Dynapac F2500C Operation & Maintenance Manual Download Page 359 | Manualshive

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F 73 5

f

Any work on the pretensioned spring element must only be carried out by trained,
specialist personnel!

f

The spring elements must only be removed by a specialist workshop! The following
applies to all spring elements in the event of a necessary repair: replace the complete
unit only!

f

Repairing the spring elements involves significant safety measures and should only
be carried out by a specialist workshop!

A

Your Dynapac customer service will be happy to provide support during maintenance,
repair and the replacement of wearing parts!

Danger from pretensioned springs

Incorrectly performed maintenance and repair work can
cause severe or fatal injuries!
- Always observe the maintenance instructions.
- Do not perform any unauthorised maintenance or repair

work to pretensioned springs.

- Comply with all further information in these instructions

and in the safety manual.

WARNING

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Summary of Contents for F2500C

Page 1: ...MAINTENANCE Paver Finisher Dynapac F2500C F2500CS Typ 890 891 Keep for later use in document compartment 4812019692 A5 04 0516 Valid for _________________ _________________ _________________ ________...

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

Page 3: ...ge 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 d...

Page 4: ...Measuring point configuration 35 7 7 Vibration acting on the entire body 36 7 8 Vibrations acting on hands and arms 36 7 9 Electromagnetic compatibility EMC 36 C10 Transportation 1 1 Safety regulation...

Page 5: ...feguard 16 Screed lock mechanical o 16 Screed lock hydraulic o 17 Paving thickness indicator 18 Auger lighting o 19 Engine compartment lighting o 19 LED working light o 20 500 watt spotlight o 21 Came...

Page 6: ...for the machine operator 3 1 1 Starting the paver finisher 6 Before starting the paver finisher 6 Normal starting 6 External starting starting aid 8 After starting 11 Observe indicator lamps 13 Engin...

Page 7: ...ecial notes on safety 1 2 Distribution auger 2 2 1 Height adjustment 2 Grain sizes up to 16 mm 2 Grain sizes 16 mm 2 2 2 Mechanical adjustment with ratchet o 3 2 3 Hydraulic adjustment o 3 2 4 Height...

Page 8: ...aligning the sensor 43 Connecting the sensor 43 Automatic steering unit operating instructions 44 7 Emergency stop during feeder operation 45 8 Limit switch 46 8 1 Auger limit switches left and right...

Page 9: ...nance review 1 F30 Maintenance conveyor 1 1 Maintenance conveyor 1 1 1 Maintenance intervals 3 1 2 Points of maintenance 4 Chain tension conveyor 1 4 Conveyor drive drive chains 2 6 Conveyor deflector...

Page 10: ...eeding the filter 8 Ventilation filter 8 High pressure filter 3 9 Pump distribution gear 4 10 Bleeder 11 Hydraulic hoses 5 12 Marking hydraulic hoses storage period period of use 14 Auxiliary flow fil...

Page 11: ...or and auger 5 5 3 Cleaning optical or acoustic sensors 6 6 Preserving the paver finisher 7 6 1 Shutdowns for up to 6 months 7 6 2 Shutdowns lasting from 6 months to 1 year 7 6 3 Recommissioning the m...

Page 12: ...10...

Page 13: ...xample 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 vehi...

Page 14: ...sible 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 t...

Page 15: ...esult 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 ta...

Page 16: ...tched 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 st...

Page 17: ...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 18: ...tart 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...

Page 19: ...ggles 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 fe...

Page 20: ...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 pr...

Page 21: ...c 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 wi...

Page 22: ...cified 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 t...

Page 23: ...ting 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 tra...

Page 24: ...he 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 us...

Page 25: ...e 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...

Page 26: ...A 2...

Page 27: ...ynapac F2500C F2500CS paver finisher is a paver finisher with a caterpillar drive which is used for paving bituminous mixed material roll down or lean mixed concrete track laying ballast and unbound m...

Page 28: ...5 t Levelling cylinder for paving thickness 6 t Traction roller 7 t Crossbeam pull bar 8 t Paving thickness indicator 9 t Crossbeam 10 t Travel drive of the caterpillar drive 11 t Auger 12 t Screed 13...

Page 29: ...he speed of the paver fin isher to be matched to all work conditions The operation of the paver finisher is considerably facilitated by the automatic mate rial handling system the independent travel d...

Page 30: ...vel drive The continuously adjustable travel drive pumps are connected to the travel drive engines by means of high pressure hydraulic hoses These hydraulic motors drive the caterpillar chains via pla...

Page 31: ...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...

Page 32: ...e control system Crossbeams screed lifting device The screed lifting device is used to lift the screed during transportation The screed s approach angle can be changed using the eccentric adjustment f...

Page 33: ...nd 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 dang...

Page 34: ...B 8 4 Safety devices 1 3 5 10 7 9 11 4 5 6 7 12 2 8...

Page 35: ...ese devices at regular intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation 1 Hopper transport safeguard 2 Screed lock mecha...

Page 36: ...al data standard configuration 5 1 Dimensions all dimensions in mm A For screed technical data refer to the screed operating instructions R65 6400 2900 6145 950 1850 2845 3100 3900 3400 3290 2550 1990...

Page 37: ...ing your vehicle in an inclined position 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 a...

Page 38: ...operating instruc tions for the screed Paver finisher without screed Approx 14 5 Paver finisher with screed V5100 Approx 18 2 With extension parts for max working width additionally max Approx xxx Wit...

Page 39: ...m paving width with cut off shoe Continuously hydraulically adjustable up to Maximum paving width with extension parts V5100TV 2 55 2 00 5 10 8 10 m Transport speed 0 4 km h Operating speed 0 30 m min...

Page 40: ...with cut off shoe Continuously hydraulically adjustable up to Maximum paving width with extension parts V5100TV 2 55 2 00 5 10 8 10 m V6000TV 3 00 2 00 6 00 9 00 m Transport speed 0 4 km h Operating s...

Page 41: ...sumption full load Fuel consumption 2 3 load 29 8 l h 19 9 l h Fuel tank capacity See chapter F Make type Cummins QSB 6 7 C173 Version 6 cylinder diesel engine water cooled Performance 129 kW 175 hp a...

Page 42: ...separately controllable Drive Hydrostatic 0 1 Conveying volume controller Fully automatic via configurable switching points Auger diameter 380 mm Drive Hydrostatic central drive continuously controll...

Page 43: ...stop Screed stop with pretensioning max pressure 50 bar During paving Screed charging Screed relieving max pressure 50 bar Levelling system Mechanical grade control Optional systems with and without...

Page 44: ...igns pose a danger 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...

Page 45: ...B 19 22 21 22 21 22 21 52 11 8 53 22 6 52 51 50 2 1 26 28 29 25 3 22 32 31 30 6 3 54 20 24 60 14 4 5 27 1 23 15...

Page 46: ...B 20 71 70 40 41 42 xxxxxxxxxxxxxxxxx 9 10 9 10 7 7...

Page 47: ...gine and remove the ignition key before per forming any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause se vere or fatal injuries Switch th...

Page 48: ...om incorrect tow ing Movements of the machine can cause severe or fatal injuries The traction system brakes must be re leased before towing Always observe the operating instruc tions 9 Caution Possibl...

Page 49: ...th water Handling tyres filled with water incorrect ly can cause severe to fatal injuries Always observe the operating instruc tions 14 Maintenance for the starter batteries Maintenance work has to be...

Page 50: ...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...

Page 51: ...of the filling and control point 28 Hydraulic oil Position of the filling point 29 Hydraulic oil level Position of the control point 30 Engine oil drainage point Position of the drainage point 31 Gea...

Page 52: ...26 6 3 CE marking No Pictogram Meaning 33 Tamper speed adjuster Position of the speed adjuster 34 Vibration speed adjuster Position of the speed adjuster No Pictogram Meaning 40 CE sound output level...

Page 53: ...ymbols prohibitive symbols warning symbols No Pictogram Meaning 50 Wear ear protection devices 51 Do not enter the area 52 Do not spray the area or part with water 53 Warning on dangers posed by batte...

Page 54: ...a tions 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...

Page 55: ...only at crown adjustment zero Screed lock only for transportation Do not enter or work under screed only secured with screed lock for transportation 71 Caution Danger of high voltage in vehicle electr...

Page 56: ...ressure working width speed preselection 74 Overview Tyre pressure working width speed preselection 75 Engine start All switches in neutral The engine cannot be started when func tions are switched on...

Page 57: ...Item 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...

Page 58: ...B 32 6 8 Explanation of 17PIN serial number A Manufacturer B Family Model C Check letter F Serial number 10002014JHG002076 A B C F...

Page 59: ...gine 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 See also op...

Page 60: ...109 2 dB A Sound pressure level at the vehicle 7 2 Operating conditions during measurement The diesel engine was running at maximum speed The screed was lowered into working position Tamper and vibrat...

Page 61: ...B A Sound pressure level at the vehicle 7 5 Operating conditions during measurement The diesel engine was running at maximum speed The screed was lowered into working position Tamper and vibration uni...

Page 62: ...the EMC di rective 2004 108 CE Interference emission according to DIN EN 13309 35 dB V m for frequencies of 30 MHz 1 GHz measured at a distance of 10 m 45 db V m for frequencies of 30 MHz 1 GHz measur...

Page 63: ...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...

Page 64: ...taken into consideration when selecting the attachment and loading equipment 2 1 Preparations Prepare the paver finisher for transportation see chapter D Remove all overlaying or loose parts from fin...

Page 65: ...he 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...

Page 66: ...le 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 lash...

Page 67: ...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 Caution Possible collision of parts When driving up inclines...

Page 68: ...orce 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...

Page 69: ...of gravity of the paver finisher Comply with the following if the paver finisher has to be placed in the front section of the low bed trailer B for load distribution reasons or on account of the leng...

Page 70: ...n both sides Position the non slip mats under the screed across the whole width of the vehicle 3 and lower the screed Switch off the paver finisher Attach and secure the protective hood 4 to the opera...

Page 71: ...the paver finisher and on the low load trailer Fasten the lashing chains as shown 4 2 Securing at the front m Diagonal lashing secures the paver finisher at the front using the lashing points on the p...

Page 72: ...ecures the paver finisher at the rear at right angles to the direction of travel using the lashing points on the paver finisher eyebolts and on the low load trailer Fasten the lashing straps as shown...

Page 73: ...inisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing straps as shown Step 2 fasten lashing chains m Diagonal lashing secures the paver fini...

Page 74: ...Protective roof Lift the screed to the transportation position Start the engine and drive from the trailer at a low engine traction speed Park the paver finisher in a secure spot lower the screed and...

Page 75: ...is at the bottom wheeled paver Driver s seats swivelled to middle setting and in lowest position Backrests and armrests of driver s seats tilted forwards Front and side windows closed Engine hood and...

Page 76: ...st pipe is lowered or raised to gether with the roof Connect the pump lever 1 to the pump 2 Tighten bolts 3 on both sides of the roof Operate the pump lever 1 until the roof has reached the upper or l...

Page 77: ...se parts from finisher and screed see also Screed op erating instructions Store these parts in a safe place f When screed is operated with the optional gas heat ing system Remove the gas bottles for t...

Page 78: ...he 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...

Page 79: ...t 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...

Page 80: ...y 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...

Page 81: ...he screed mounted is located in area 3 of the vehicle Secure vehicle wherever it is parked up Engage the transport safeguards Remove any attachments and extension parts from the paver finisher and the...

Page 82: ...ar to the four attachment points 1 2 m The max permissible attachment point load at the attachment points is 73 5 kN m The permissible load applies in the vertical direction m Make sure that the paver...

Page 83: ...for towing heavy con struction machines m The towing vehicle must be capable of securing the paver finisher even on slopes Use only approved tow bars If necessary remove any attachments and accessorie...

Page 84: ...al number 2014 2016 2021 et seq Push knob 3a into the valve body While pumping next step check that the knob remains in the pressed position Actuate lever 4 of hand pump until sufficient pressure has...

Page 85: ...hten the lock nut 7 to a torque of 22 Nm m On completion of the towing process restore the initial status Attach the tow bar to the coupling 9 located in the bumper A Now carefully and slowly tow the...

Page 86: ...tion 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...

Page 87: ...m 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 adequatel...

Page 88: ...C 10 26...

Page 89: ...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 ascertaine...

Page 90: ...or conveying vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries Do not enter the danger zone Do not reach into rotating or conveying parts Only wear close fitting clo...

Page 91: ...s 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 MA...

Page 92: ...D 10 4 10 15 16 19 18 20 17 14 11 12 13 10 21 22...

Page 93: ...the engine the button must be pulled out again 12 Engine speed adjuster Continuously variable engine speed setting if drive lever is extended Min setting Idling speed Max position Nominal speed A For...

Page 94: ...D 10 6 10 15 16 19 18 20 17 14 11 12 13 10 21 22...

Page 95: ...er the following functions can be activated 1st position Conveyor and auger on 2nd position Screed motion tamper vibration on travel drive on increase speed until the stop is reached A Use the presele...

Page 96: ...D 10 8 10 15 16 19 18 20 17 14 11 12 13 10 21 22...

Page 97: ...eed 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 19 Steering potentiometer The steering whe...

Page 98: ...D 10 10 24 23...

Page 99: ...t hopper lid Lower switch position Open left hopper lid f On actuation heed danger zones of moving parts of the vehicle 24 Open close right hopper Pushbutton function Upper switch position Close right...

Page 100: ...D 10 12 28 26 27 25...

Page 101: ...pacity with out material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 26 Right auger Operating mode AUTO OFF MANUAL Detent switch function Operating m...

Page 102: ...D 10 14 28 26 27 25...

Page 103: ...c function is overrid den with reduced delivery capacity f On actuation heed danger zones of moving parts of the vehicle 28 Right auger MANUAL conveying direction outwards inwards Pushbutton function...

Page 104: ...D 10 16 30 29...

Page 105: ...creed Right switch position Retract left half of screed f On actuation heed danger zones of moving parts of the vehicle 30 Retract extend right screed Pushbutton function Left switch position Retract...

Page 106: ...D 10 18 32 31...

Page 107: ...y rate without material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 32 Right conveyor Operating mode AUTO OFF MANUAL Detent switch function Operating...

Page 108: ...D 10 20 34 35 33...

Page 109: ...inserted f On actuation heed danger zones of moving parts of the vehicle 34 Raise lower screed Pushbutton function Upper switch position Lift the screed m Switch 33 must be deactivated for this funct...

Page 110: ...D 10 22 37 36...

Page 111: ...out Operating mode OFF Screed vibration is switched off Operating mode MANUAL Screed vibration is switched on constantly 37 Tamper Operating mode AUTO OFF MANUAL Detent switch function Operating mode...

Page 112: ...D 10 24 39 38...

Page 113: ...er Lower switch position Extend left levelling cylinder f On actuation heed danger zones of moving parts of the vehicle 39 Retract extend right levelling cylinder Pushbutton function Upper switch posi...

Page 114: ...D 10 26 40 41 42 43...

Page 115: ...void dazzling other road users 42 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...

Page 116: ...D 10 28 44 46 47 45...

Page 117: ...level operating speed slow 47 Turning on the spot Detent switch function Upper switch position Straight ahead travel standard operation Lower switch position Turning on the spot The paver finisher tur...

Page 118: ...D 10 30 77 78 79 80 81 82 83 70 71 72 73 74 75 76...

Page 119: ...been switched on for checking purposes 73 Not used 74 Indicator lamp hydraulic filter Lights up when the hydraulic filter needs replacing A Replace filter element acc to Maintenance Instructions 75 Tr...

Page 120: ...D 10 32 77 78 79 80 81 82 83 70 71 72 73 74 75 76...

Page 121: ...damage from occurring Each fault should be rectified as soon as possible A The error code can be called up using the switch Call up error malfunction A Lights up for a few seconds once the ignition h...

Page 122: ...D 10 34 2 2 Truck Assist System o 84 85 86 87 88 A...

Page 123: ...instructed in how the Truck Assist system works and understand the system Comply with all further information in the operating instructions and in the safety manual Item Designation Brief description...

Page 124: ...D 10 36 84 85 86 87 88...

Page 125: ...l truck to End Tipping lower truck hopper tell truck to Detach Depart Pushbutton function with LED feedback To change over to the End Tipping sig nal YELLOW SIGNAL running light de scending Press butt...

Page 126: ...D 10 38 84 85 86 87 88...

Page 127: ...ase for truck to approach GREEN SIGNAL A The truck is detected by a laser sensor at a distance of 6 m between the paver and the material truck GREEN SIGNAL flashing A The flashing frequency of the dis...

Page 128: ...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 Th...

Page 129: ...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 Det...

Page 130: ...D 10 42 90 91 92 94 93 95 96 96...

Page 131: ...witch 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 heigh...

Page 132: ...D 10 44...

Page 133: ...ling 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 a...

Page 134: ...is at the bottom wheeled paver Driver s seats swivelled to middle setting and in lowest position Backrests and armrests of driver s seats tilted forwards Front and side windows closed Engine hood and...

Page 135: ...e or Lower position Raise the roof The lever points for wards Lower the roof The lever points backwards Operate the pump lever 1 until the roof has reached the upper or lower limit position Roof in up...

Page 136: ...rson Set the latch 1 on both sides of the ladder to the intended position f The ladder must not be locked when driving or paving Storage space There are two removable containers 2 under the lockable b...

Page 137: ...D 30 5 Control platform moveable o 9 6 2 5 7 4 3...

Page 138: ...nction see operating panel A To shift the control platform the latch 9 must be released m Shifting the platform increases the basic width of the paver finisher f If the platform is moved ensure that t...

Page 139: ...and slide panel console to the desired position using the handle 3 Insert panel latch 2 into one of the detent positions 4 Swivelling the operating panel Lift latch 5 swivel operating panel to the req...

Page 140: ...D 30 8 Protective cabin o A D B C B A C D 1 3 4 5 2...

Page 141: ...close the front window pull the latch 4 and pull the sliding frame at the handle 4 Windscreen wiper Activate the windscreen wiper screen wash on the operating panel if necessary A Ensure that the was...

Page 142: ...raulically it can be pushed back to its central position by hand Remove the screw cap 1 next to the right footwell window Remove screw 2 A This undoes the connection between the platform and the frame...

Page 143: ...yond the outer edge of the vehicle Press latch 1 swivel seat console to the desired position and allow latch to engage again Fold hinged step 2 down if neces sary m Make sure it is latched properly f...

Page 144: ...dually 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...

Page 145: ...t 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...

Page 146: ...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 15 10 15 25 15 10 15 25 1...

Page 147: ...g 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 fus...

Page 148: ...n dan ger during transportation Screed lock mechanical o A The screed locks must additionally be engaged on both sides of the vehicle pri or to transportation with the screed lifted f Transportation w...

Page 149: ...tion with an unsecured screed leads to a risk of accidents Lift the screed Activate the function on the operating panel A The two screed locks 1 extend hydrau lically m ATTENTION Insert screed lock on...

Page 150: ...situations the same paving thickness should be set on both sides of the vehicle Other displays o are on the crossbeam guide To change the reading position the scale 2 can be raised and lowered again i...

Page 151: ...mpartment They are engaged together with the working lights A These are activated together with the other working lights on the operating panel Engine compartment lighting o A The engine compartment l...

Page 152: ...0 20 LED working light o There are two LED spotlights 1 at the front of the machine and also at the back f Always align the working lights to avoid dazzling the operating personnel or other road users...

Page 153: ...uipped with an electric screed it is possible for the lamps to flicker irreg ularly during the heating up phase with simultaneous operation of 500 watt spot lights o and illuminated balloon o Preferab...

Page 154: ...and right ratchets A The current height can be read on both auger height indicators A Observe the notes on adjusting the auger height in the chapter Set up and modifica tion Auger height indicators A...

Page 155: ...ses 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...

Page 156: ...fter releasing the wing nuts 5 the end section of the sensor rod extension 6 can be set to the desired length the angle can additionally be changed by swivel ling on the joint 7 A Either the adjustabl...

Page 157: ...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 m...

Page 158: ...When released the hose automatically engages here The hose is automatically retracted into the guide after pulling and discharging again Actuate button 4 to activate and de activate the pump The indic...

Page 159: ...ntrol the material flow on the relevant half of the conveyor The conveyors should stop when the materi al has roughly reached the area below the auger tube A This requires that the auger height has be...

Page 160: ...conveyor The conveyors should stop when the material has roughly reached the area below the au ger tube A This requires that the auger height has been adjusted correctly see chapter E To set the deac...

Page 161: ...r 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...

Page 162: ...et 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...

Page 163: ...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 wh...

Page 164: ...stop with relieving This is used to set the pressure for Screed control with paver finisher stop floating stop with relieving Switching on see screed stop paving stop Chapters Operating panel Operati...

Page 165: ...as the drive engine is started Pumping time 4 min Pause time 2 h m It is prohibited to change the factory set durations of pumping and break without consulting the technical customer serv ice A Changi...

Page 166: ...clearer 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 i...

Page 167: ...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 i...

Page 168: ...ve the locking plate 3 on the lower side of the crossbar Remove insert plate 5 Move the push roller crossbar to stop to the front rear position A Shift the push roller crossbar at the tow ing eye 6 or...

Page 169: ...90 mm Activate the function on the operating panel as necessary m Extending the push roller increases the transportation length of the paver finish er f On actuation ensure that nobody is in the dang...

Page 170: ...onnel must be fa miliarised with fire extinguisher 2 oper ation A Observe the inspection intervals for the fire extinguisher First aid kit o f Any dressings that have been used must be replaced immedi...

Page 171: ...nd 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 tube 3 to the desired height and secure with the clamping bolt 4 Ac...

Page 172: ...2 into the container which is to be emptied A To enable the container to be emptied completely the suction hose must reach down to the floor of the container Activate the function on the operating pan...

Page 173: ...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 ill...

Page 174: ...fastener 4 in the balloon skin and smooth away any large wrinkles in the skin Guide the holding tube 3 into the premounted holder 5 and tighten the screws 6 correctly to fix the holding tube Once the...

Page 175: ...d during the heating up phase Maintenance m Occasionally clean or replace the air filter 9 beneath the connection plate m Do not use solvents to clean the balloon skin Replacing the lamp Disconnect th...

Page 176: ...of the paver and the driver of the material truck The corresponding signal system shows the truck driver which action to perform reversing stop tip material depart The system consists of Two LED ligh...

Page 177: ...Diesel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector Two filled propane gas bottles Shovel and broom Scraper spatula for cleaning the auger and the hopper...

Page 178: ...ghting 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...

Page 179: ...p immediately Steering The paver finisher must immediately follow every steering wheel movement in a precise manner Check straight ahead travel Horn On the operating panel on both remote controls Brie...

Page 180: ...rely 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 tran...

Page 181: ...D 40 5 1 3 10 2 8 9 6 7 4 5...

Page 182: ...sition and the speed adjuster 2 to minimum Insert the ignition key 3 in position 0 A Starting is not possible when the Start inhibit 4 or drive mode 5 indicator lamps indicate that an emergency stop b...

Page 183: ...D 40 7 1 3 10 2 8 9 6 7 4 5...

Page 184: ...attery to the posi tive terminal 2 of the vehicle battery Then connect the negative terminal 3 of the starting aid battery to the ground of the discharged vehicle e g to the engine block or to a bolt...

Page 185: ...t the other vehicle Press the starter button 10 to start the engine Run the starter continuously for a maximum of 30 seconds then take a break for 2 minutes If the engine still has not started after t...

Page 186: ...D 40 10 2 1...

Page 187: ...D 40 11 After starting m Let the paver finisher warm up for approx 5 minutes if the engine is cold...

Page 188: ...D 40 12 2 3 1...

Page 189: ...led down automatically Driving mode remains possible After cooling down to normal temperature the engine will run with full per formance again Battery charge indicator 2 Must go out after starting whe...

Page 190: ...D 40 14 1 2 5 7 6 3...

Page 191: ...the 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 basi...

Page 192: ...D 40 16 2 2 3 1 5 4...

Page 193: ...travel drive preselector 2 to 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 Carry out s...

Page 194: ...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...

Page 195: ...raight 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 Pull the direction indicator out of the bump...

Page 196: ...D 40 20 5 4 A 2 1 3...

Page 197: ...d the conveyor on the remote controls if applica ble to auto Switch the conveyors on The conveyor limit switches A must switch off when the material has approximate ly reached the area beneath the aug...

Page 198: ...D 40 22 3 1 4 8 9 2 5 7 6 10 11...

Page 199: ...or drive 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...

Page 200: ...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 pav...

Page 201: ...with relief when the paver finisher is halting floating paving when the paver finisher is driving floating paving with screed charging or relieving when the paver finisher is driving A Relieving reduc...

Page 202: ...D 40 26 1 2 B A C A C...

Page 203: ...nisher stop in paving operation screed stop floating stop floating paving Switch 2 has the following positions A screed stop floating position OFF screed is hydraulically held in position A Function f...

Page 204: ...D 40 28 1 2 B A C A C 3 4...

Page 205: ...neutralised thus preventing the screed from possibly sinking into the material A The pressure is set to approx 20 bar in the factory Adjusting the pressure Pressure adjustments can only be made while...

Page 206: ...D 40 30 1 2 B A C A C 3 4...

Page 207: ...ting stop with relief Set the drive lever 4 to the centre position Set switch 2 to position C Set the pressure using pressure regu lating valve 7 read the pressure off at the manometer 6 Basic set tin...

Page 208: ...D 40 32 1 2...

Page 209: ...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...

Page 210: ...D 40 34 1 3 10 9 2 8 7 6 5 4...

Page 211: ...s OFF Switch the screed heater system off Switch lighting OFF Switch off the ignition 9 Close the main shut off valves and the bottle valves for the screed gas heater system Remove the levelling units...

Page 212: ...D 40 36 2 Malfunctions 2 1 Error code query for engine 3 1 2...

Page 213: ...the warning lamps 1 or 2 a code to which a defined fault is assigned can be displayed using the query switch 3 Output of the flash code is performed by the other warning lamp if a fault is displayed b...

Page 214: ...h 3 into display position until the three digit code has been output via the warning lamp While the switch for error queries is being actuated the warning lamp which first signalled the fault which oc...

Page 215: ...the warning lamp which signalled the fault lights up again This continues until the corresponding error or malfunction has been rectified A If several errors occur at the same time the various flash c...

Page 216: ...D 40 40 2 2 Error codes...

Page 217: ...D 40 41...

Page 218: ...D 40 42...

Page 219: ...D 40 43...

Page 220: ...D 40 44...

Page 221: ...D 40 45...

Page 222: ...D 40 46...

Page 223: ...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...

Page 224: ...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 cha...

Page 225: ...he 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 H...

Page 226: ...Hydraulic oil level is too low Top up oil Leak in the suction line Tighten the connections Flow rate regulator defective Replace Leaking seals of the hydraulic cylinder Replace Control valve is defect...

Page 227: ...pply interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote con trol is set to Auto Set the switch to Manual Power supply interrupted Check...

Page 228: ...ervo 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 Repla...

Page 229: ...ydrau lic system hot hydraulic fluid may spurt out at high pressure Switch off the engine and depressurise the hydraulic system Protect your eyes Mount all protective devices before re commissioning t...

Page 230: ...g thickness 10 cm Min height setting 18 cm from the ground A An incorrect height setting can result in the following problems during paving Auger too high Too much material in front of the screed mate...

Page 231: ...by alternatingly adjusting the right hand and the left hand side The current height can be read at the scale 2 2 3 Hydraulic adjustment o Determine the currently set height of the auger crossbeam left...

Page 232: ...the attaching point on the material shaft Carry out height adjustment Push the slewing brackets with braces onto the attaching point on the material shaft Install the split pin 1 and retaining pin 2 a...

Page 233: ...g the adjustment rods 5 until the retaining pins can be inserted Retighten the lock nuts 4 Install the split pin 1 and retaining pin 2 m Each time the height is adjusted the auger must be realigned vi...

Page 234: ...king widths of more than 3 00 m the auger should be fitted with extension parts on both sides to improve material distribution and to reduce the wear f The diesel engine must be switched off whenever...

Page 235: ...ts 2 bolts washers nuts Dismantle the assembly parts 3 of the adjacent auger blade remove plug 4 Insert the auger shaft extension into the auger shaft Reinstall the previously removed assembly parts 3...

Page 236: ...ing to the brace shaft with the relevant assembly parts 4 bolts washers pins A If necessary insert fitted plates 5 Reinstall the previously removed assembly parts 1 and simultaneously tighten the auge...

Page 237: ...ismantle the assembly parts 5 of the adjacent auger blade remove plug 6 Insert the auger end bearing 7 into the auger extension Secure the auger end bearing to the material shaft with the relevant ass...

Page 238: ...640L Auger extension part 640 mm left 640R Auger extension part 640 mm right 960L Auger extension part 960 mm left 960R Auger extension part 960 mm right 320 Material shaft 320 mm 640 Material shaft 6...

Page 239: ...E 10 11 Symbol Meaning Outer auger bearing Auger end bearing...

Page 240: ...E 10 12 Auger upgrading working width 3 14 m Auger upgrading working width 3 78 m Auger upgrading working width 4 42 m 320 R 320 L 320 320 640 640 640 R 640 L 640 640 640 R 640 L 320 R 320 L 320 320...

Page 241: ...E 10 13 Auger upgrading working width 5 06 m Auger upgrading working width 5 70 m 320 L 320 320 R 320 960 R 960 L 960 960 960 R 960 L 960 960 640 640 640 R 640 L...

Page 242: ...E 10 14 Auger upgrading working width 6 34 m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960...

Page 243: ...E 10 15 Auger upgrading working width 6 98 m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960 320 L 320 320 R 320...

Page 244: ...E 10 16 Auger upgrading working width 7 62 m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960...

Page 245: ...E 10 17 Auger upgrading working width 8 26 m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960 320 L 320 320 R 320...

Page 246: ...E 10 18 Auger upgrading working width 8 90 m 960 BR 640 R 160 L 640 L 960 BL 640 640 640 R 640 L 640 640 L 640 640 R 960 L 960 160R 960 R 960 m m...

Page 247: ...E 10 19 3 3 Mounting the auger brace 11 8 12 20 19 15 14 26 16 18 26 21 1 10 13 17 27 23 1 2 3 4 5 6 7 18 22 23 24 25...

Page 248: ...ace bracket 8 and secure with the retain ing pin 11 Secure the retaining pins 11 with a split pin 12 A The first brace set must be set in the rear bore If the operating width necessitates a second bra...

Page 249: ...ust the length of the adjustment rod here The rotational direc tion for extending or shortening the adjustment rod is determined by the left hand thread L or right hand thread R A A cord which aligns...

Page 250: ...reed retraction Mount the left right material shafts on the auger box with the relevant assembly parts 1 A If a terminal bearing is mounted for the existing auger width the adapter plate 2 also has to...

Page 251: ...hopper scrapers 1 must be adjusted at both hopper halves Loosen the mounting screws 2 Adjust a gap of 6 mm across the whole length of the scraper Retighten the mounting screws 2 properly f Risk of inj...

Page 252: ...t be adjusted to the prevailing paving conditions e g positive or negative crowning etc Loosen screw 2 and remove screws 3 Adjust guide plate to the required size basic setting 25mm Retighten the moun...

Page 253: ...between the auger and screed Loosen the four mounting screws 1 Remove the screws and move the ve hicle forwards The crossbeam remains in its position on slide rails now tighten the screws 1 back down...

Page 254: ...are provided for mounting on the sensor s retaining plate A The digital slope controller must be mounted in such a way that the marking arrow on the housing points in the direction of travel A The an...

Page 255: ...d Tighten the pin 2 so that the sensor arm is just still able to swivel A The sensor arm can be secured on the side board with the lock 3 5 3 Mounting the grade control system Insert the grade control...

Page 256: ...at the lock 5 Height adjustment for analogue grade sensors is carried out by means of a crank 6 To lock it the crank is inserted into one of the available notches following the adjustment work A All...

Page 257: ...xtensions A The big ski enables the alignment of the individual sensors at the front and rear to be shifted over the reference The sonic ski can actually be positioned in front of and be hind the vehi...

Page 258: ...side next to the screed or also above the screed This is dependent on the paving width required in each case A The procedure for mounting the big ski is the same in both cases A So that the big ski ca...

Page 259: ...et directly at the existing bores or as described in the following to secure it to the crossbeam using clamp ing plates A The front bracket is mounted directly be hind the traction point the rear brac...

Page 260: ...s 45 chamfer must point upwards Then slide the two swivel arms 3 onto the tube of the big ski bracket A The rear swivel arm is positioned rotat ed by 180 on the big ski bracket Slide a fixing ring 4 f...

Page 261: ...centre element together with the rear swivel arm until the front sliding part 4 can be pushed onto the front swivel arm from above Then secure the rear sliding part with a fixing ring 5 and the releva...

Page 262: ...th the 9 m and 13 m versions A Structure of the 9 m version Extension part at the front rear each Structure of the 13 m version Two extension parts at the front rear each Place the extension module 1...

Page 263: ...nce away from it A Extendable sensor brackets 1 are mounted in the two outer positions the normal sensor bracket 2 is mounted in the centre Place the sliding bracket 3 over the corresponding big ski e...

Page 264: ...bles the two outer sensors to be swivelled during paving for diverse requirements e g cornering By loosening the star handle bolts 5 the length of the extension arm can be adjusted The sensor bracket...

Page 265: ...ed to initially mount the distributor box 1 on the mounting plate 2 A The input connector always points in the direction of travel Then mount the mounting plate on one of the two sliding brackets 4 on...

Page 266: ...on diagram A The three sensors are connected to the distributor box and the distributor to the machine according to the following scheme Sensors Front 1 Centre 2 Rear 3 Distributor box 4 Machine inter...

Page 267: ...ending the screed Push the levelling piece 1 in the extension pipe 2 Tighten the clamping bolts at the extension pipe Push the extension 3 into the levelling piece 1 Secure properly with wing nuts 4 I...

Page 268: ...height sensing unit so that the sensing arm 13 lies on the refer ence wire 14 in the middle A Tighten the reference wire with the rope tensioner if too loose Connect the corresponding cable lead with...

Page 269: ...E 10 41 6 Automatic steering unit 20 2 1 3 6 7 8 4 12 9 10 5 11 17 18 15 16 14 21 13 19...

Page 270: ...nsion 5 onto the connection tube and fix in the same way Fix support wheel 6 in a suitable position using the corresponding assembly parts Heed vertical alignment Insert tube 7 to the required length...

Page 271: ...A The distance between the sensor and reference cable should be 350 mm A All assembly parts must be mounted and tightened properly to ensure safe and precise operation of the automatic steering unit...

Page 272: ...e operating panel as necessary The automatic steering unit can be overridden by actuating the steering potentiometer The switch 1 is used to set the sens ing side Right Automatic steering unit on the...

Page 273: ...E 10 45 7 Emergency stop during feeder operation A If the function is not in use the bridge connector must be fitted to the corres ponding socket as otherwise the travel drive is blocked 1...

Page 274: ...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...

Page 275: ...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 remo...

Page 276: ...et is placed in the open hopper and secured in position It is used to take larger volumes of material provided by a feeder m The material bucket may only be used in the following combinations MH2500 b...

Page 277: ...ap 2 t Swivelling side flaps 3 t Maintenance door 4 t Reflector plate for feeder clearance sensor 5 t Reflector plate extension pipe for operation on the side 6 t Fixture for paver option extraction s...

Page 278: ...E 10 50 Technical data Dimensions bucket MH2500 short version 3700 2185 1395 1645 3700 2550 1425 2185 1895...

Page 279: ...E 10 51 Dimensions bucket MH2550 long version 3690 2070 1320 1470 3690 3020 2070 1930 3000...

Page 280: ...ts Volume Bucket MH2500 short version approx 1 2t Bucket MH2550 long version approx 1 7t Bucket MH2500 short version approx 10 9 m3 24 0t approx 10 0m3 22 0t OFFSET Bucket MH2550 long version approx 1...

Page 281: ...ger 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 po...

Page 282: ...tted at these points No Pictogram Meaning C Warning hot surface risk of burning Hot surfaces can cause severe injuries Keep your hands a safe distance away from the danger area Use protective clothing...

Page 283: ...E 10 55 10 4 Instructive symbols prohibitive symbols warning symbols No Pictogram Meaning E Do not open hazard...

Page 284: ...g 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 o...

Page 285: ...th the stated values for permitted lashing force and load rating m Always tighten the lashing chains as stated by the manufacturer m Tighten the lashing straps as tight as possible m Lashing equipment...

Page 286: ...E 10 58 Lashing 1 2...

Page 287: ...the bucket and on the low load trailer Fasten the lashing straps as shown A Fasten the lashing straps diagonally to the bucket and to the lashing points on the low load trailer A Use non slip mats at...

Page 288: ...E 10 60 Loading with the crane MH2500 A 1 2 3...

Page 289: ...E 10 61 Loading with the crane MH2550 1 2 3 B...

Page 290: ...s 1 2 A A Loading example bucket MH2500 short version m The max permissible attachment point load at the attachment points is 44kN A B Loading example bucket MH2550 long version m The max permissible...

Page 291: ...E 10 63 Lash the bucket in the paver 1 4 3 2...

Page 292: ...s and straps must be secured to prevent them working loose and falling down unintentionally m Clean bucket and paver hopper before inserting the bucket remove material residues Removing adhering mater...

Page 293: ...E 10 65 Operation 2 1 1 7 A B 5 4 6 3 6 8 9 10...

Page 294: ...pe extension with the corresponding clamping levers 7 m When the reflector plate is fitted to the side this increases the basic width of the vehicle Note the danger area A The magnetic foil included i...

Page 295: ...If the bucket is inserted in a paver during cleaning the paver must be switched off and secured to prevent it being switched on again Spray all surfaces coming into contact with asphalt material with...

Page 296: ...s 1 when the mechanical assemblies have been mounted and set up PLC version Auger limit switches 2 Remote control 3 Grade control system 4 External levelling system 5 A When using an external levellin...

Page 297: ...esponding bridge connectors have been fitted on both sides of the machine Side board with mounted remote bracket Fit bridge connector 1 in the socket of the remote control and secure with cap Check th...

Page 298: ...E 10 70...

Page 299: ...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 ig...

Page 300: ...ces 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 pa...

Page 301: ...F 20 1 F 20 Maintenance review 1 Maintenance review 73 40 50 80 90 100 30 60...

Page 302: ...after the following service hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F30 q q q Auger F40 q q q q q q q Engine F50 q q q q q q Hydraulics F60 q q q q q...

Page 303: ...F 30 1 F 30 Maintenance conveyor 1 Maintenance conveyor...

Page 304: ...ransport close both halves of the hopper and fit the cor responding hopper transport safeguards When the vehicle is parked and during maintenance and transport raise the screen and fit the correspondi...

Page 305: ...f 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...

Page 306: ...e stopped or to break when material falls into the space between the chain and the sprocket An excessively slack chain may catch on protruding objects and be destroyed Adjustment of chain tension A On...

Page 307: ...g the chains would lead to the destruction of 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 Conveyo...

Page 308: ...has been set properly the chain must be able to move freely approx 10 15 mm To re tension the chains Unfasten mounting screws A and lock nut B slightly Use the tensioning screw C to set the required...

Page 309: ...eflectors 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...

Page 310: ...F 30 8...

Page 311: ...F 40 1 F 40 Maintenance auger assembly 1 Maintenance auger assembly...

Page 312: ...move 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 togethe...

Page 313: ...lanetary gear Check oil level q Auger planetary gear Top up oil g q Auger planetary gear Change oil 3 q Auger drive chains Check tension q Auger drive chains Adjust tension 4 q Auger box Check oil lev...

Page 314: ...If necessary 6 g Gearbox bolts Check tightening q Gearbox bolts Tighten to correct torque 7 g g Outer bearing bolts Check tightening q Outer bearing bolts Tighten to correct torque 8 q Auger blade Ch...

Page 315: ...any bitumen res idues which may have entered and to supply the bearings with fresh grease when warm A If the auger is extended the outer rings should be loosened slightly when initially greasing the o...

Page 316: ...oil into the filler bore at B until the oil level has reached the lower edge of the inspec tion bore A Screw the filler B and inspection screws A back in To change oil A The oil should be changed when...

Page 317: ...augers outer circumference should be 10 mm f Risk of injury due to sharp edged parts To re tension the chains Release the mounting screws A Set the chain tension correctly using the threaded pins B Ti...

Page 318: ...hange oil A The oil should be changed when at oper ating temperature Place a suitable collecting container under the auger box Loosen bolts D from the circumfer ence of the worm shaft flange A The oil...

Page 319: ...ing rings 5 A After reaching operating temperature check the gearbox for leaks m In case of visible leaks e g between the flange surfaces A of the gearbox re placement of the seals and sealing rings i...

Page 320: ...box bolts must be checked A Please check which gear version is used in your vehicle Tighten to the following torques if nec essary A 86 Nm B 83 Nm C 49 Nm D 49 Nm E 86 Nm m Check that each bolt has at...

Page 321: ...ng the running in period the tightening torques of the outer auger bearing mounting screws must be checked Tighten to the following torques if nec essary F 210 Nm m If the auger s working width is cha...

Page 322: ...ed 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...

Page 323: ...enance engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work a...

Page 324: ...move 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 togethe...

Page 325: ...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 syste...

Page 326: ...lter Air filter cartridge Replace 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...

Page 327: ...0 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 Engine drive belt Replace drive belt Maintenance...

Page 328: ...not run dry and time consuming venting bleeding can therefore be avoided For filling in the fuel Unscrew cap A Fill in fuel through the filling port until the required fill lever is achieved Replace t...

Page 329: ...in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use dipstick to check level again Oil change A The oil drain screw is accessed via t...

Page 330: ...optional asphalt fume control system there is a drainage hose behind the left side flap Place the end of the oil drain port hose E1 in the collection container Remove the screw cap with a wrench and a...

Page 331: ...ch or filter strap and unscrew it Clean the contact surface Apply light coating of oil to the gasket on the new filter and fill filter with oil before installing it Tighten filter by hand A After inst...

Page 332: ...leting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two fil ters Prefilter with water separator C Main filter D Prefilter draining of water A Drain t...

Page 333: ...lunger is now pressed out via the spring Pump until a very high resistance is perceptible and pumping can only be carried out very slowly Now continue pumping a few more times The return line must be...

Page 334: ...ty dust collector Empty the dust removal valve A on the air filter housing by compressing the discharge slot Remove any baked on dust by press ing together the upper valve section A Clean the dust rem...

Page 335: ...r Open the air filter housing B at the clips C Move filter element D to the side a lit tle and then pull it out of the housing Pull out the safety element E and check for signs of damage A Replace the...

Page 336: ...m is under pressure When it is opened there is 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 r...

Page 337: ...y 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 concentrat...

Page 338: ...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...

Page 339: ...F 60 1 F 60 Maintenance hydraulic system 1 Maintenance hydraulic system...

Page 340: ...cure 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...

Page 341: ...il tank Top up with oil q Hydraulic oil tank Change oil and clean 2 q Hydraulic oil tank Check maintenance indicator q q Hydraulic oil tank Intake return hydraulic filter change vent q Hydraulic oil t...

Page 342: ...p oil q Pump distribution gear Change oil q Pump distribution gear Check bleeder q Pump distribution gear Clean bleeder 5 g q Hydraulic hoses Visual inspection g q Hydraulic system Leak test q Hydraul...

Page 343: ...on the side of the tank For filling in the oil Remove cap B Fill in oil through the filling opening un til the oil level rises to the centre of the sight glass A 5mm Screw cap B on again A Regularly...

Page 344: ...w seal A When using the drainage hose o Unscrew seal cap E Screwing on the oil drainage hose F opens the valve to let the oil drain out Place the end of the hose in the collecting vessel and let the o...

Page 345: ...mounting screws A and lift off cover Disassemble the removed unit into Cover B Separating plate C Filter D Dirt trap E Clean the filter housing cover sepa rating plate and dirt trap Check the O rings...

Page 346: ...ace a transparent hose H onto the bleed screw ending in a suitable con tainer Start the up drive engine at idle speed Close the bleed screw G as soon as the oil forced through the hose is clear and th...

Page 347: ...cartridge Clean the filter housing Insert the new filter cartridge Replace the seal ring of the filter hous ing Turn on the filter housing by hand and tighten it using a wrench Start trial operation a...

Page 348: ...r a moment as the oil which has been poured in first has to flow off 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 col...

Page 349: ...F 60 11 Bleeder A The bleeder A can be found on the rear of the pump distribution gear housing The functioning of the bleeder must be ensured If soiling has occurred the bleeder should be cleaned A...

Page 350: ...ng 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 f...

Page 351: ...ning 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...

Page 352: ...oth 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 Whe...

Page 353: ...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...

Page 354: ...F 60 16...

Page 355: ...F 73 1 F 73 Maintenance drive units 1 Maintenance drive units...

Page 356: ...ransport close both halves of the hopper and fit the cor responding hopper transport safeguards When the vehicle is parked and during maintenance and transport raise the screen and fit the correspondi...

Page 357: ...1000 annually 2000 every 2 years If necessary 1 q Chain tension Check q Chain tension Adjust q Chains Relieve 2 q Bottom plates Check wear q Bottom plates Replace 3 q Rollers Check for leaks q Roller...

Page 358: ...years If necessary 4 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality q Planetary gear Screw connections Check q Planetary...

Page 359: ...nt safety measures and should only be carried out by a specialist workshop A Your Dynapac customer service will be happy to provide support during maintenance repair and the replacement of wearing par...

Page 360: ...ler wheel thereby increasing wear levels m If the chains are tensioned too tightly this increases wear on the idler wheel and drive unit mounting and also increases wear on track bolts and bushes Chec...

Page 361: ...ain to the idler wheel is as shown in diagram A A Correct if necessary by moving the vehicle a little Insert a measuring rule between the sliding piece C and D of the track to determine the maximum sl...

Page 362: ...nce again as described above A If the tension is too high see section Relieving the chain A Repeat this procedure on both drive units Relieving the chain f The grease in the tensioning element is unde...

Page 363: ...e with the front edge A over the chain links bolt eye B Lubricate the threads and the contact surfaces beneath the bolt heads with a thin film of oil or grease Insert the bolts C into the holes and sc...

Page 364: ...measures when rais ing and securing loads Remove the defective roller Install the new roller using new as sembly parts Tighten the bolts without applying sig nificant torque Tighten the bolts diagonal...

Page 365: ...bore at A until the oil level has reached the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at oper ating temperature m Ensure that no dir...

Page 366: ...re located at the rear of the gearbox Oil inlet B Oil level check C Oil drain D A Carry out the oil level check and oil change as per the description above m When draining using the drain D a small re...

Page 367: ...to increased wear and to the destruction of components The correct tightening torque for the connecting screws for the gearbox chain sprocket A is 150Nm 17Nm 90 9 The correct tightening torque for the...

Page 368: ...F 73 14...

Page 369: ...F 80 1 F 80 Maintenance electrical system 1 Maintenance electrical system...

Page 370: ...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...

Page 371: ...electrolyte check q Top up with distilled water q Apply grease to battery terminals 2 q Generator Electrical system insulation monitoring Check function o q Alternator Visual check for pollution or d...

Page 372: ...ust be free of oxide and protected with a special termi nal grease m When removing the batteries always first remove the negative terminal en suring that the battery terminals cannot be short circuite...

Page 373: ...very 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 automat...

Page 374: ...s conducted successfully work may be undertaken with the screed and external consumers may be used If the insulation fault indicator lamp displays a fault even before the test button is pressed or if...

Page 375: ...ied 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...

Page 376: ...erator m The generator must be regularly checked for excessive dirt and must be cleaned if necessary The air intake 1 and fan shroud 2 must be kept free of dirt m Cleaning with a high pressure cleaner...

Page 377: ...9 Electrical fuses relays 2 Main fuses A A Main fuses B Fuses in terminal box C Relays in terminal box F A F1 1 Main fuse 50 F1 2 Main fuse 50 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 C...

Page 378: ...F 80 10 Fuses in terminal box B 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10...

Page 379: ...used F16 24V sockets 10 F17 Indicator displays 5 F18 Auger 10 F19 not used F20 Rotary beacon o 10 F21 Travel drive computer voltage supply 25 F22 not used F23 Horn 10 F24 Engine start 10 F25 not used...

Page 380: ...F 80 12 Relays in terminal box C 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10...

Page 381: ...working lights 8 Rear working lights 9 Horn 10 Start inhibit emergency stop 11 Start inhibit 12 Rotary beacon o 13 not used 14 not used 15 not used 16 Reverse buzzer o 17 not used 18 not used 19 not...

Page 382: ...nel D K 1 Floating position 2 Screed start auto 3 Screed hazard warning flashers left hand 4 Screed hazard warning flashers right hand 30 Lock screed extend retract l h 31 Lock screed extend retract r...

Page 383: ...F 80 15 Relays in the engine compartment E K 0 Engine start...

Page 384: ...F 80 16...

Page 385: ...Maintenance 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...

Page 386: ...m 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...

Page 387: ...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 hyd...

Page 388: ...n a fill level above the MIN mark a on the tank Top up lubricant tank A lubricating nipple b is located on the lubricant tank a for filling purposes Connect the grease gun c enclosed on delivery to th...

Page 389: ...ricant 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 cons...

Page 390: ...Remove the lubrication line a and install a normal lubricating nipple b Connect the grease gun c en closed on delivery to the lubricating nipple b Operate the grease gun until the lu bricant visibly...

Page 391: ...F 90 7 Bearing points 2 A One lubricating nipple A is located at each hydraulic cylinder bearing point top and bottom A One lubricating nipple B is located at each push roller bearing point 2x A 2x B...

Page 392: ...F 90 8...

Page 393: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping...

Page 394: ...00 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...

Page 395: ...actions to correct any detected malfunction to avoid damages dan gers or environmental hazards 3 Check that the bolts and nuts fit firmly Bolts and nuts must be checked regularly to ensure that they f...

Page 396: ...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 Remo...

Page 397: ...rts 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...

Page 398: ...F 100 6 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 399: ...ved 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 build...

Page 400: ...sposal 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 electro...

Page 401: ...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 1...

Page 402: ...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...

Page 403: ...s listed below or comparable 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...

Page 404: ...F 110 2 2 4 7 5 6 6 3 1...

Page 405: ...es 3 Fuel tank Diesel fuel 350 litres 4 Hydraulic oil reservoir Hydraulic oil 200 litres 5 Pump distribution gear Gearbox oil 7 0 litres 6 Planetary gear drive unit Gearbox oil 3 5 litres 7 Planetary...

Page 406: ...o Exxon Fuchs Mobil Shell Paroil E Emission Green Dynapac AGIP Chevron Caltex Delo Petronas Coolant 100 Antifreeze Spezial Extended Life Coolant Extended Life Coolant Extended Life Coolant Frost G12 D...

Page 407: ...rease A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 200 Omala S2 GX 220 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 200 Omala S2 GX 220 Dynapac Aral BP Esso Exxon Fuchs...

Page 408: ...l pressure fluids to biodegradable pressure fluids please contact our factory advisory service Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 Shell Naturelle HF E46 Panolin HLP SYNTH 46...

Page 409: ...encounter any operational problems or have enquiries about spare parts Our trained specialist staff will ensure that you receive prompt attention and repairs in the event of any ac cident or malfuncti...

Page 410: ...www dynapac com...

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