all connections and lines for leaks C A B ...

Page 325: ...F 90 18 7 Bearing points 2 A One lubricating nipple A is located at each hydraulic cylinder bearing point top and bottom 2x A ...

Page 326: ...F 90 18 8 ...

Page 327: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping ...

Page 328: ...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 4 q Cleaning sensors 5 q Preserving the paver finisher Maintenance q Maintenance during the running in period g ...

Page 329: ... 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 330: ...isher screed and optional gas or electric system checked by a trained spe cialist 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 331: ...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 332: ...arts can cause severe or 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 before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including thos...

Page 333: ...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 334: ...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 335: ...isposal must be carried out after replacing wear and spare parts and after the machine 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 env...

Page 336: ... 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 337: ... 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...

Page 338: ...F 100 12 ...

Page 339: ...le qualities of well known brands m Only use containers which are clean on inside and outside for filling oil or fuel A Note capacities see section Capacities m Incorrect oil or lubricant levels promote rapid wear and feeder failure m Never mix synthetic oils with mineral oils m Please heed the equipment related fuel specification requirements ...

Page 340: ...F 111 18 2 2 6 6 1 7 3 4 5 ...

Page 341: ...em Cooling liquid 12 0 litres 3 Fuel tank Diesel fuel 73 0 litres 4 Hydraulic oil reservoir Hydraulic oil 80 0 litres 5 Pump distribution gear Gearbox oil 2 0 litres 5 Pump distribution gear as of s n 3309 3510 ff Gearbox oil 1 5 litres 6 Planetary gear Traction unit Gearbox oil approx 2 4 litres 1 2 l per side 7 Auger box Liquid grease 3 5 kg Batteries Distilled water ...

Page 342: ...n 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 ...

Page 343: ...in at the factory Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Engine Oil 200 Dynapac AGIP Chevron Caltex Delo 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 ...

Page 344: ...ded 2 11 Grease A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 100 Omala S2 GX 220 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Auger Grease Gadus S5 V142W 00 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Chevron Paver Grease Gadus S5 T460 1 5 High Temp Premium2 ...

Page 345: ... m 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 Natural 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 346: ...F 111 18 8 ...

Page 347: ......

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

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Dynapac F1800W, Operation & Maintenance Manual

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