Dynapac MF2500CM Operating Instructions Manual Download | Manualshive

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D 41 37

A hydraulic emergency function can be used if a technical defect means it is no longer
possible to lower the slewing belt or hydraulic end piece.

m

Observe the danger zone of the conveyor belt being lowered! Proceed with two

people

(one person on each side of the machine).

A

There is a lowering brake valve (3). in each case on both hoisting cylinders (1)
on

the

left and right of the slewing belt / on both hoisting cylinders (2) of the hydraulic

end piece.

- Remove the protective cap from the lowering brake valve.
- Loosen the lock nut (4) of the hexagon socket screw (5).
- Tighten the hexagon socket screw (5) a quarter of a turn clockwise alternately at

the left and right hoisting cylinder until the conveyor belt starts to lower and finally
reaches its end position.

A

There is no possibility of readjusting the lowering brake valve on site.

This is why the lowering brake valve then has to be replaced at both cylinders!

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Summary of Contents for MF2500CM

Page 1: ...Operating Instructions Feeder MF2500CS MF2500CM Type 704 705 04 0119 4812071991 ...

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

Page 3: ...es and functions 2 2 1 Vehicle 5 Construction 5 3 Danger zones 9 3 1 Danger zone standard version 9 3 2 Danger zone with slewing belt option 9 4 Safety devices 11 5 Technical data 13 5 1 Dimensions MF2500CS standard version all dimensions in mm 13 5 2 Dimensions MF2500CS with slewing belt option SW5500 all dimensions in mm 14 5 3 Dimensions MF2500CS with slewing belt option SW6500 all dimensions i...

Page 4: ...42 o 43 6 10 Engine type plate 44 7 EN standards 45 7 1 Continuous sound pressure MF2500CS CM Cummins QSB 6 7 B6 7 45 7 2 Operating conditions during measurement 45 7 3 Vibration acting on the entire body 45 7 4 Vibrations acting on hands and arms 45 7 5 Electromagnetic compatibility EMC 45 C11 Transportation 1 1 Safety regulations for transportation on a low bed trailer 1 2 Transportation on low ...

Page 5: ...ng unit front 58 Side operating unit rear 62 Side operating unit slewing conveyor belt SW5500 o 66 Side operating unit slewing conveyor belt SW6500 o 70 Joystick travel drive slewing belt o 74 D23 Operating the display 1 1 Operation of the input and display terminal 2 Button layout on the display 2 1 1 Menu operation procedure for adjusting parameters 5 Selecting and changing an adjustment paramet...

Page 6: ...e following information 40 Lock menu 41 Service report menu 42 Display of the following information 42 Report for Dynapac service technician step I 43 Report for Dynapac service technician step II 44 Report for servicing carried out by the customer step I 45 Report for servicing carried out by the customer step II 46 3 Terminal error messages 47 Status warning and error messages symbols 47 3 1 Err...

Page 7: ...or 29 Distance display 30 Automatic steering unit 32 1 1 Mounting the automatic steering unit on the feeder 33 Mounting and aligning the sensor 34 Connecting the sensor 34 Tray 35 Fuse box 35 Illuminated balloon o 36 Installation and operation 38 Decommissioning 39 Cleaning 39 Service safety 39 D41 Mode of operation 1 1 Preparing for operation 1 Required devices and aids 1 Before starting work in ...

Page 8: ...function 36 2 3 Lower height adjustable platform o in the event of a malfunction 38 E Set up and modification 1 1 Special safety instructions 1 2 Automatic steering unit 2 2 1 Mounting the automatic steering unit 3 Mounting and aligning the sensor 4 Connecting the sensor 4 Automatic steering unit operating instructions 5 3 Mount slewing belt SW5500 o 6 Preparing the vehicle 6 Preparing the slewing...

Page 9: ...scraper into working position before starting work carry out function test adjust distance 21 Clean scraper routine check 23 Wear check readjust replace scraper blades 25 Scraper basic setting 26 Screw connections 5 27 Lubrication points 6 28 Belt drive guide 28 Bearing points 28 Guide rails 7 29 Conveyor side shields 8 30 F32 Maintenance slewing belt 1 1 Maintenance conveyor belt 1 1 1 Maintenanc...

Page 10: ...nveyor belt frame for deposits clean 2 11 Double scraper 4 13 Relieve scraper 14 Move scraper into working position before starting work carry out function test adjust distance 16 Clean scraper routine check 18 Wear check readjust replace scraper blades 20 Screw connections 5 21 Lubrication points 6 22 Swivel joint bearing 22 Belt drive guide 22 Bearing points 23 Chain guide 7 24 Conveyor side shi...

Page 11: ...ve belt 7 32 Crankshaft ventilation filter 8 33 Exhaust system diesel oxidisation catalytic converter 9 34 F53 Maintenance engine assembly Stage V o 1 1 Maintenance engine assembly 1 1 1 Maintenance intervals 3 1 2 Points of maintenance 7 Engine fuel tank 1 7 Engine lube oil system 2 9 Engine fuel system 3 12 Engine air filter 4 14 Engine cooling system 5 16 AdBlue DEF tank 6 18 AdBlue DEF tank su...

Page 12: ...ce intervals 3 1 2 Maintenance points 6 Chain tension 1 6 Bottom plates 2 9 Rollers 3 10 Planetary gear 4 11 Screw connections 12 Lubrication points 5 13 Drive unit guide 13 F81 Maintenance electrical system 1 1 Maintenance electrical system 1 1 1 Maintenance intervals 3 1 2 Maintenance points 4 Batteries 1 4 Recharging the batteries 5 2 Electrical fuses relays 6 2 1 Main fuses A 6 2 2 Fuses in te...

Page 13: ...intervals 2 2 General visual inspection 3 3 Check that the bolts and nuts fit firmly 3 4 Inspection by an expert 4 5 Ladders steps 4 6 Cleaning general 5 7 Cleaning the conveyor system 6 Before the work session 7 During the work session 7 After the work session 8 8 Preserving the feeder 11 8 1 Shutdowns for up to 6 months 11 8 2 Shutdowns lasting from 6 months to 1 year 11 8 3 Recommissioning the ...

Page 14: ...ecifications 4 2 1 Drive engine TIER IV o fuel specification 4 2 2 Drive engine TIER 3 4F Stage V o lubricating oil 4 2 3 Cooling system 5 2 4 Hydraulic system 5 2 5 Pump distribution gear 5 2 6 Drive unit planetary gear 5 2 7 Separator emulsion 6 2 8 Chain oil 6 2 9 Grease 6 2 10 Drive engine AdBlue DEF 7 2 11 Hydraulic oil 8 ...

Page 15: ...age 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 vehicle descr...

Page 16: ... responsible 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 and prop...

Page 17: ... 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 impo...

Page 18: ... switched 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 ...

Page 19: ...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 20: ...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 21: ...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 22: ... 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 23: ...tion m Also observe the manufacturer s documentation and additional documentation A For example the maintenance instructions of the engine manufacturer t Used to indicate standard equipment o Used to indicate optional equipment ...

Page 24: ...ecified in the valid regulations and amendments together with harmo nised standards and other valid provisions 3 Guarantee conditions A The guarantee conditions are included in the scope of supply of the vehicle This contains a complete specification of the valid conditions The guarantee becomes null and void if damage occurs through malfunctions caused by improper use and incorrect operation repa...

Page 25: ...the operating range of the vehicle caused by wrong or improper use of the vehicle defective or missing safety devices use of the vehicle by untrained uninstructed staff defective or damaged parts incorrect transport of the vehicle incorrect maintenance or repairs leaking operating substances emission of noise and vibrations impermissible operating substances Existing residual risks can be avoided ...

Page 26: ...predictable incorrect usage of the vehicle includes presence in the danger zone of the vehicle transporting persons leaving the operator s platform while the vehicle is operating removing protection or safety devices starting and using the vehicle outside of the operator s platform failing to comply with the maintenance instructions omission or incorrect execution of maintenance or repair work spr...

Page 27: ... operator An operator within the meaning of these operating instruc tions is defined as any natural or legal person who either uses the feeder himself or on whose behalf it is used In special cases e g leasing or renting the operator is considered to be the person who in accordance with existing contractual agreements between the owner and the user of the feeder is charged with the observance of t...

Page 28: ...A 2 ...

Page 29: ...nsport ve hicles for the provision of material A material compartment whose lateral covers can be folded in to achieve better emp tying and even material conveying is used to accept material Material conveying is carried out using a rubber conveyor belt Material transfer is carried out into a material compartment adapted to the paver fin isher it is positioned in the paver finisher s hopper ...

Page 30: ...B 2 2 Description of assemblies and functions 1 3 6 4 11 16 2 5 7 15 18 14 12 8 10 9 20 21 19 13 17 23 11 22 ...

Page 31: ...B 3 24 25 ...

Page 32: ...acket seat swivelling 10 t Operating panel laterally moveable swivelling 11 t Protective roof 12 t Conveyor belt 13 t Conveyor belt drive 14 t Conveyor belt heat resistant 15 t Conveyor scraper 16 t Working lights 17 o Slewing conveyor belt 18 o Swivel cylinder left right 19 o Conveyor belt heat resistant 20 o Conveyor belt drive 21 o Conveyor scraper 22 t Material chute stone guard 23 o Hoppers w...

Page 33: ...evant work conditions Operation of the feeder is made considerably easier by the clearly arranged operating elements and controls The following extra equipment option is available o Slewing conveyor belt o Automatic steering unit o Feeder paver finisher distance control o Material requirement signal system o Additional headlights warning lamps work lighting o Camera system o Reverse buzzer o 12 vo...

Page 34: ...ctive Catalytic Reducer and an AdBlue DEF injection system The emission of exhaust gases which are harmful to the environment and health is significantly reduced Drive unit Both caterpillar drives are directly driven by separate drives They operate directly without any drive chains which require maintenance or servicing The tension of the caterpillar chains can be readjusted using tensioners For a...

Page 35: ... positions Material compartment hopper The hopper inlet is equipped with a conveyor sys tem for emptying and transporting the material onwards The hopper can hold approx 12 0 t To facilitate emptying and achieve even material transfer each of the lateral covers of the hopper can be hydraulically folded in The hydraulic front hopper flaps ensure that no material remains in the front area of the hop...

Page 36: ...ly maintained Central lubricating system o A central lubrication pump ensures that the convey or belt chain links are lubricated with chain oil at adjustable intervals Hopper remixer o Two wear resistant conical augers in the hopper halves ensure that the material temperature is homogenised The somewhat colder material the outside is added uniformly to the hot flow of mate rial on the conveyor The...

Page 37: ...B 9 3 Danger zones 3 1 Danger zone standard version 3 2 Danger zone with slewing belt option ...

Page 38: ...vehicle operator must ensure that no one is in the danger zone Sound the horn before driving away Comply with all further information in these instructions and in the safety manual Heed the danger zones of other vehicles and machin ery being used in the construction site area Persons in the danger zone can suffer severe or fatal inju ries from movements and functions of the vehicle Never stand in ...

Page 39: ...B 11 4 Safety devices 3 4 5 7 1 1 6 11 8 9 2 10 ...

Page 40: ... the function of these devices at regular intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation 1 Hopper transport safeguard 2 Main switch 3 Emergency stop button 4 Horn 5 Ignition key 6 Lights 7 Protective roof latch 8 Warning lights 9 Fire extinguisher 10 Hopper hazard warning flasher 11 Covers lateral flaps coverings ...

Page 41: ...B 13 5 Technical data 5 1 Dimensions MF2500CS standard version all dimensions in mm 2500 1255 3240 2550 2090 320 3090 3345 9200 2520 3100 2365 4000 3100 570 3900 2155 2280 ...

Page 42: ...B 14 5 2 Dimensions MF2500CS with slewing belt option SW5500 all dimensions in mm 5995 55 55 5025 14300 4320 3310 2005 1080 2705 ...

Page 43: ...B 15 5 3 Dimensions MF2500CS with slewing belt option SW6500 all dimensions in mm 7057 55 55 5025 15284 4993 3887 2237 1322 3787 ...

Page 44: ...B 16 5 4 Dimensions MF2500CS hydraulically adjustable end piece all dimensions in mm 2560 2180 ...

Page 45: ...B 17 5 5 Dimensions slewing belt SW5500 solo all dimensions in mm 7605 2260 1630 5420 ...

Page 46: ...B 18 5 6 Dimensions slewing belt SW6500 solo all dimensions in mm 8555 2170 6953 1850 ...

Page 47: ...B 19 5 7 Dimensions MF2500CM standard version all dimensions in mm 10240 2155 2440 min 2130 4000 3100 530 3900 2950 max 3020 min 3050 max 3925 2280 2500 1255 3240 2550 2090 320 3090 3345 ...

Page 48: ...B 20 5 8 Allowed angle of rise and slope 5 9 Allowed angle of rise and slope with slewing belt option max 15 max 15 max 15 max 15 max 10 max 10 max 15 max 15 max 15 ...

Page 49: ...B 21 5 10 Permissible approach angle max 10 max 10 ...

Page 50: ...approx 4 5 Slewing belt SW6500 approx 4 6 With additional hopper remixer approx 0 5 With additional conveyor remixer approx 0 5 Transport speed 0 4 km h Operating speed 0 25 m min Conveying rate solo feeder 4000 t h Conveying rate with conveyor remixer 1000 t h Conveying rate with slewing belt SW5500 o 2000 t h Conveying rate with slewing belt SW6500 o 1500 t h Main belt Slewing belt MF2500CS CM 1...

Page 51: ...age IIIa Tier 3 Fuel consumption full load Fuel consumption 2 3 load 44 8 l h 29 9 l h Fuel tank capacity See chapter F Make type Cummins QSB 6 7 C225 Version 6 cylinder diesel engine water cooled Performance 168 KW 225 PS at 2200 rpm Pollutant emissions in accordance with Stage IV Tier 4final Fuel consumption full load Fuel consumption 2 3 load 42 1 l h 28 1 l h Fuel tank capacity See chapter F M...

Page 52: ...ive Conveyor belt Operating functions Fan Hydraulic oil reservoir volume See chapter F Volume Approx 6 5 m3 approx 13 0 t Minimum inlet height centre 580 mm Hopper width outside open 3335 Type Rubber conveyor belt Width main conveyor belt 1200 mm Width slewing conveyor belt 1380 mm Drive Hydrostatic continuously controllable Conveying volume controller Fully automatic via configurable switching po...

Page 53: ...s 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 meaning and position of the warning and information signs Comply with all further information in these instructions and in the safety manual CAUTION ...

Page 54: ...B 26 50 1 3 2 4 5 26 24 60 20 53 27 22 21 51 8 34 24 3 7 33 28 23 29 30 31 52 22 21 22 21 25 1 12 ...

Page 55: ...B 27 42 xxxxxxxxxxxxxxxxx 40 41 70 6 6 72 73 73 10 10 75 75 ...

Page 56: ...B 28 9 74 76 3 21 21 22 22 75 11 76 11 21 22 21 22 75 42 54 77 55 9 3 72 4 4 4 ...

Page 57: ...B 29 A on both sides of the vehicle 78 ...

Page 58: ...B 30 6 1 Remixer sign o 10 13 13 13 10 10 ...

Page 59: ...engine and remove the ignition key before performing any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause se vere to fatal injuries Switch the engine off and remove the ignition key 3 Warning Danger of crushing Crushing points can cause severe or fatal injuries Maintain a safe distance from the danger area 4 Warning Hot surface Risk of bu...

Page 60: ...uctions 8 Warning Danger from running engine If the drive engine is left running this can cause severe to fatal injuries Never open the engine hood while the engine is running 9 Warning Danger of crushing from above Crushing points can cause severe or fatal injuries Maintain a safe distance from the danger area 10 Warning Danger of crushing fingers and hands due to moving accessible vehicle parts ...

Page 61: ...o the engine electronics After the drive engine is switched off the on board voltage may not be switched off until after a period of 100 seconds main switch Always observe the operating instructions 13 Warning Danger of being pulled in by the chain or belt drive Being pulled in by the chain or belt drive can cause severe injuries to the hands and arms Keep your hands a safe distance away from the ...

Page 62: ...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 63: ... of the filling and control point 28 Engine oil drainage point Position of the drainage point 29 Hydraulic oil Position of the filling point 30 Hydraulic oil level Position of the control point 31 Engine oil drainage point Position of the drainage point 32 Gearbox oil Position of the filling and control point ...

Page 64: ...B 36 No Pictogram Meaning 33 Gear oil drainage point Position of the drainage point 34 Separator fluid spraying system filling point Position of the filling point m Only fill in Belt Guard 4812019375 ...

Page 65: ...B 37 6 4 CE marking No Pictogram Meaning 40 CE sound output level ...

Page 66: ...mponent with water 52 Warning on dangers posed by batteries 53 First aid kit 54 O Escape route A In the event of a vehicle malfunction the raised control platform can be left via this route Emergency steps ladder 55 O Not an escape route A In the event of a vehicle malfunction this route may not be used to leave the raised control platform ...

Page 67: ...mmation Avoid contact with the human body also avoid inhaling the vapours and seek med ical 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 dis posal regulations Diesel fuel complies ...

Page 68: ...r belt sag When the conveyor belt end piece is in the horizontal position conveyor belt sag must be correctly set at the marked position Always observe the maintenance instructions 74 Attention Note rigid slewing con veyor belt scraper hydraulic switching Set hydraulic valve accordingto vehicle equipment Always observe the operating instructions 75 Attention Danger zone Entering the danger zone be...

Page 69: ...efore transport on the low bed trailer For transport on the low bed trailer all stand up vehicle elements must be adjusted to their lowest transport height Remove any loose removable items of equipment and stow them safely Always observe the operating instructions 78 Attention Sections of the vehicle move Danger of squeezing Vehicle movements can cause severe or fatal injuries Never enter the dang...

Page 70: ...n 1 Vehicle designation 2 Designation type 3 Year of construction 4 Serial number product identification number PIN 5 Operating mass incl all extension parts in kg 6 Maximum permitted total mass in kg 7 Maximum permitted axle load kg axle 1 8 Maximum permitted axle load kg axle 2 9 Maximum permitted axle load kg axle 3 10 Nominal power in kW 1 2 4 5 7 9 3 6 10 8 ...

Page 71: ... o A The punched serial number on the slewing belt must match the serial number 4 Item Designation 1 Vehicle designation 2 Slewing belt type 3 Year of construction 4 Serial number 5 Operating mass incl all extension parts in kg 1 2 4 5 3 ...

Page 72: ...ngine 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 operating instructions for the engine ...

Page 73: ... according to DIN EN 1032 are not exceeded 7 4 Vibrations acting on hands and arms When the vehicle is used properly the weighted effective acceleration values at the driver s seat of ahw 2 5 m s2 according to DIN EN ISO 20643 are not exceeded 7 5 Electromagnetic compatibility EMC The following limit values are observed according to the protection requirements of the EMC Directive 2004 108 EC Inte...

Page 74: ...B 46 ...

Page 75: ... trailer and cause severe to fatal injuries The transportation vehicle must always meet the requirements for transportation and be designed for this Ensure that the transportation vehicle is secured correctly during loading and unloading Do not enter the danger zone Always work with a banksman during loading and unloading Do not leave any load or loose parts on the vehicle Comply with all further ...

Page 76: ...y 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 the meaning of ...

Page 77: ...t escape when driv ing on an incline m Attachment and loading equipment must meet the conditions of the applicable acci dent prevention regulations m Remove all protruding or loose parts from the feeder Stow all parts securely m The vehicle must be cleaned all material deposits removed and all maintenance flaps closed correctly m Swivel in the operating panel guide and seat consoles insert the rel...

Page 78: ...r control platform o Close the hopper lids Engage both hopper transport safeguards Fully extend drive unit frame cylinders Raise slewing belt o Bring slewing belt into the centre position o Lower main conveyor belt o A Heed note Insert the retaining pin at the swivel arm o Deactivate set up mode ...

Page 79: ...C 11 5 m When fitted with SW6500 Once the vehicle has been driven onto the low bed trailer first the slewing belt must be aligned The vehicle must be restarted before the main conveyor can be lowered ...

Page 80: ... for securing loads positive fit force connection diagonal lashing etc in accordance with the specific transport vehicle m The low bed trailer must have the necessary number of lashing points with a lashing strength of LC 6 000 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 lo...

Page 81: ... for this Ensure that the transportation vehicle is secured cor rectly during loading and unloading Do not enter the danger zone Always work with a banksman during loading and unloading Only reliable persons may be used as banksmen who must have been received instructions about their task before taking up their activity This refers in particular to the hand signals to be used Standardised hand sig...

Page 82: ...ehicle s loading ramps must not exceed a ver tical angle of 10 Use the work gear and low engine speeds to drive onto the low bed trailer Caution Possible collision of parts When driving up inclines lock the lane clearer in the upper position NOTE ...

Page 83: ...ce 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 when fitted with slewing belt o Lashing chain permissible lashing force LC 6 000 daN or heavy load strap permissible la...

Page 84: ...e load has to be positioned further to the back of the vehicle Always observe the specifications regarding load distribution for the vehicle and the centre of gravity of the vehicle m The overall height X of 4 m must not be exceeded m The overall width X of 2 55m must not be exceeded X X MF2500CS standard MF2500CS slewing belt ...

Page 85: ...position Close the hopper and set the hopper transport safeguards 3 on both sides Lower slewing belt o to lowest position Lower height adjustable o conveyor belt to lowest position Lower control platform to lowest position o Switch the vehicle off Insert the retaining pin 4 at the swivel arm o Attach and secure the protective hood 5 to the operating panel Lower the roof and set the latches 6 prope...

Page 86: ... the vehicle in the direction of travel The lashing points on the vehicle and on the low bed trailer must be used The lashing equipment must be installed as shown m The vertical angle a must not be less or more than the 19 36 ranges The horizontal angle ß must not be less or more than the 6 39 ranges ...

Page 87: ...g must be performed to secure the vehicle counter to the direction of travel The lashing points on the vehicle and on the low bed trailer must be used Fas ten the lashing straps as shown m The lashing angles should be ß between 6 55 and a between 20 65 ...

Page 88: ...s the conveyor belt must be se cured by lashing down with lashing equipment and edge guards The lashing points on the low load trailer must be observed A The edge guards and the lashing straps must run beneath the supply lines m The lasting straps must reveal an LC value of at least 2 500 daN ...

Page 89: ...sk of collision Raise the front area of the vehicle chassis by completely extending the drive unit cylinders Start the engine and drive from the trailer at a low engine traction speed Park the vehicle in a secure spot and switch off the engine Remove the key and or cover the operating panel with the protective hood and secure it ...

Page 90: ...rsion 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 lower limit position Set bolts 3 in the respective posi tion on both sides of the roof A Place the pump lever in the bracket 6 m After lowering check whether the pin 7 of the side windows is located in the rel evant mounting 6 5 1 2 3 7 ...

Page 91: ...ust be made before lowering the roof Seat consoles swivelled in and locked Operating panel locked in a central position in front of one of the driver s seats Side windows closed Engine hood and lateral flaps closed Rotary beacon swivelled inwards and in lowest setting NOTE ...

Page 92: ...ow bed trailer must have the necessary number of lashing points with a lashing strength of LC 2 000 daN 5 1 Prepare low bed trailer and conveyor belt m Before loading begins non slip mats 1 must be fitted to the contact points where the conveyor belt stands on the low bed trailer A The conveyor belt can be raised with suitable lifting gear or a forklift truck The conveyor belt must be prepared for...

Page 93: ...tanding legs must be secured in lowered position with the corresponding retaining pins 3 Open the openings 4 for the forklift truck fork lock nut 5 Insert the retaining pin 6 at the swivel arm The hose package 7 must be fastened to the parking coupling 8 m Always work with a banksman when approaching with the forklift truck and inserting the forklift tines in the openings ...

Page 94: ...trailer requirements m The low bed trailer must have the necessary number of lashing points with a lashing strength of LC 2 000 daN 6 1 Prepare low bed trailer and conveyor belt m Before loading begins non slip mats 1 must be fitted to the contact points where the conveyor belt stands on the low bed trailer A The conveyor belt can be raised with suitable lifting gear or a forklift truck 1 2 8 9 3 ...

Page 95: ...ose package 6 must be fastened to the parking coupling 7 The openings 8 for the forklift truck fork are open wing bolts 9 m Always work with a banksman when approaching with the forklift truck and inserting the forklift tines in the openings The conveyor can be lifted onto the intended attachment points or openings on the low bed trailer using suitable lifting equipment or a forklift truck A After...

Page 96: ...es for permitted 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 min LC 2 200 daN Lashing straps permissible lashing...

Page 97: ...distribution during loading On some vehicles the kingpin load is too low so that the load has to be positioned further to the back of the vehicle Always observe the specifications regarding load distribution for the vehicle and the centre of gravity of the vehicle ...

Page 98: ...he load counter to the direction of travel The lashing points on the vehicle and on the low bed trailer must be used The lashing equipment must be installed as shown m The vertical angle a must not be less or more than the 20 65 ranges The horizontal angle ß must not be less or more than the 6 55 ranges ...

Page 99: ...ing must be performed to secure the load counter to the direction of travel The lashing points on the vehicle and on the low bed trailer must be used Fasten the lashing straps as shown m The lashing angles should be ß between 6 55 and a between 20 65 ...

Page 100: ...s on the low bed trailer using suitable lifting equipment or a forklift truck A SW6500 Before stopping the slewing belt extend the standing legs by hand into the parking position and secure with the corresponding retaining pins After stopping extend the hydraulic supports until the conveyor is aligned in a hori zontal position ...

Page 101: ...r transportation on public roads m In Germany feeders must never be driven as self propelling vehicles on public roads Note that in other countries different regulations may apply The operator must be in the possession of a valid permit for vehicles of this type Danger due to restricted vision Restricted vision poses a risk of injury Before starting work arrange the intended driver s seat to ensur...

Page 102: ...e Lower control platform o Close the hopper lids Engage both hopper transport safeguards Fully extend drive unit frame cylinders Raise slewing belt o Bring slewing belt into the centre position o Lower main conveyor belt o Insert the retaining pin at the swivel arm o Deactivate set up mode ...

Page 103: ... 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 104: ...g conveyor belt o from the vehicle before loading by crane The vehicle and conveyor belt must be loaded separately 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 an...

Page 105: ...pper transport safeguards on both sides Switch the vehicle off Attach and secure the protective hood to protect the operating panel Remove protruding or loose parts see chapters E and D Then lower and set the latches properly on both sides A See section entitled Protective roof Attach lifting gear to the four attachment points 1 2 m The max permissible attachment point load at the attachment point...

Page 106: ...C 11 32 Loading the slewing conveyor belt o 4 5 6 7 8 ...

Page 107: ... the corresponding retaining pins 6 The retaining pin 7 must be inserted at the swivel arm SW6500 The locking plates 8 must be fitted Attach lifting gear to the four attachment points 4 5 m The max permissible attachment point load at the attachment points is 4 16 KN 5 7 KN m The permissible load applies in the vertical direction m Make sure that the conveyor belt remains in a horizontal position ...

Page 108: ...stem 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 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 been built up and traction system brakes have been released m On completion of the towing pro...

Page 109: ...re is a shuttle valve 6 on each of the travel drive pumps 5 To activate the bypass function unscrew the shuttle valve 7 with an Allen key SW8 turning counterclockwise as far as it will go 8 m On completion of the towing process restore the initial status 5 8 7 6 ...

Page 110: ... The plastic safety cap is destroyed on removal m Towing with activated bypass drains the closed hydraulic circuit This may result in unintended functions when restarting the travel drive Do not start the travel drive until the hydraulic circuit has been completely filled and bled Switch the bypass function off immediately after towing has finished Use an Allen key SW5 to tighten the screw 8 turni...

Page 111: ...The vehicle can now be towed carefully and slowly out of the construction site 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 5m min m The max permissible towing eye 9 load is 200 kN 9 ...

Page 112: ...portation position and lock properly in position Close the hopper and set the hopper transport safeguards 3 on both sides Lower slewing belt o to lowest position Lower height adjustable o conveyor belt to lowest position The conveyor belt must stand on all standing legs 4 The standing legs must be secured in lowered position with the corresponding retaining pins 5 Lower control platform to lowest ...

Page 113: ... main switch 9 and take it with you do not leave it hidden on the vehicle Store loose parts and accessories in a safe place Caution Possible damage to the engine electronics After the drive engine is switched off the on board voltage may not be switched off until after a period of 100 seconds main switch Always observe the operating instructions 9 NOTE ...

Page 114: ...C 11 40 ...

Page 115: ...rk 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 allow anyone to ride along on the vehicle Remove obstacles from the road and the work area Always try to choose a driver s position that is opposite to the...

Page 116: ... 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 maintenance work Comply with all further information in these instructions and i...

Page 117: ... of an EMERGENCY STOP or on restarting the con trol system If settings are changed when the diesel engine is stopped AUTO or MANUAL these are reset to STOP on starting the diesel engine The Turning on the spot function is reset to Straight ahead travel f Only adjust the operating panel position whilst the vehicle is stationary m Make sure it is latched properly ...

Page 118: ...D 11 4 10 13 16 15 17 11 12 ...

Page 119: ...o its starting position A After activating the ignition voltage the input and display terminal requires a few seconds for the booting process A On shutting off the vehicle first switch off the ignition then deactivate the main switch A Before the main battery switch is deactivated a period of at least 100 seconds must elapse after switching off the vehicle 12 Starter drive engine OFF For starting ...

Page 120: ...D 11 6 10 13 16 15 17 11 12 ...

Page 121: ...ntre position Engine in neutral no travel drive To swivel the drive lever out release by pulling the handle up Engagement of the conveying functions set to AUTO 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 deflec ted drive lever even if the travel drive preselector is set to zero A If the engine is...

Page 122: ...D 11 8 10 13 16 15 17 11 12 ...

Page 123: ...with deflec ted drive lever even if the travel drive preselector is set to zero 16 Steering potentiometer The steering wheel movement is transferred electrohydraulically A For precise adjustments position 0 straight ahead see the straight ahead travel synchronisation For turning on the spot see switch Turning on the spot 17 Horn Press in the case of emergencies and to indicate when the ve hicle st...

Page 124: ...D 11 10 18 19 20 21 ...

Page 125: ...ar and side working lights o AUS Schaltung durch erneuten Tastendruck f Eine Blendung anderer Verkehrsteilnehmer vermeiden 20 Conveyor belt working lights ON OFF Button with detent switch function and LED feedback For engaging the working lights on the conveyor belt Switch OFF by pressing the button again f Avoid dazzling other road users 21 Rotary beacon ON OFF o Button with detent switch functio...

Page 126: ...D 11 12 22 23 24 25 ...

Page 127: ...hed OFF with time control 24 Raise control platform o Pushbutton function with LED feedback To raise the control platform m The platform lock must be released before moving the control platform f On actuation heed danger zones of moving parts of the vehicle f When negotiating bridges tunnels overhead wires un derpasses etc always ensure that you maintain a safe distance from them at all times 25 L...

Page 128: ...D 11 14 26 27 28 ...

Page 129: ...Switch OFF by pressing the button again 27 Seat heating ON OFF o Button with detent switch function and LED feedback For switching on the seat heating Switch OFF by pressing the button again 28 Illuminated balloon ON OFF o Button with detent switch function and LED feedback For engaging the illuminated balloon Switch OFF by pressing the button again ...

Page 130: ...D 11 16 29 30 31 ...

Page 131: ...D 11 17 Item Designation Brief description 29 Not used 30 Not used 31 Not used ...

Page 132: ...D 11 18 33 32 ...

Page 133: ...ctivated in the working gear travel drive slow speed A If the Turning on the spot function has been inadver tently activated and the steering is set to straight ahead travel the paver finisher does not move This is often interpreted as a malfunction f When the vehicle turns persons and objects next to the paver finisher are in extreme danger Monitor the area where the vehicle turns 33 Traction dri...

Page 134: ...D 11 20 35 34 36 37 ...

Page 135: ...there is only limited space at one side or when obstacles obstruct truck unloading f On actuation heed danger zones of moving parts of the vehicle 36 Open hopper left Pushbutton function To open the left half of the hopper A If the hoppers are hydraulically actuated at the same ti me both the left and the right switch can be used for ac tuation f On actuation heed danger zones of moving parts of t...

Page 136: ...D 11 22 39 38 40 41 42 ...

Page 137: ...nd understand the system Comply with all further information in the operating instructions and in the safety manual Item Designation Brief description LED display 38 Tell truck to reverse Pushbutton function with LED feedback To change over to the Start Reversing signal GREEN SIGNAL Press button again to change signal over to Stop Button LED 39 on RED SIGNAL Press button once more to switch again ...

Page 138: ...D 11 24 39 38 40 41 42 ...

Page 139: ...ll truck to End Tipping lower truck hopper tell truck to Detach Depart Pushbutton function with LED feedback To change over to the End Tipping signal YELLOW SIGNAL running light descending Press button again to change signal over to Pause YELLOW SIGNAL flashing A The button LED button LED 40 flas hes in the PAUSE MODE Press button once more to switch again to Start Tipping signal YELLOW SIGNAL run...

Page 140: ...D 11 26 39 38 40 41 42 ...

Page 141: ...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 display in creases with decreasing distance bet ween paver and material truck On reaching the preset minimum dis tance the signal changes over to STOP RED SIGNAL A The minimum distance is adjusted in the...

Page 142: ...D 11 28 43 45 46 44 ...

Page 143: ...es of moving parts of the vehicle 44 Lower slewing belt o Pushbutton function To lower the slewing belt A This function is not used in vehicle configurations wit hout a slewing belt f On actuation heed danger zones of moving parts of the vehicle 45 Slew slewing belt to the left o Pushbutton function For slewing the conveyor belt to the left A This function is not used in vehicle configurations wit...

Page 144: ...D 11 30 48 47 ...

Page 145: ...ction for the first time or when ac tuating functions 43 46 131 134 Function buttons 47 and 48 are then deactivated until the next restart Item Designation Brief description 47 Raise main conveyor belt Pushbutton function To raise the main conveyor belt m When fitted with SW6500 f On actuation heed danger zones of moving parts of the vehicle 48 Lower main conveyor belt Pushbutton function To lower...

Page 146: ...D 11 32 50 49 ...

Page 147: ...ncrease con veying rate Pushbutton function To adjust the conveying rate to max output Adjustment is carried out in 5 steps 50 Main conveyor belt slewing conveyor belt o Reduce conveying rate Pushbutton function To adjust the conveying rate to min output Adjustment is carried out in 5 steps ...

Page 148: ...D 11 34 51 54 52 53 ...

Page 149: ...e A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 52 Main conveyor belt slewing conveyor belt o MANUAL Slow speed Button with detent switch function and LED feedback The conveying function is switched on continuously at half of the delivery rate without material control via the limit switches Switch OFF by pressing the button ...

Page 150: ...D 11 36 51 54 52 53 ...

Page 151: ... restarting the vehicle A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 54 Slewing conveyor belt o MANUAL Slow speed Button with detent switch function and LED feedback The conveying function is switched on constantly wi thout material control via the limit switches Switch OFF by pressing the button again A The function is shu...

Page 152: ...D 11 38 58 57 56 55 ...

Page 153: ... right Pushbutton function with LED feedback Press and hold button the current position slewing angle and slewing height is saved Press button briefly slewing released LED flashes Press button 57 to start slewing A Slewing can only begin while the LED is flashing A It is not possible to save a position that is further to the right than the position saved with button 56 f On actuation heed danger z...

Page 154: ...D 11 40 60 59 62 61 ...

Page 155: ...ined A If the current position is maintained the LEDs on the distance control light up Switch OFF by pressing the button again or actua ting the drive lever To save the current distance value press the button for approx 2 sec Press the button again to use the stored distance value A If the distance value from the memory is used the re levant button s LED lights up Switch OFF by pressing the button...

Page 156: ...D 11 42 60 59 62 61 ...

Page 157: ...ained A If the current position is maintained the LEDs on the distance control light up Switch OFF by pressing the button again or actuating the drive lever To save the current distance value press the button for approx 2 sec Press the button again to use the stored distance value A If the distance value from the memory is used the rele vant button s LED lights up Switch OFF by pressing the button...

Page 158: ...D 11 44 60 59 62 61 ...

Page 159: ...max Adjustment is carried out in defined cm steps The step size is adjusted in the password area A Adjustment range max 1 m 62 Distance control Reduce distance o Pushbutton function To adjust the distance to min Adjustment is carried out in defined cm steps The step size is adjusted in the password area A Adjustment range max 1 m ...

Page 160: ...D 11 46 64 63 ...

Page 161: ...eed and all functions set to Automatic are engaged A The main function switch must be set to the OFF position Switch OFF by pressing the button again or by swivel ling the drive lever out to the paving position On reaching the adjusted material height material sen sor the filling function is automatically switched off f On actuation heed danger zones of moving parts of the vehicle 64 Set up mode D...

Page 162: ...D 11 48 66 65 ...

Page 163: ...uto settings in the individual functions these are not activated when the drive lever is swi velled out Switch OFF by pressing the button again A The preset vehicle can be relocated and released at the new paving location The conveying process is continu ed on swivelling the drive lever out A On restarting the function is set to ON 66 Not used ...

Page 164: ...D 11 50 68 67 ...

Page 165: ...it frame Pushbutton function To raise the drive unit frame f On actuation heed danger zones of moving parts of the vehicle 68 Lower drive unit frame Pushbutton function To lower the drive unit frame f On actuation heed danger zones of moving parts of the vehicle ...

Page 166: ...D 11 52 70 69 ...

Page 167: ... hopper Pushbutton function To close the front hopper flap f On actuation heed danger zones of moving parts of the vehicle 70 Open front hopper Pushbutton function To lower the front hopper flap f On actuation heed danger zones of moving parts of the vehicle ...

Page 168: ...D 11 54 72 71 ...

Page 169: ... button again f Do not spray into open flame or on hot surface Danger of explosion A If the tank is empty the pump shuts off automatically 72 Conveyor belt spraying system AUTO Button with detent switch function and LED feedback The conveyor belt spraying system is switched on on engaging the conveying function Switch OFF by pressing the button again A Automatic shut off takes place after one comp...

Page 170: ...D 11 56 74 73 ...

Page 171: ...ding material or indicate its conveying Alternate switching with Signal system green press the button again to switch off 74 Signal system green ON OFF o Button with detent switch function and LED feedback Engage signal system GREEN to request the corre sponding material or indicate its conveying Alternate switching with Signal system red press the button again to switch off ...

Page 172: ...D 11 58 Side operating unit front 101 103 105 106 107 102 104 100 ...

Page 173: ...in 101 Open hopper left Pushbutton function To open the left hopper lid front hopper f On actuation heed danger zones of moving parts of the vehicle 102 Close hopper left Pushbutton function To close the left hopper lid front hopper f On actuation heed danger zones of moving parts of the vehicle 103 Open hopper right Pushbutton function To open the right hopper lid front hopper f On actuation heed...

Page 174: ...D 11 60 101 103 105 106 107 102 104 100 ...

Page 175: ...F o Button with detent switch function E g for communication with material transporter and material recipient during compact asphalt paving Engage signal system RED to request the corre sponding material or indicate its conveying Alternate switching with Signal system green press the button again to switch off 107 Emulsion spraying system ON OFF Button with detent switch function On engagement wor...

Page 176: ...D 11 62 Side operating unit rear 108 109 110 112 113 114 111 ...

Page 177: ...elt mainte nance functions Switch setting I functions released Switch setting 0 functions blocked remove key A Observe maintenance intervals for conveyor belt tension m If the function is not required remove the key from the switch A When conveyor belt maintenance is engaged all con veyor belt functions on the operating panel are blocked 110 Increase conveyor belt tension Button with pushbutton fu...

Page 178: ...D 11 64 108 109 110 112 113 114 111 ...

Page 179: ...ones of moving parts of the vehicle 113 Reverse conveyor belt drive manual Button with pushbutton function For temporarily driving the conveyor belt during main tenance work A The conveyor belt is driven at low speed for a defined time f On actuation heed danger zones of moving parts of the vehicle m Risk of damage to equipment Only allow the conveyor belt to run in reversing mode if the conveyor ...

Page 180: ...D 11 66 Side operating unit slewing conveyor belt SW5500 o 115 116 117 118 ...

Page 181: ...f accident To restart the engine the button must be pulled out again 116 Key switch conveyor belt maintenance Key switch with detent switch function For releasing and blocking the conveyor belt mainte nance functions Switch setting I functions released Switch setting 0 functions blocked remove key A Observe maintenance intervals for conveyor belt tension m If the function is not required remove th...

Page 182: ...D 11 68 115 116 117 118 ...

Page 183: ...anger zones of moving parts of the vehicle 118 Reverse conveyor belt drive manual Button with pushbutton function For temporarily driving the conveyor belt during main tenance work A The conveyor belt is driven at low speed for a defined time f On actuation heed danger zones of moving parts of the vehicle m Risk of damage to equipment Only allow the conveyor belt to run in reversing mode if the co...

Page 184: ...D 11 70 Side operating unit slewing conveyor belt SW6500 o 115 118 116 117 ...

Page 185: ...f accident To restart the engine the button must be pulled out again 116 Key switch conveyor belt maintenance Key switch with detent switch function For releasing and blocking the conveyor belt mainte nance functions Switch setting I functions released Switch setting 0 functions blocked remove key A Observe maintenance intervals for conveyor belt tension m If the function is not required remove th...

Page 186: ...D 11 72 115 118 116 117 ...

Page 187: ...anger zones of moving parts of the vehicle 118 Reverse conveyor belt drive manual Button with pushbutton function For temporarily driving the conveyor belt during main tenance work A The conveyor belt is driven at low speed for a defined time f On actuation heed danger zones of moving parts of the vehicle m Risk of damage to equipment Only allow the conveyor belt to run in reversing mode if the co...

Page 188: ...D 11 74 Joystick travel drive slewing belt o 123 122 121 120 ...

Page 189: ...r to the driver s seat 121 Turning knob Height adjustment Press the knob to adjust the armrest up or down 122 Latch for horizontal adjustment For fixing armrest and control unit horizontal adjustment 123 Emergency stop button In the case of an emergency danger to persons possible col lision etc press the button Pressing the emergency stop button switches off the engi ne the drives and the steering...

Page 190: ...D 11 76 113 114 128 129 130 127 133 134 131 132 126 125 ...

Page 191: ...educed to 0 with the preselector The vehicle advances slightly with deflec ted 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 drive is blocked To be able to start the travel drive the drive lever must first be returned to the centre position A When changing over between forwards and reverse tra vel the drive leve...

Page 192: ...D 11 78 113 114 128 129 130 127 133 134 131 132 126 125 ...

Page 193: ... via the limit switches Switch OFF by pressing the button again briefly Engaging the AUTO mode Press button 124 min 1 second A The conveying function is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switches Switch OFF by pressing the button again min 1 second A The function is shut off by pressing the EMERGENCY STOP button or restarting th...

Page 194: ...D 11 80 113 114 128 129 130 127 133 134 131 132 126 125 ...

Page 195: ...ion is engaged The vehicle speed is automatically adapted to the speed of the paver finisher When the paver finisher comes to a stop the feeder is halted and all Auto functions are paused Activate distance control when the feeder has reached the desired position and the distance is to be maintained Switch OFF by pressing the button again A Distance control can be activated in a distance range betw...

Page 196: ...D 11 82 113 114 128 129 130 127 133 134 131 132 126 125 ...

Page 197: ...wing belt Pushbutton To raise the slewing belt f On actuation heed danger zones of moving parts of the vehicle 132 Lower slewing belt Pushbutton To lower the slewing belt f On actuation heed danger zones of moving parts of the vehicle 133 Swivel slewing belt to the left Pushbutton function For slewing the conveyor belt to the left f On actuation heed danger zones of moving parts of the vehicle 134...

Page 198: ...D 11 84 ...

Page 199: ...D 23 1 D 23 Operating the display ...

Page 200: ...n a menu Press to release the adjustment of a parameter to confirm a parameter adjustment to confirm a selection possibility B Home button To show the home menu directly C Upwards button To show the higher level menu higher level display D Function buttons To select the menus assigned in the display area D1 To activate the functions assigned in the display area D1 E Function buttons To select the ...

Page 201: ...es from pale to dark grey A Press the corresponding function button again to go back to the previous page F Display area for status warning and error messages To show current earnings or error messages A The colour of the symbol indicates whether it is a status warning or error message 2x ...

Page 202: ... error messages Colour code Explanation RED error message Reports a serious fault that must be checked and rec tified immediately YELLOW warning message Reports a current condition that needs to be observed or rectified at short notice to ensure correct working BLUE GREEN status message Confirms an activated function ...

Page 203: ...D 23 5 1 1 Menu operation procedure for adjusting parameters A B ...

Page 204: ... Drive engine measured value display menu is open in the display Turn jog dial B to make the cursor appear A A blue frame appears around the adjustment parameter Press jog dial B to activate the adjustment Turn jog dial B in the corresponding direction to reach the required value Press jog dial B to adopt the adjusted value A The blue frame around the adjustment parameter disappears ...

Page 205: ...ars around the top adjustment parameter in the menu Turn jog dial C in the corresponding direction until the blue frame is around the required adjustment parameter Press jog dial C to activate the parameter adjustment Turn jog dial C in the corresponding direction to reach the required value Press jog dial C to adopt the adjusted value C ...

Page 206: ...te the memory location selection A A blue frame appears around the top memory location in the menu Turn jog dial C in the corresponding direction until the blue frame is around the required memory location Press jog dial C to adopt the current value in the memory location C ...

Page 207: ...ial to activate the parameter adjustment A A blue frame appears around the top selection possibility in the menu Turn jog dial in the corresponding direction until the blue frame is around the re quired selection possibility Press jog dial to activate the selection possibility ...

Page 208: ...sion tank filling level 5 Paving material paver finisher hopper filling level 6 Conveyor capacity m Optional features of the vehicle e g slewing belt or remixer may limit the conveying capacity 7 Remixer mode o 7 1 Rear mixer mode AUTO MANUAL OFF 7 2 Front mixer mode AUTO MANUAL OFF 8 Distance feeder paver finisher m ft o 10 Distance feeder paver finisher memory location o 1 7 11 8 5 13 15 14 2 3 ...

Page 209: ...s the same as the Truck Assist LED display at the hopper 12 Distance Assist control o A The display is the same as the distance LED display at the vehicle roof 13 Distance travelled counter m ft 14 Time of day hh mm AM PM 15 Menu display symbol 11 12 ...

Page 210: ...lowing sub menus 1 Show Home functions Quick settings 2 Call Engine speed menu Engine measured value display sub menus 3 Material control menu 4 Camera display menu sub menus o 5 Error memory menu sub menus 6 Basic menu sub menus 1 2 3 4 5 6 ...

Page 211: ...on button activates or deac tivates the functions The function is activated when the corresponding symbol appears blue 1 Eco mode function The engine speed is constantly regulated to 1600 rpm 2 Chain lubrication function The central lubrication system is engaged for a lubrication cycle 3 Joint hopper actuation function Both hopper halves are actuated together with one of the hopper function switch...

Page 212: ...g the laser OFF also disables the distance control A When the function is activated at the operating panel the current distance between feeder paver 5 1 appears in the display A If the distance is controlled by a saved value then the corresponding memory location 1 2 is displayed 5 2 6 Preselection function belt spraying system A Press the button repeatedly to select whether the spray ing system i...

Page 213: ...ed out in steps of 50 the engine speed is adapted directly 2 Actual engine speed 3 Engine oil pressure bar 4 On board voltage V 5 Engine coolant temperature C F 6 Engine operating hours h 7 Fuel consumption l h o Open the following sub menus 8 Particulate filter regeneration menu o 9 Paving area Automatic steering unit menu o 10 Conveyor an distance control adjustment and display menu 11 Slewing b...

Page 214: ...ration 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 1a comes on permanently and the regeneration warning sign 1b flashes A Particulate filter regeneration takes about 20 60 minutes m Regeneration may only be carried out if the vehicle is parked correctl...

Page 215: ... regeneration can occur immediately after being unlocked again Danger 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 people 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 ob...

Page 216: ...0 seconds during reset 2 Steering monitoring is used for distance control scanning reference Reset reference to zero Select function 2 1 with the job dial and press to reset A As confirmation the display changes for 5 to 10 seconds during reset A Ideal distance scanning reference is the value 0 in display 2 Excursions indicate increased or reduced distances A If necessary carry out correction via ...

Page 217: ...urrent distance feeder paver finisher m ft 2 Stored parameter Short distance m ft memory location 1 3 Stored parameter Long distance m ft memory location 2 4 Current slewing angle conveyor x o 5 Saved parameter conveyor angle top x o memory location 1 6 Saved parameter conveyor angle bottom x o memory location 2 2 4 1 3 5 6 ...

Page 218: ...urrent distance feeder paver finisher m ft 2 Stored parameter Short distance m ft memory location 1 3 Stored parameter Long distance m ft memory location 2 4 Current slewing angle conveyor x o 5 Saved parameter conveyor angle top x o memory location 1 6 Saved parameter conveyor angle bottom x o memory location 2 2 4 1 3 5 6 ...

Page 219: ... angle x 2 Saved parameter slewing conveyor belt slope left x 3 Saved parameter slewing conveyor belt slope right x A Setting range 0 27 4 Current slewing conveyor belt slewing angle x 5 Saved parameter slewing conveyor belt slewing angle left x 6 Saved parameter slewing conveyor belt slewing angle right x A Adjustment range 55 0 55 5 1 3 6 4 2 ...

Page 220: ...usting the belt speed in manual mode 1 Current filling height deactivation point A Adjustment range 0 100 2 Main belt speed in manual mode of max A Adjustment range 1 30 m Optional features of the vehicle e g slewing belt or remixer may limit the conveying capacity Open the following sub menus 3 Front mixer rear mixer set up menu 2 1 3 ...

Page 221: ...O 1 3 The function is switched on by swivelling the drive lever out and controlled with the material limit switches 2 Rear mixer mode REAR mixer OFF 2 1 The function is switched off or there is no rear mixer on the vehicle Front mixer MANUAL 2 2 The function can switched on with the Set up mode button see operating panel Front mixer AUTO 2 3 The function is switched on by swivelling the drive leve...

Page 222: ...er raise rear mixer to working position 5 1 A Function buttons 6 7 are only active when the function is switched on The belt speed is limited when the function is switched on 25 6 Raise rear mixer hydraulically Pushbutton function Press and hold until end position is reached 7 Lower rear mixer hydraulically Pushbutton function Press and hold until end position is reached 1 2 3 6 7 4 5 1 1 1 2 1 3 ...

Page 223: ...amera display menu o Vehicle parts partly concealed from view can be displayed by the camera system A When this function is called up display camera 1 appears 1 Show camera 2 display 2 Show camera 2 display 2 1 ...

Page 224: ...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 4 System error display A Notify the customer service department for your vehicle if necessary of the system error number which is displayed the customer service department will then discuss the further procedure with you 2 1 3 4 1 1 2 1 3 1 ...

Page 225: ...y Error messages with travel drive stop Display of existing error messages in a table 1 Error code 2 Error description 3 Designation of the faulty part as per BMK EIC list A Press the job dial to scroll through the list 1 2 3 ...

Page 226: ...rror messages in a table 1 Error code 2 Error description 3 Designation of the faulty part as per BMK EIC list A Press the job dial to scroll through the list Delete list of error messages 4 A As confirmation the display changes for 5 to 10 seconds during deleting 1 2 3 4 ...

Page 227: ...rror messages Display of existing error messages in a table 1 SPN code 2 FMI code 3 OC error frequency A All error messages can be identified in the section Drive engine error codes A Press the job dial to scroll through the list 1 2 3 ...

Page 228: ... menus 1 Home menu Display and quick settings menu 2 Service menu Menu for service technician password required 3 Info settings menu Menu for adjusting various functions 4 Service report menu Menu for recording service work performed on the vehicle 5 Remote lock menu For locking and unlocking vehicle functions 1 2 3 4 5 ...

Page 229: ...D 23 31 Service menu Password protected menu for various service settings ...

Page 230: ...ay 3 Engine operating hours h 4 Vehicle serial numbers 17 digit PIN VIN 5 Dynalink module number o 15 digit number IMEI A If consultation with Technical Support is required for your vehicle always specify the software version Open the following sub menus 6 Functions intervals set up menu 7 Belt control conveying belt functions set up menu 8 Day night lighting set up menu 9 Display set up menu 6 7 ...

Page 231: ... to the prevailing paving situation 2 Truck Assist selection Truck Distance A In order to adjust to the prevailing situation the truck s automatic detection function can be preset to 3 different distances feeder truck 2 1 Shortened distance 2 2 Medium distance 2 3 Extended distance 3 Display and adjustment parameters for Delayed Front Hopper delay time sec o A After closing the hopper lids the fro...

Page 232: ... Reverse conveyor reversing time sec A Setting range 1 5 sec 2 Display and adjustment parameters for Emulsion spraying system main belt spraying interval spraying time sec A Setting range 0 99 sec 3 Display and adjustment parameters for Emulsion spraying system slewing belt spraying interval spraying time sec o A Setting range 0 99 sec 1 2 3 ...

Page 233: ...s 2 Monitor brightness display and adjustment parameters 2 1 daytime light 2 2 nighttime light 3 Truck Assist display and adjustment parameters 3 1 daytime light 3 2 nighttime light 4 Distance Assist display and adjustment parameters 4 1 daytime light 4 2 nighttime light 2 3 2 1 2 2 3 1 3 2 4 4 1 4 2 ...

Page 234: ...tem language English German 2 Selection Units of measurement Metric Imperial US 3 Time display and adjustment parameters h h min min 24h PM AM 4 Date display and adjustment parameters dd mm yyyy Open the following sub menus 5 Camera display set up menu 6 Licence text display 1 3 4 5 2 6 ...

Page 235: ...the camera display 1 Brightness display and adjustment parameters 2 Contrast display and adjustment parameters 3 Colour display and adjustment parameters Setting range 0 100 Open the following sub menus 4 Display set up menu 5 Licence text display 1 2 3 4 5 ...

Page 236: ...D 23 38 Licence text display Display of the software licence text Exit display B Back to the previous page B ...

Page 237: ...g unlocking function A Remote Lock not active Display of the following information 1 Request number empty cannot be edited Open the following sub menus 2 Lock menu 3 Basic menu display A Locking only possible with engine OFF Note A 2 3 1 3 5 1 2 A B A A ...

Page 238: ...essed after entering the TAN The lock is cancelled A Ask the owner of the vehicle for the TAN which is only valid once The request number has to be stated to this end The requested TAN has to be entered in the corresponding field 2 to unlock Open the following sub menus 5 Basic menu display A Locking only possible with engine OFF Note A ...

Page 239: ...ays sub menus A Remote Lock warning appears 1 When vehicle already locked Open Unlock menu 2 Basic menu display m The lock function is activated by pressing function button 3 A After locking button 3 has no function and the corresponding error message 4 appears 3 1 2 A 1 2 A 3 4 ...

Page 240: ...information 1 Operating hours 2 Remaining operating hours until the next service 3 Pending service scope Service 1 Service 2 Service 3 o Open the following sub menus 4 Report for Dynapac service technician 5 Report for servicing carried out by the customer 6 Back to Basic menu 5 6 2 1 3 4 ...

Page 241: ... 3 o 2 Technician number of the Dynapac service technician 3 PIN of the Dynapac service technician A When the input field appears with a red surround this indicates the technician number or PIN were entered incorrectly Perform the following functions 4 Report for Dynapac service technician step II 5 Back to previous mask 6 Back to Basic menu 2 1 3 5 6 4 ...

Page 242: ...u for confirming forwarding the service report 1 The warning Service Report appears 1 Perform the following functions 2 Send service report A Confirmation is followed by returning to the Service Report mask 3 Back to previous mask 4 Back to Basic menu 1 3 4 2 ...

Page 243: ...tion Performed service Service 1 Service 2 Service 3 o 2 Technician number 3 PIN 1 1 1 1 A When the input field appears with a red surround this indicates the PIN was entered incorrectly Perform the following functions 4 Report for service technician step II 5 Back to previous mask 6 Back to Basic menu 2 1 3 5 6 4 ...

Page 244: ...I Menu for confirming forwarding the service report 1 The warning Service Report appears 1 Perform the following functions 2 Send service report A Confirmation is followed by returning to the Service Report mask 3 Back to previous mask 4 Back to Basic menu 1 3 4 2 ...

Page 245: ...shes Urgent maintenance level II Particular filter regeneration must be carried out as soon as possible The engine output may be automatically reduced under certain circumstances Indicator lamp flashes indicator lamp Engine malfunction is on permanently Urgent mainte nance level III Particulate filter regeneration is vitally necessary to avoid subsequent damage and repairs The engine output is aut...

Page 246: ...g cleaned by the engine f Keep the outlet of the exhaust 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 I...

Page 247: ... fault Depend ing on the type 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 che...

Page 248: ... op erating panel are blocked Indicator lamp separator fluid The separator fluid is down to the reserve level in the tank A Approx 10 remains m Urgent need to refill separator fluid Distance control Distance control cannot be activated a malfunc tion is detected during operation accompanied by an acoustic signal A Distance control can be deactivated with the corresponding switch A The feeder canno...

Page 249: ...ant 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 centre position let the engine cool down while idling Determine the cause and rectify if necessary refer to Malfunctions section After cooling down to normal temperature the engine will run with full performance ag...

Page 250: ...gether with Error Message Hydrostatic travel drive oil pressure indicator m The oil pressure is insufficient Switch off the engine immediately For other possible errors see engine s operating instructions 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...

Page 251: ...hicle for the TAN which is only valid once The request number has to be stated to this end Distance Assist in standby The feeder has been at a standstill for more than 10 seconds with active Distance Assist A The paver finisher cannot push the feeder when standby is activated Release by pressing the Distance Assist button on the operating panel LED in the button flashes ...

Page 252: ...he vehicle can be moved away from the construction site in emergency mode Turn the travel drive preselector 1 to zero The LEDs in buttons 2 and 3 flash Forwards travel Press and hold the function button turn on the spot 2 adjust speed with the travel drive preselector 1 Reverse travel Press and hold the function button transport gear 3 adjust speed with the travel drive preselector 1 2 3 1 ...

Page 253: ...D 23 55 3 2 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 254: ... fault after decoding A Press the job dial to scroll through the list 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 1 2 3 ...

Page 255: ...D 23 57 Example C ...

Page 256: ...y 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 257: ...D 23 59 3 3 Error codes A Scan QR Code to access failure code chart ...

Page 258: ...23 60 4 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 259: ...of falling from the vehicle which can cause severe to fatal injuries The operator must be at the intended driver s seat during operation Never jump onto or off a moving vehicle Keep accessible surfaces free of any soiling e g operat ing substances to avoid the risk of slipping Use the steps provided and hold onto the handrail with both hands Comply with all further information in these instruction...

Page 260: ... on the vehicle dur ing travel Hold tight when climbing up and down f The ladder must not be used when the control platform is raised m Folded down the step increases the ba sic width of the vehicle f During transportation in road traffic and when transporting the vehicle on trans porters the step must be folded up f Always choose the ladder on the side away from road traffic 2 2 ...

Page 261: ...tc always ensure that you maintain a safe distance from them at all times f During transportation in road traffic and when transporting the vehicle on trans porters the control platform must be lowered Emergency descent An emergency descent is available if it should prove impossible to lower the platform In addition to the descent two steps 1 are also available in the covering for safely climbing ...

Page 262: ... for rigid platform version Caution Possible collision of parts The following adjustments must be made before lowering the roof Seat consoles swivelled in and locked Operating panel locked in a central position in front of one of the driver s seats Side windows closed Engine hood and lateral flaps closed Rotary beacon swivelled inwards and in lowest setting NOTE ...

Page 263: ...2 Tighten bolts 3 on both sides of the roof Operate the pump lever 1 until the roof has reached the upper or lower limit position Set bolts 3 in the respective posi tion on both sides of the roof A Place the pump lever in the bracket 6 6 5 1 2 3 ...

Page 264: ...D 30 6 Protective roof o A C B C B A 1 2 D 4 3 C D ...

Page 265: ...wash on the operating panel if necessary A Ensure that the washer fluid tank 3 is always adequately filled m Replace worn wiper blades immediately Mirror The mirror 4 enables a better view into the hopper A If necessary turn the mirror on its bracket Risk of crushing hands When closing the spring loaded front and side windows there is a risk of crushing which can cause injuries Do not reach into t...

Page 266: ...swivelling the seat console out the driver s seat must be moved to the fore most position and the side window o must be swivelled open Release the latch 1 and swivel the seat console out to stop To swivel the seat console in release the latch 1 again A The latch must audibly engage in both positions m When swivelled out the seat consoles increase the basic width of the vehicle m Make sure it is la...

Page 267: ...30 9 f During transportation in road traffic and when transporting the vehicle on transport ers the seat console must be swivelled in f Only adjust the operating position whilst the vehicle is stationary ...

Page 268: ...ition and allow to engage in one of the detent positions 2 Extending shortening the operating panel bracket Release the latch 3 set the panel bracket to the desired length and lock the latch Swivelling the operating panel console Release the latch 4 swivel the panel console to the desired position and lock the latch f Only adjust the operating position whilst the vehicle is stationary m Make sure ...

Page 269: ...idually 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 s...

Page 270: ... the vehicle f After locking the individual elements it must no longer be possible to shift then to another position Horizontal setting 1 Height and slope setting front 2 Height and slope setting rear 3 Weight setting 4 Backrest setting 5 Armrests with tilt adjustment 6 Lumbar support setting 7 Seat heating ON OFF 8 6 1 2 6 4 3 5 7 8 ...

Page 271: ...nance flap closed during operation never open whilst the conveyor belt is running Danger from damaged or missing operating instructions Failure to comply with the operating instructions can cause severe to fatal injuries Familiarise yourself with the contents of the operating instructions Always keep the operating instructions in the intended place on the vehicle Replace any missing or damaged ope...

Page 272: ...t according to the instructions see section Starting the feeder external starting starting aid Main battery switch The main battery switch separates the current circuit from the battery to the main fuse A For the assignment of all fuses see chapter F To interrupt the battery s current cir cuit turn the key pin 3 to the left and pull it out A Do not lose the key pin as in this case the feeder can n...

Page 273: ...upwards and the transport safe guards for the hopper must be inserted on both sides of the vehicle Pull the locking pin 1 and place the transport safeguard 2 with the handle above the hopper cylinder s piston rod f Without transport safeguards inserted the hopper lids will slowly open danger during transportation 1 2 ...

Page 274: ...l Engine compartment lighting o A The engine compartment lighting can be activated when the ignition is switched on On off switch 1 for the engine com partment lighting Light Assist o A There are additional working lights at the front and on the side of the vehicle roof When the battery main switch is pressed ON and when the engine is switched off the rear working lights are switched on for a limi...

Page 275: ...D 30 17 LED working light 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 ...

Page 276: ...icle The cameras can be swivelled in vari ous directions Front of vehicle hopper 1 Material transfer area 2 Rear of vehicle 3 A The pictures are shown in the control panel display f Several cameras are located in the vehi cle s danger zone Carry out set up work only when the ve hicle is stationary 2 3 1 ...

Page 277: ...ed to indicate to the drivers of the material transporters and the paver finisher whether surface or binder course material is required or the material with which the paver finisher is fed Red signal lamp 1 surface course Green signal lamp 2 binder course Insert the lamp unit in the intended bracket 3 connect the connection cable to the relevant socket 4 A The signal lamps are switched using the o...

Page 278: ...s quick action cou plers for the spray hose are located on the left right in the front and rear area of the vehicle 5 6 A The spraying bar installed on the con veyor belt is engaged with time control on activation of the conveying function A The separator fluid functions most effi ciently when it is sprayed on the convey or belt while it is still hot to removed any material residues This means tha...

Page 279: ...ationary f Do not spray into open flame or on hot surface Danger of explosion m Use only approved separator fluid See section entitled Lubricants and operating substances Hose reeling device connect supply hose with quick action coupling Pull the spray hose out of the device until a click is audible When released the hose automatically engages here The hose is automatically rolled up again by pull...

Page 280: ...able to minimise dirt and wear on the conveyor belt A The scraper is equipped with several scraper plates which scrape off bonded material residues during conveyor belt operation A See chapter F for operation mainte nance and cleaning of the scraper ...

Page 281: ...kets o Additional 2 V 24 V sockets 1 are lo cated in several positions Additional working lights can be con nected here for example Control platform 1 Rear of vehicle 2 A Voltage is present when the main switch is switched on 1 2 ...

Page 282: ...rvoir 1 is filled with chain oil and ensures that the conveyor belt chain links are lubricated at set intervals of time A Factory setting of the chain lubrication system operating intervals when the conveyor belt is running 4 minutes operation 20 minutes break A Observe the instructions in section Maintenance O 1 ...

Page 283: ...lane clearers Swivel the lane clearers 1 up and se cure in the uppermost position with a hook 2 m To avoid collisions in operating mode the lane clearer may only be lowered so that a space of a few mm is available be tween the ground and the blade 3 Fire extinguisher o A The machine personnel must be famil iarised with operation of the fire extin guisher 1 A Observe the inspection interval for the...

Page 284: ...ct and secure with a wing bolt 2 Extend the rotary beacon with tube 3 to the desired height and secure with the clamping bolt 4 Activate the function on the operat ing panel as necessary On completion of work release the bolt 5 and swivel the bracket 90 A The rotary beacon is easy to remove and should be stored securely at the end of work o 1 2 3 4 5 ...

Page 285: ... 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 286: ...sense the height of the material in the paver fin isher s hopper The lever 1 is used to clamp the sensor in the retaining fixture Rough adjustment can be undertaken by swivelling gently A The deactivation point is defined using the terminal on the operating panel Ultrasch_MF300 1 ...

Page 287: ... distance between the feeder and the paver finisher As soon as the engaged sensor regis ters the paver finisher on approaching the feeder s speed is adjusted to that of the paver finisher and the distance is maintained A The function is engaged and disen gaged on the operating panel 1 ...

Page 288: ...m the paver finisher operator about the meaning of the following displays Meaning Symbol in the display OFF A Travel by drive lever Stop for paver finisher A Feeder is at a standstill Heed warning A Distance Assist after 10 sec onds standstill in standby Release by pressing the Distance Assist button on the operating panel LED in the button flashes Restart for paver finisher A Release for start up...

Page 289: ... in the display Large distance max 2 0m Small distance max 1 5m Very small distance max 1 0m Control range reached 0 25m Position change too narrow Reverse travel m Collision possible General fault A Distance Assist inactive ...

Page 290: ...D 30 32 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 291: ...extension 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 and also fix with bolts and lock nuts 8 Fit the clamping piece 9 with extension arm 10 to the end of the tube A Heed vertical alignment If necessary adjust the height of the support wheel at the a...

Page 292: ...8 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 pre cise operation of the automatic steering unit Connecting the sensor A A socket for connecting the sensing system to the vehicle s control system is located on the left and right sides of the vehicle on the inner side of the bumper Connect the r...

Page 293: ... rear po sition with the latch 3 A Construction site documents can be completed or a laptop set down on the tray Fuse box Open the door 4 to access the terminal box The terminal box contains all fuses and relays etc A An assignment plan for fuses and relays can be found in chapter F8 1 2 3 4 ...

Page 294: ...D 30 36 Illuminated balloon o 1 6 3 9 8 2 7 10 5 4 ...

Page 295: ...d gas a safety distance of at least 1 metre must be maintained from combustible materials f Ensure that the area above the balloon is free and open without any power lines and hindrances There should be a linear distance of at least 50 m between overhead high voltage power lines and the illuminated balloon There should be a distance of at least 2 5 m between overhead power lines and railway tracks...

Page 296: ... the holding tube Once the illuminated balloon is completely mounted and secured connect the plug 9 of the illuminated balloon in the corresponding sockets 10 m Route the supply lines so as to rule out any risk of stumbling or damage to the lines A Engagement is carried out on the operating panel A The holding tube most be removed during transport or to lower the roof Danger due to electric shock ...

Page 297: ...ing agent for the upper and lower skin Never use aggressive cleaners such as cleaning solvent turpentine or other products that could corrode the material Service safety Danger due to electric shock Electric shock can cause severe or fatal injuries Do not start to dismantle the Powermoon until it has been disconnected from the power grid High voltage Danger due to electric shock This unit uses hig...

Page 298: ...D 30 40 ...

Page 299: ...eck before starting work whether or not the following devices and aids are present Diesel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector Shovel and broom Any devices required to clean various parts of the vehicle Protective clothing signal vest gloves ear protection ...

Page 300: ...t 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 During operation the operator must be at the intended driver s seat and be seated properly ...

Page 301: ...safety instructions Check the personal protective equipment Take walk around the vehicle to inspect it and check for any leaks and damage Install parts removed for transportation or for the night Perform the check according to the Checklist for the vehicle operator given below ...

Page 302: ...al must sound Lights Switch on with the ignition key walk around the vehicle check and switch off again Warning lights The warning lights must be engageable when the ignition is switched on Hopper transport safeguard When the hopper is closed it must be possible to swivel the safeguards over the hopper cylinders Protective roof The locking bolts must be set properly Other facilities Engine panels ...

Page 303: ...D 41 5 108 100 13 11 12 10 15 ...

Page 304: ...ty devices and protective devices Normal starting Set the drive lever 13 to the centre position and the travel drive preselector 15 to minimum Insert the ignition key 11 in position 0 m The lights should be switched off during starting to reduce the current drain on the battery A It is impossible to start the vehicle if an emergency stop button 10 100 108 is pressed Error shown on the display Pres...

Page 305: ...D 41 7 108 100 13 11 12 10 15 ...

Page 306: ...e travel drive preselector 15 to minimum m The starting aid cable must be connect ed to 24 V First connect the positive terminal 1 of the starting aid battery to the posi tive terminal 2 of the vehicle battery Then connect the negative termi nal 3 of the starting aid battery to the ground of the discharged vehicle e g to the engine block or to a bolt 4 on the vehicle frame f Do not connect the sta...

Page 307: ...rt the other vehicle Press the starter button 12 to start the engine Run the starter continuously for a maximum of 20 seconds then take a break for 2 minutes If the engine still has not started after two attempts ascertain the cause If the engine starts up disconnect the starting aid cable again in reverse order ...

Page 308: ...D 41 10 64 ...

Page 309: ...1 After starting To increase the engine speed Press button 64 to increase engine speed A The engine speed is increased to the preset value m Let the vehicle warm up for approx 5 minutes if the engine is cold ...

Page 310: ...D 41 12 13 A B C ...

Page 311: ...down automatically Driving mode remains possible After cooling down to normal temperature the engine will run with full per formance again Battery charge indicator lamp B Must go out after starting when the engine revs up m If the lamp does not go out or lights up during operation Briefly rev up the engine Switch off the engine and determine the fault if the lamp does not go out For further possib...

Page 312: ...D 41 14 13 D 64 52 53 ...

Page 313: ...se the entire hydraulic system could be damaged Activate set up mode function 64 Set conveyor belt functions 52 or 63 to manual The conveyor belts start to operate Let the hydraulics warm up until the indicator lamp goes out A The Lamp goes out when the pressure drops below 2 8 bar 40 psi For further possible faults refer to the section Malfunctions ...

Page 314: ...D 41 16 35 34 15 13 48 44 25 ...

Page 315: ...ons 34 35 Lower the platform with button 25 o Lower the main conveyor belt with button 48 Lower the slewing conveyor belt o with button 44 Engage both hopper transport safeguards 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 must first be returned to the centre position ...

Page 316: ...D 41 18 2 15 13 16 10 33 ...

Page 317: ...he drive lever 13 forward or backward according to the drive direction desired Adjust the speed with the preselector 15 Carry out steering movements by actuating the steering potentiometer 16 f In case of an emergency press the emergency stop button 10 To stop set the preselector 15 to 0 and move the drive lever 13 into its centre position ...

Page 318: ...D 41 20 72 107 71 ...

Page 319: ...ush roll ers scraper with separator fluid m Do not use diesel fuel as it dissolves the bitumen prohibited in Germany Switch the conveyor belt spraying sys tem function to AUTO with button 72 A The conveyor belt spraying system is switched on on engaging the conveying function A Automatic shut off takes place after one complete conveyor belt revolution m Repeat the process after long interruptions ...

Page 320: ...D 41 22 37 36 51 A 63 65 62 61 48 47 50 49 44 43 46 45 ...

Page 321: ...F2500CS For joint use of slewing conveyor belt o and height adjustable main conveyor belt o the main conveyor belt must be set up to its lowest position Use switch 36 37 to open the hopper Instruct the truck driver to dump the material Switch the conveyor belt functions 51 to AUTO Activate function 63 to fill the vehicle for the paving process The paver finisher hopper is now filled to the set hei...

Page 322: ...D 41 24 15 63 62 61 60 49 13 50 51 33 59 ...

Page 323: ...e control 59 60 LED ON Adjust the distance with buttons 61 62 f During feeder operation without distance control o always adjust the vehicle speed to the paver finisher s speed Always equip and operate the paver finisher with the Emergency stop during feeder operation function Observe the distribution of the material and adjust the limit switch if necessary Item Travelling direction Position 63 Fi...

Page 324: ...D 41 26 15 63 13 37 36 74 73 62 61 60 49 50 51 11 48 47 25 24 33 59 ...

Page 325: ...istance between the paver finisher and feeder has been reached activate distance control 59 60 LED ON and adjust the dis tance 61 62 if necessary If necessary regulate the output of the main conveyor belt using buttons 49 50 Raise lower the operator s platform using buttons 24 25 if necessary Material change with empty hopper Switch the conveyor belt functions 51 to OFF Set the main conveyor belt ...

Page 326: ... displays Meaning Symbol in the display OFF A Travel by drive lever Stop for paver finisher A Feeder is at a standstill Heed warning A Distance Assist after 10 sec onds standstill in standby Release by pressing the Distance Assist button on the operating panel LED in the button flashes Restart for paver finisher A Release for start up Distance outside range 2 5m Very large distance max 2 5m Large ...

Page 327: ...D 41 29 Meaning Symbol in the display Very small distance max 1 0m Control range reached 0 25m Position change too narrow Reverse travel m Collision possible General fault A Distance Assist inactive ...

Page 328: ...D 41 30 13 11 12 15 ...

Page 329: ...duration Run the vehicle empty if it is anticipated that the material will cool below the mini mum paving temperature Set the drive lever 13 to the centre position During longer interruptions e g lunch break Set the drive lever 13 to the centre position and the speed adjuster 15 to minimum Stop engine 12 and switch ignition 11 off ...

Page 330: ...D 41 32 13 11 15 46 45 35 34 25 24 12 ...

Page 331: ... them in the storage boxes close flaps Remove or secure all projecting parts if the vehicle is to be transported over public roads on a low loader Read and check the operating hour counter to determine whether maintenance work must be performed see chapter F Cover and lock the operating panel Remove material residues from the vehicle and spray all parts with separator fluid Caution Possible damage...

Page 332: ...r is soiled Clean the filter if necessary replace the filter Conveyor belt can not be raised Oil pressure too low Increase the oil pressure Leaking seal Replace Power supply is interrupted Check fuse and cables replace if necessary Switch is defective Replace the switch Conveyor belt lowers inadvertently Control valve is defective Replace Leaking hydraulic cylinder sleeves Replace Hopper cannot be...

Page 333: ...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 Electrical power de...

Page 334: ...D 41 36 2 2 Lower slewing belt o hydraulic end piece o in the event of a malfunction 1 1 3 4 5 3 2 4 5 2 ...

Page 335: ...1 on the left and right of the slewing belt on both hoisting cylinders 2 of the hydraulic end piece Remove the protective cap from the lowering brake valve Loosen the lock nut 4 of the hexagon socket screw 5 Tighten the hexagon socket screw 5 a quarter of a turn clockwise alternately at the left and right hoisting cylinder until the conveyor belt starts to lower and finally reaches its end positio...

Page 336: ... technical defect means it is no longer possible to lower the platform m Observe the danger zone of the platform being lowered A There is a ball valve 1 on the hydraulic block Slowly swivel the valve lever 2 upwards until the platform begins to lower Close the valve again once the platform has reached the lowest position 2 1 ...

Page 337: ...om being lowered 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 pressure Switch off the engine and depressurise the hydraulic system Protect your eyes Mount all protective devices before re commissioning the feeder Danger due to changes at the vehicle Structural...

Page 338: ...E 2 2 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 339: ... 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 and also fix with bolts and lock nuts 8 Fit the clamping piece 9 with extension arm 10 to the end of the tube A Heed vertical alignment If necessary adjust the height of the support wheel at the adjustment...

Page 340: ...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 pre cise operation of the automatic steering unit Connecting the sensor A A socket for connecting the sensing system to the vehicle s control system is located on the left and right sides of the vehicle on the inner side of the bumper Connect the rel...

Page 341: ...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 right side of the vehicle Left Automatic steering unit on the left side of the vehicle The LEDs 2 indicate the distance from the reference LED Distance from the reference too high too low Centre LED Dis...

Page 342: ... load rating Dismantle the ultrasonic sensor and holder 1 Dismantle the stone guard fit the material chute 2 to the conveyor belt A The material chute is included in the scope of supply of the slewing belt Raise the conveyor belt 3 to max position o Switch the drive engine off and remove the main key 3 2 1 ...

Page 343: ...onveyor belt with a crane The conveyor belt must be cleaned all material deposits removed and all mainte nance flaps closed correctly m The retaining bolt 6 must be inserted at the swivel arm Remove the bolts 7 on both sides Attach lifting gear to the four attachment points 4 5 4 5 6 7 ...

Page 344: ...eed the overall weight of the slewing belt Do not enter the danger zone Use only lifting gear that can bear the load Attachment and loading equipment must meet the condi tions of the applicable accident prevention regulations Heed the centre of gravity of the slewing belt Do not leave any load or loose parts on the slewing belt Comply with all further information in these instructions and in the s...

Page 345: ...ame of the feeder Insert the collar 8 in the opening 8a on both sides and lower the slewing belt slowly until the drilled hole 9 is in line with the bearing 9a Insert the bolts 7 on both sides and secure with the screw 10 Lower the lifting gear and take the crane hook out of the lifting eyes 8 8a 9a 9 7 10 ...

Page 346: ...ng belt with the corre sponding quick release couplings of the feeder Remove the dummy connector 14 and insert the slewing belt connector secure it with the corresponding shackles m All hydraulic hoses 11 must be coupled properly to prevent a greater increase in pressure Check that connected cou plings fit properly 11 14 12 13 ...

Page 347: ...8 remove the hose pack age 20 and insert in the compact coupling 15 Move the locking clamp 16 into lock ing position Insert the plate 17 in the parking cou pling 18 Open the valve 21 swivel the handle upwards f If the slewing conveyor belt is not mount ed to the vehicle the hose package 20 must always be fastened to the parking coupling 18 16 17 19 18 20 21 17 15 ...

Page 348: ...ount the ultrasonic sensor and holder 1 to the slewing belt Check the tension of the conveyor belt proceed with maintenance if necessary Trial operation Proceed with trial operation of the slewing belt test slewing and height adjustment Check functions of the chain lubrication system and spraying system 6 22 22 6 23 1 1 ...

Page 349: ... load rating Dismantle the ultrasonic sensor and holder 1 Dismantle the stone guard fit the material chute 2 to the conveyor belt A The material chute is included in the scope of supply of the slewing belt Raise the conveyor belt 3 to max position o Switch the drive engine off and remove the main key 3 2 1 ...

Page 350: ... Make sure that the bolt 3 is removed on both sides of the vehicle Check the height setting of the conveyor the lower edge of the bearing 4 must be 2 5 centimetres above the opening 5 so that when the feeder continues to reverse the conveyor and feeder can be joined without a collision If necessary extend or lower the lift supports to the necessary height Remove the bolts 6 on both sides Insert th...

Page 351: ...y contact with the ground A If necessary adjust the changeover valve at the pump The bearing 4 is now in the opening 5 m To proceed the relative positions of the through holes and positioning holes 9 10 for the bolt 3 must be as shown Check this on both sides of the vehicle 5 4 10 9 ...

Page 352: ...ng belt with the corresponding quick release cou plings of the feeder Remove the dummy connector 14 and insert the slewing belt connector secure it with the corresponding shackles m All hydraulic hoses 11 must be coupled properly to prevent a greater increase in pressure Check that connected cou plings fit properly 11 14 12 13 ...

Page 353: ... position Insert the plate 17 in the parking cou pling 18 Open the valve 21 swivel the handle upwards f If the slewing conveyor belt is not mount ed to the vehicle the hose package 20 must always be fastened to the parking coupling 18 Press the function button operating panel to lower the conveyor Close the ball valve 21 at the quick release coupling A On reaching the end position continue the low...

Page 354: ...E 18 Remove the locking plate 22 on both sides of the vehicle and keep in the in tended position for safe storage 22a 22 22a ...

Page 355: ...h the ground Push the standing legs 2 into the upper position by hand and secure them here with the corresponding retaining bolt Using the pump retract the lift supports 1 completely and secure with the corre sponding retaining bolt Insert the bolts 3 on both sides and secure with the corresponding screw 1 2 1 2 3 ...

Page 356: ...e lift of the conveyor end piece the latch must be moved from the parking position A to the working position B On both sides of the vehicle 1 move the latch 1 to the working position and fas ten with the corresponding wing bolts 3 1 A B ...

Page 357: ...e tension of the conveyor belt proceed with maintenance if necessary Trial operation Proceed with trial operation of the slewing belt test slewing and height adjustment Check functions of the chain lubrication system and spraying system ...

Page 358: ...ewing belt so that the rear standing legs 1 can be lowered Lower the standing legs into the lower position by hand and secure them here with the corre sponding retaining bolt Using the pump extend the lift supports 2 until they are just above the ground and secure with the corresponding retaining bolt A If necessary adjust the changeover valve at the pump 2 1 ...

Page 359: ...lower the conveyor com pletely As soon as the cylinders are fully re tracted close the ball valve 4 at the quick release coupling Switch off the engine A On reaching the end position continue the lowering function until the ball valve is closed Remove the locking plate 5 from the storage position on both sides of the vehicle and fit in the intended place 5a 3 3a 4 5a 5 ...

Page 360: ...the corresponding quick release cou plings of the feeder Seal all connec tions with the safety caps Disconnect the connector 9 and seal with the safety cap Fit the dummy connector 10 to the feeder socket secure it with the corre sponding shackles A Position hoses and cables so that these are not damaged when the vehicle moves 6 10 7 8 9 ...

Page 361: ...You must work with a banksman The banksman must observe sufficient safety clearance to the danger zones A Heed the notes for directing the vehicle in chapter C Move the vehicle slowly forwards away from the slewing conveyor Make sure that the bearing 11 moves out of the opening 12 without touching Secure lift supports 2 with the corre sponding retaining pins 2 11 12 11 2 ...

Page 362: ...E 26 6 Stone guard 1 2 ...

Page 363: ... must be replaced immediately Danger from material being flung out During operation particularly when conveying loose mate rial e g gravel the scraper can fling stones or particles out at the back of the vehicle opposite to the direction of travel When operating without the slewing belt the main con veyor may only be operated with fitted stone guard The slewing belt may only be operated with fitte...

Page 364: ...E 28 ...

Page 365: ...ceed with expert inspection every twelve months Eliminate all ascertained faults straight away Do not restart the vehicle until all ascertained faults have been eliminated Failure to comply with the prescribed inspection and maintenance work renders the operating licence null and void Comply with all further information in these instructions and in the safety manual Danger due to changes at the ve...

Page 366: ...ter on electric or electronic components Maintenance work to the electric system should only be carried out by trained specialist staff Comply with all further information in these instructions and in the safety manual Danger from heavy loads Lowering vehicle parts may cause injuries When the vehicle is parked and during maintenance and transport close both hopper lids and fit the correspond ing h...

Page 367: ...umes must be conducted into the open air Propane gas bottles must not be stored in closed rooms 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 A Information on how to maintain the optional equipment can be found in the individual sub s...

Page 368: ...king below the raised control platform if this has not been locked Raise the control platform completely and insert the cor responding locking mechanisms correctly according to the instructions After maintenance and repair work keep the locking mechanisms in the holder provided Comply with all further information in these instructions and in the safety manual DANGER ...

Page 369: ...t locking mechanisms A in the corresponding recesses B on the vehicle frame f Always wear a safety helmet when working beneath the control platform After completing the work remove the two locking mechanisms and keep them in the holder provided If necessary the platform may have to be raised again to re move the locking mechanisms A B B ...

Page 370: ...F 11 6 ...

Page 371: ...F 25 1 F 25 Maintenance overview 1 Maintenance overview F70 F81 F90 F95 F60 F30 F52 F50 T i e r 3 S t a g e I I I a T i e r 4 F S t a g e I V F33 F53 S t a g e V F32 F100 ...

Page 372: ...0000 If necessary Conveyor belt F30 q q q q q q Conveyor belt F32 q q q q q q Drive engine Tier 3 Stage IIIa F50 q q q q q q Drive engine Tier4F Stage IV F52 q q q q q q q Drive engine Stage V F53 q q q q q q q Hydraulic system F60 q q q q q q Drive units F70 q q q q q q q Electrical system F81 q q q q q Lubrication points F90 q q q q Special Equipment F95 q q q q q q Checking shutdown F100 q q q ...

Page 373: ...F 30 1 F 30 Maintenance conveyor belt 1 Maintenance conveyor belt ...

Page 374: ...s The vehicle may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces i...

Page 375: ...eyor belt Check tension q Conveyor belt Adjust tension q Conveyor belt Replace chain q Conveyor belt Check for damage q Conveyor belt Check screw connections q Conveyor belt Repair exchange conveyor belt 2 q Emulsion spraying system Check filling level q Emulsion spraying system Top up tank Maintenance q Maintenance during the running in period g ...

Page 376: ...000 every 2 years If necessary 3 q Central lubrication system Check filling level q Central lubrication system Top up oil q Central lubrication system Function check check oil brush q Central lubrication system Exchange oil brush Maintenance q Maintenanceduringtherunning inperiod g ...

Page 377: ...0 every 2 years if necessary 4 q Relieve scraper q q Scraper Check function q Scraper Adjust distance q q Scraper Cleaning routine check q Scraper Wear check for blades q Scraper Replace blades q Scraper Carry out basic setting Maintenance q Maintenance during the running in period g ...

Page 378: ...ions q Screw connections Tighten screw connections 6 q Lubrication points Grease belt drive guide q Lubrication points Lubricate bearing points 7 q q Guide rails Check wear q Guide rails Replacing the guide rails 8 q q Conveyor side shields Check adjustment q Conveyor side shields Adjust distance Maintenance q Maintenance during the running in period g ...

Page 379: ...intenance Conveyor belt tension 1 Check tension m When the conveyor belt end piece is in the horizontal position conveyor belt sag A must be correctly at the marked position to the lower edge of the chain must be 0 mm 5 mm A ...

Page 380: ...ackened e g for cleaning purposes it can be driven slackened condition by pressing switches D and E m Risk of damage to equipment Only allow the conveyor belt to run in reversing mode if the conveyor belt scraper has been disengaged f Ensure that nobody is located in the danger area when working on the conveyor belt Danger of crushing A At the latest the drive chains and conveyor belt must be exch...

Page 381: ...eyor belt Replace chain Caution Heed wear limits The chain must be replaced if the conveyor belt chain has lengthened to such an extent that it is no longer possible to adjust the prescribed conveyor belt sag NOTE ...

Page 382: ...ower the conveyor belt and secure the conveyor belt drive to prevent reactivation Gradually move and check the convey or belt using the lateral operating unit A Check the entire conveyor belt B for the following defects Cracks breakage and wear on the surface and at the sides Missing or loose assembly parts Wear damage and soiling on the drive chains and chain sprockets A If necessary remove cover...

Page 383: ...y check that the screw connections are fastened correctly Conveyor belt conveyor belt web D flat headed bolts The bolt head must be positioned plane with the rubber surface and may be recessed by max 1 mm Drive chain conveyor belt E hexag onal bolts The bolts must not be tightened too tightly m Self locking nuts must be replaced and must not be retightened D E D E ...

Page 384: ...using the dis play on the operating panel A Increased emulsion consumption due to use of the manual spray To top up the tank Remove cap B Fill in emulsion through the filler open ing until the required filling level is achieved Screw cap B on again f Refill the tank only whilst the vehicle is stationary m Only operate the spraying system with approved emulsion B A ...

Page 385: ...lic systems m Ensure maximum cleanliness when working on the central lubrication system Central lubrication system Check filling level m The lubricant tank should always be filled sufficiently to ensure that the sys tem cannot run dry and that sufficient drive chain lubrication is ensured To top up with lubricant Top up the tank to the MAX mark be fore starting work or on receipt of an electronic ...

Page 386: ...e chain is located on both sides of the conveyor belt After trial operation check whether an oil film was applied onto the chain when the central lubricating system was running In the event of malfunctions deter mine and immediately rectify the cause If the brushes are worn on visual in spection they must be exchanged immediately m A disturbed lubricant flow leads to increased wear ...

Page 387: ... the conveyor belt from asphalt residues during and after work and to prevent contamination and wear The scraper is equipped with several scraper blades that scrape off material residues during operation The scraper can be disengaged for cleaning and maintenance A ...

Page 388: ...ve scraper Remove spring cotter pin B Push mounting lever C into recess D and slightly raise scraper Fold away adjusting screw E to side Carefully set down scraper in chain F Repeat process on other side B C D E F G ...

Page 389: ... properly Repeat process on other side Exit danger area and carry out test run Visually check whether all scraper blades are in permanent contact with belt while conveyor belt is running Carry out a complete belt circulation when doing so If necessary switch off conveyor belt and retension adjusting screws D on both sides in steps of 0 5 rotations A Locking pin G must be raised for adjustment Repe...

Page 390: ...otect the conveyor belt from asphalt residues during and after work and to prevent contamination and wear The scraper is equipped with several scraper blades that scrape off material residues during operation The scraper can be disengaged for cleaning and maintenance A ...

Page 391: ...F 30 19 Relieve scraper Remove spring cotter pin B Push mounting lever C into recess D and slightly raise scraper B B C D ...

Page 392: ...F 30 20 Fold away adjusting screw E to side Carefully set down scraper in chain F Repeat process on other side E F ...

Page 393: ...craper into working position Tighten the scraper at the T bolts A so that the lower edge of the two scrapers is flush with the lower edge of the holders B First adjust the rear scraper in the travel direction Tighten the T bolts A evenly at the right and left of the machine possibly count ing the turns A A B C ...

Page 394: ...A Repeat process until correct setting is achieved A The following drawing shows a typical adjustment The distance between the lower edge of the guide plate and the visible ends of the bolt D acts as guidance A The depicted adjustment serves as an indicative value the position of the scrapers can vary by a few millimetres depending on conveyor belt tension pay attention to correct adjustment scrap...

Page 395: ...aces including those behind covering parts together with engine combustion gases 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 from burner Incorrectly performed work on burners ...

Page 396: ...ose This results in asphalt residues falling down at the front Rework with a spatula if necessary f Allow scraper to cool down Move scraper into working position see section entitled Move scraper into working position Spray scraper with separator fluid Routine check following cleaning m Check that all fastening parts have been tightened correctly Tighten any loose connections properly ...

Page 397: ...lades must always be installed at the same position A If the scraper blades are worn at the up per position they must be replaced as a set for the entire scraper m Following adjustment or reinstallation of the scraper blades a basic setting must be carried out see section entitled Scraper basic setting Sharp edged components Surfaces subject to wear can be very sharp edged and can cause injuries W...

Page 398: ...lt while conveyor belt is running Carry out a complete belt circulation when doing so If necessary switch off conveyor belt and retension adjusting screws E on both sides in steps of 0 5 rotations Repeat process until correct setting is achieved m Should the conveyor belt chain tension be changed then the adjustment of the scrap er must also be checked and if necessary adjusted Caution Possible co...

Page 399: ...0 hours of operation at full load check that all mounting and connecting screws are firmly seated m Improperly tightened screws may lead to increased wear and to the destruction of components Tighten loose or loosened screw con nections properly A ...

Page 400: ...brication points 6 Belt drive guide A Grease the belt drive guide surfaces A on both sides of the conveyor belt Bearing points A One lubricating nipple B is located at each hydraulic cylinder bearing point A 2x B ...

Page 401: ... that the belt is changed A The guide rails A B must be re placed at the latest when the wear limit of 7 mm is no longer achieved in the marked areas C m If the guide rails have to be replaced this always has to happen in complete sets A Your Dynapac customer service will be happy to provide support during mainte nance repair and the replacement of wearing parts B A C ...

Page 402: ... ed if necessary m The correct distance B between the lower edge of the conveyor side shield and the conveyor belt is 3 mm across the entire length Adjust distance To adjust the correct distance first re move any adhered material and deposits Loosen the mounting screws C of the side shields and adjust the cor rect distance Lower the loosened shield on a suita ble spacer measuring 3 mm thick Retigh...

Page 403: ...F 32 1 F 32 Maintenance slewing belt 1 Maintenance conveyor belt ...

Page 404: ...s The vehicle may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces i...

Page 405: ...nsion q Conveyor belt Replace chain q Conveyor belt Check for damage q Conveyor belt Check screw connections q Conveyor belt Repair exchange conveyor belt 2 q Conveyor belt frame Check for deposits q Conveyor belt frame Clean 3 q Central lubrication system Function check check oil brush q Central lubrication system Exchange oil brush Maintenance q Maintenance during the running in period g ...

Page 406: ...0 every 2 years If necessary 4 q Relieve scraper q q Scraper Check function q Scraper Adjust distance q q Scraper Cleaning routine check q Scraper Wear check Blades q Scraper Replace blades q Scraper Carry out basic setting Maintenance q Maintenance during the running in period g ...

Page 407: ...hten screw connections 6 q Lubrication points Swivel joint lubricate bearing q Lubrication points Grease belt drive guide q Lubrication points Lubricate bearing points 7 q q Guide rails Check wear q Guide rails Replacing the guide rails 8 q q Conveyor side shields Check adjustment q Conveyor side shields Adjust distance Maintenance q Maintenance during the running in period g ...

Page 408: ...s in the horizontal position conveyor belt sage must be correctly at the marked position to the lower edge of the chain must be 0 mm 5 mm m After completing the adjustments check whether the belt tension has been restored evenly on both sides The length of the spindle B must be identical on both sides A B ...

Page 409: ... left hand spindle if the drum is rotating clockwise or vice versa for anti clockwise rotation m Avoid an inclined position of the reversing drum because this can cause damage to the conveyor belt m After completing the adjustments check whether the belt tension has been restored evenly on both sides The length of the spindle C must be identical on both sides A At the latest the drive chains and c...

Page 410: ...eyor belt Replace chain Caution Heed wear limits The chain must be replaced if the conveyor belt chain has lengthened to such an extent that it is no longer possible to adjust the prescribed conveyor belt sag NOTE ...

Page 411: ...secure the conveyor belt drive to prevent reactivation A Check the entire conveyor belt A for the following defects Cracks breakage and wear on the surface and at the sides Missing or loose assembly parts Wear damage and soiling on the drive chains and chain sprockets Remove encrusted material from the sealing plates B A Your Dynapac customer service will be happy to provide support during mainten...

Page 412: ... check that the screw connections are fastened cor rectly Conveyor belt conveyor belt web D flat headed bolts The bolt head must be positioned plane with the rubber surface and may be recessed by max 1 mm Drive chain conveyor belt E hexag onal bolts The bolts must not be tightened too tightly m Self locking nuts must be replaced and must not be retightened D E D E ...

Page 413: ...n the frame of the conveyor belt can cause subsequent damage A There are maintenance flaps under neath the frame and at the rear reversal Loosen wind bolts A and open all flaps B Remove material deposits possibly spray the surfaces with sepa rator fluid Close all maintenance flaps again cor rectly f All maintenance flaps must be closed during operation A B A B ...

Page 414: ...ve chain is located on both sides of the conveyor belt After trial operation check whether an oil film was applied onto the chain when the central lubricating system was running In the event of malfunctions deter mine and immediately rectify the cause If the brushes are worn on visual in spection they must be exchanged immediately m A disturbed lubricant flow leads to increased wear ...

Page 415: ...tect the conveyor belt from asphalt residues during and after work and to prevent contamination and wear The scraper is equipped with several scraper blades that scrape off material residues during operation The scraper can be disengaged for cleaning and maintenance A ...

Page 416: ...F 32 14 Relieve scraper Remove spring cotter pin B Push mounting lever C into recess D and slightly raise scraper B B C D ...

Page 417: ...F 32 15 Fold away adjusting screw E to side Carefully set down scraper in chain F Repeat process on other side E F ...

Page 418: ...craper into working position Tighten the scraper at the T bolts A so that the lower edge of the two scrapers is flush with the lower edge of the holders B First adjust the rear scraper in the travel direction Tighten the T bolts A evenly at the right and left of the machine possibly count ing the turns A A B C ...

Page 419: ...A Repeat process until correct setting is achieved A The following drawing shows a typical adjustment The distance between the lower edge of the guide plate and the visible ends of the bolt D acts as guidance A The depicted adjustment serves as an indicative value the position of the scrapers can vary by a few millimetres depending on conveyor belt tension pay attention to correct adjustment scrap...

Page 420: ...aces including those behind covering parts together with engine combustion gases 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 from burner Incorrectly performed work on burners ...

Page 421: ...ose This results in asphalt residues falling down at the front Rework with a spatula if necessary f Allow scraper to cool down Move scraper into working position see section entitled Move scraper into working position Spray scraper with separator fluid Routine check following cleaning m Check that all fastening parts have been tightened correctly Tighten any loose connections properly ...

Page 422: ...lades must always be installed at the same position A If the scraper blades are worn at the up per position they must be replaced as a set for the entire scraper m Following adjustment or reinstallation of the scraper blades a basic setting must be carried out see section entitled Scraper basic setting Sharp edged components Surfaces subject to wear can be very sharp edged and can cause injuries W...

Page 423: ...50 hours of operation at full load check that all mounting and connecting screws are firmly seated m Improperly tightened screws may lead to increased wear and to the destruction of components Tighten loose or loosened screw con nections properly ...

Page 424: ... 22 Lubrication points 6 Swivel joint bearing A One lubricating nipple A is located at each bearing point Belt drive guide A Grease the belt drive guide surfaces B on both sides of the conveyor belt 3x A B ...

Page 425: ...F 32 23 Bearing points A One lubricating nipple C is located at each hydraulic cylinder bearing point 2x C ...

Page 426: ... is changed A The guide rails A must be replaced at the latest when the wear limit of 7 mm is no longer achieved in the marked areas B m If the guide rails have to be replaced this always has to happen in complete sets A Your Dynapac customer service will be happy to provide support during mainte nance repair and the replacement of wearing parts A B ...

Page 427: ... ed if necessary m The correct distance B between the lower edge of the conveyor side shield and the conveyor belt is 3 mm across the entire length Adjust distance To adjust the correct distance first re move any adhered material and de posits Loosen the mounting screws C of the side shields and adjust the correct distance Lower the loosened shield on a suit able spacer measuring 3 mm thick Retigh...

Page 428: ...F 32 26 ...

Page 429: ...F 33 1 F 33 Maintenance slewing belt SW6500 1 Maintenance conveyor belt ...

Page 430: ...s The vehicle may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces i...

Page 431: ...tension q Conveyor belt Replace chain q Conveyor belt Check for damage q Conveyor belt Check screw connections q Conveyor belt Repair exchange conveyor belt 2 q Conveyor belt frame Check for deposits q Conveyor belt frame Clean 3 q Central lubrication system Function check check oil brush q Central lubrication system Exchange oil brush Maintenance q Maintenanceduringtherunning inperiod g ...

Page 432: ...0 every 2 years If necessary 4 q Relieve scraper q q Scraper Check function q Scraper Adjust distance q q Scraper Cleaning routine check q Scraper Wear check Blades q Scraper Replace blades q Scraper Carry out basic setting Maintenance q Maintenance during the running in period g ...

Page 433: ...onnections Tighten screw connections 6 q Lubrication points Swivel joint lubricate bearing q Lubrication points Grease belt drive guide q Lubrication points Lubricate bearing points 7 q Guide rails Replacing the guide rails 8 q q Conveyor side shields Check adjustment q Conveyor side shields Adjust distance Maintenance q Maintenance during the running in period g ...

Page 434: ... in the horizontal position conveyor belt sag A must be correctly at the marked position to the lower edge of the chain must be 0 mm 5 mm m After completing the adjustments check whether the belt tension has been restored evenly on both sides The length of the spindle B must be identical on both sides A B ...

Page 435: ... left hand spindle if the drum is rotating clockwise or vice versa for anti clockwise rotation m Avoid an inclined position of the reversing drum because this can cause damage to the conveyor belt m After completing the adjustments check whether the belt tension has been restored evenly on both sides The length of the spindle C must be identical on both sides A At the latest the drive chains and c...

Page 436: ...eyor belt Replace chain Caution Heed wear limits The chain must be replaced if the conveyor belt chain has lengthened to such an extent that it is no longer possible to adjust the prescribed conveyor belt sag NOTE ...

Page 437: ...secure the conveyor belt drive to prevent reactivation A Check the entire conveyor belt A for the following defects Cracks breakage and wear on the surface and at the sides Missing or loose assembly parts Wear damage and soiling on the drive chains and chain sprockets Remove encrusted material from the sealing plates B A Your Dynapac customer service will be happy to provide support during mainten...

Page 438: ...ntire conveyor belt m Visually and mechanically check that the screw connections are fastened correctly Conveyor belt conveyor belt web D flat headed bolts The bolt head must be positioned plane with the rubber surface and may be recessed by max 1 mm m Self locking nuts must be replaced and must not be retightened D D ...

Page 439: ...onveyor belt can cause subsequent damage A There is a tarpaulin A underneath the frame and maintenance flaps and at the rear reversal B Loosen tarpaulin A as far as necessary snap hook Open maintenance flaps B wing bolts Remove material deposits possibly spray the surfaces with separator fluid Then put the tarpaulin back in the correct position and close all maintenance flaps A B ...

Page 440: ...ve chain is located on both sides of the conveyor belt After trial operation check whether an oil film was applied onto the chain when the central lubricating system was running In the event of malfunctions deter mine and immediately rectify the cause If the brushes are worn on visual in spection they must be exchanged immediately m A disturbed lubricant flow leads to increased wear ...

Page 441: ...tect the conveyor belt from asphalt residues during and after work and to prevent contamination and wear The scraper is equipped with several scraper blades that scrape off material residues during operation The scraper can be disengaged for cleaning and maintenance A ...

Page 442: ...F 33 14 Relieve scraper Remove spring cotter pin B Push mounting lever C into recess D and slightly raise scraper B B C D ...

Page 443: ...F 33 15 Fold away adjusting screw E to side Carefully set down scraper in chain F Repeat process on other side E F ...

Page 444: ...craper into working position Tighten the scraper at the T bolts A so that the lower edge of the two scrapers is flush with the lower edge of the holders B First adjust the rear scraper in the travel direction Tighten the T bolts A evenly at the right and left of the machine possibly count ing the turns A A B C ...

Page 445: ...A Repeat process until correct setting is achieved A The following drawing shows a typical adjustment The distance between the lower edge of the guide plate and the visible ends of the bolt D acts as guidance A The depicted adjustment serves as an indicative value the position of the scrapers can vary by a few millimetres depending on conveyor belt tension pay attention to correct adjustment scrap...

Page 446: ...aces including those behind covering parts together with engine combustion gases 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 from burner Incorrectly performed work on burners ...

Page 447: ...ose This results in asphalt residues falling down at the front Rework with a spatula if necessary f Allow scraper to cool down Move scraper into working position see section entitled Move scraper into working position Spray scraper with separator fluid Routine check following cleaning m Check that all fastening parts have been tightened correctly Tighten any loose connections properly ...

Page 448: ...lades must always be installed at the same position A If the scraper blades are worn at the up per position they must be replaced as a set for the entire scraper m Following adjustment or reinstallation of the scraper blades a basic setting must be carried out see section entitled Scraper basic setting Sharp edged components Surfaces subject to wear can be very sharp edged and can cause injuries W...

Page 449: ...50 hours of operation at full load check that all mounting and connecting screws are firmly seated m Improperly tightened screws may lead to increased wear and to the destruction of components Tighten loose or loosened screw con nections properly ...

Page 450: ... 22 Lubrication points 6 Swivel joint bearing A One lubricating nipple A is located at each bearing point Belt drive guide A Grease the belt drive guide surfaces B on both sides of the conveyor belt 3x A B ...

Page 451: ...F 33 23 Bearing points A One lubricating nipple C is located at each hydraulic cylinder bearing point 2x C ...

Page 452: ...in guide 7 A There is a chain guide A near the con veyor end piece A Replace the worn parts of the chain guide every time the belt is changed m Replace guide rails B C as a com plete set in each case A B B B C C A ...

Page 453: ...t ed if necessary m The correct distance B between the lower edge of the conveyor side shield and the conveyor belt is 3 mm across the entire length Adjust distance To adjust the correct distance first remove any adhered material and deposits Loosen the mounting screws C of the side shields and adjust the correct distance Lower the loosened shield on a suit able spacer measuring 3 mm thick Retight...

Page 454: ...F 33 26 ...

Page 455: ... 3 o 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 456: ... engine and remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with engine combustion gases 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 ...

Page 457: ...n the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel system Fuel filter drain the water separator q Engine fuel system Replace fuel pre filter q Engine fuel system Replace fuel filter q Engine fuel system Bleed fuel system Maintenance q Maintenance during t...

Page 458: ...lter Exchange air filter insert 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system Top up coolant q Engine cooling system Check coolant concentration q Engine cooling system Adjust coolant concentration q Engine cooling system Change coolant Maintenance q Maintenance during the runni...

Page 459: ...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 q Maintenance during the running in period g ...

Page 460: ... dry and time consuming venting bleeding can therefore be avoided For filling in the fuel Remove cap A Fill in fuel through the filling port until the required fill lever is achieved Replace the cap A Clean the tank and system Unscrew the drain plug B at the bot tom of the tank and drain into a collec tion pan about 1 l fuel When fastening the screw again after draining make sure to use a new seal...

Page 461: ...s of the sensor rod A A Only check the oil level when the vehicle is in a horizontal position m Too much oil in engine damages gas kets too little oil results in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use sensor rod to check level again B A ...

Page 462: ...eplace the screw cap and tighten properly Fill in the specified quality of oil through the filler opening B on the engine until the oil level rises to the correct mark on the sensor rod A A Oil change s n XXXX Unscrew seal cap C Screwing on the oil drainage hose D 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 com pletely Unscrew ...

Page 463: ...rly A The new filter is inserted during an oil change once the used oil has been drained out Loosen the filter H with a filter wrench 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 installing the oil filter attention must be paid to the oil pressure disp...

Page 464: ...mpleting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two filters Prefilter with water separator C Main filter D Prefilter draining of water A Drain the collecting vessel at regular in tervals or in response to an error mes sage from the engine control unit Drain off separated water at the cock E and collect then close the cock again B A D C A G E...

Page 465: ...plunger 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 filled Start the engine and operate for approx 5 minutes at idle speed or low load Check the prefilter for leaks whilst doing this Lock the manual fuel pump s G bayonet lock by pressing and simultane...

Page 466: ...pty 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 removal valve from time to time A ...

Page 467: ...dicator 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 damage A Replace the safety element E after the filter has been serviced 3 times but after 2 years at the latest never clean it E C C B D D ...

Page 468: ...ystem 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 up to approx 7 cm C from the t...

Page 469: ...sary remove leaves dust or sand from the radiator A Observe engine s operating instructions Check coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentration if necessary A Observe engine s operating instructions ...

Page 470: ... 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 471: ...4F o 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 472: ... engine and remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with engine combustion gases 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 ...

Page 473: ... tank 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 Maintenanc...

Page 474: ...ngine air filter Exchange air filter insert 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system Top up coolant q Engine cooling system Check coolant concentration q Engine cooling system Adjust coolant concentration q Engine cooling system Change coolant Maintenance q Maintenancedurin...

Page 475: ...tank Check level q AdBlue DEF tank Top up with AdBlue DEF q q AdBlue DEF tank Replace suction filter q AdBlue DEF tank Check tank cover q AdBlue DEF tank Clean tank cover q AdBlue DEF dosing unit Inspection and cleaning q q AdBlue DEF dosing unit Change filter q Check hoses and lines for damage Maintenance q Maintenance during the running in period g ...

Page 476: ...rs 5000 If necessary 7 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt 8 q Crankshaft ventilation filter Replace filter element 9 q Exhaust system Inspect diesel oxidisation catalytic converter Maintenance q Maintenance during the running in period g ...

Page 477: ...risk of combustion from static electricity than earlier grades of die sel that contained more sulphur An explosion or combus tion can cause severe to fatal injuries When refuelling vehicles always ensure that the fuel pump is earthed with equipotential bonding to the vehi cle When a fuel pump has correct equipotential bonding there is a continuous electrically conductive connection between all com...

Page 478: ...ling port until the required fill lever is achieved Replace the cap A Clean the tank and system Unscrew the drain plug B at the bot tom of the tank and drain into a collec tion pan about 1 l fuel When fastening the screw again after draining make sure to use a new seal A B ...

Page 479: ...s of the sensor rod A A Only check the oil level when the vehicle is in a horizontal position m Too much oil in engine damages gas kets too little oil results in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use sensor rod to check level again B A ...

Page 480: ...eplace the screw cap and tighten properly Fill in the specified quality of oil through the filler opening B on the engine until the oil level rises to the correct mark on the sensor rod A A Oil change s n XXXX Unscrew seal cap C Screwing on the oil drainage hose D 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 com pletely Unscrew ...

Page 481: ...rly A The new filter is inserted during an oil change once the used oil has been drained out Loosen the filter H with a filter wrench 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 installing the oil filter attention must be paid to the oil pressure disp...

Page 482: ...mpleting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two filters Prefilter with water separator C Main filter D Prefilter draining of water A Drain the collecting vessel at regular in tervals or in response to an error mes sage from the engine control unit Drain off separated water at the cock E and collect then close the cock again B A D C A G F...

Page 483: ...plunger 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 filled Start the engine and operate for approx 5 minutes at idle speed or low load Check the prefilter for leaks whilst doing this Lock the manual fuel pump s G bayonet lock by pressing and simultane...

Page 484: ...g by compressing the discharge slot Remove any baked on dust by press ing together the upper valve section Open the collector housing B at the clips C and remove dust accumula tions Properly reposition the collector hous ing and lock at the clips C A Clean the dust removal valve from time to time C C A B ...

Page 485: ...A Clean the filter element F 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 emergency only A Do not damage cartridge when doing so Check the soundness of the filter pa pers of the filter cartridge by exposing to light and the soundness of the seals Replace them if necessary A Replace the safety element G after the filter has b...

Page 486: ...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 487: ...sary remove leaves dust or sand from the radiator A Observe engine s operating instructions Check coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentration if necessary A Observe engine s operating instructions ...

Page 488: ...0070 The storage temperature for AdBlue DEF is between 5 C and 25 C 23 F and 77 F Store in sealed containers to avoid impurities No direct sunlight It is not advisable to store in a vehicle for longer than 6 months Seal the tank breathers when stored in the urea tank If AdBlue DEF is spilt on painted surfaces or alumin ium surfaces when topping up rinse the affected areas immediately with water Do...

Page 489: ... get AdBlue DEF in your eyes rinse your eyes immediately and thoroughly in clear water for at least 15 minutes Seek medical advice immediately Wash AdBlue DEF off your skin immediately with soap and water If you have swallowed AdBlue DEF rinse your mouth out with water and drink plenty of water Seek medical advice immediately Change any clothing soiled with AdBlue DEF immediately Comply with all f...

Page 490: ...ly fill the AdBlue DEF tank in well ventilated areas Always be careful when opening the AdBlue DEF as this can cause pressure to be released AdBlue DEF may leak as a result Do not inhale the ammonia vapours Ammonia vapours have a biting smell and cause irrita tion above all to the skin mucous membranes and eyes Consult a doctor immediately if injured Comply with all further instructions in the AdB...

Page 491: ... To change the filter the supply lines B at the AdBlue DEF multi head A must be dismantled and the electrical connection plug C disconnected A Use a suitable container or cloth to take up any leaked residues Loosen screws D and remove retain ing ring E B A C D E ...

Page 492: ...ge Pull the head at the same time m Do not pull the connection cable or con nection port Carefully pull the multi head up until the lower part is beneath the tank opening Carefully tilt the lower part up and turn the head until the lower part is at the tank opening Carefully pull the lower part out of the tank opening A ...

Page 493: ...2 23 Filter change s n 003055 Loosen the fastening screw F of the filter Pull the used filter G from the suction pipe Fit the new filter onto the suction pipe and fasten with a new fastening screw F F G F ...

Page 494: ...bout 45 Place the filter side and the tip of the lower part in the tank opening as shown Gradually insert the lower part in the tank opening proceeding carefully m Do not push the parts with force directly into the tank opening This will cause damage Position the head in the required align ment and press on the top until the head fits completely in the tank opening H G ...

Page 495: ...the retaining ring E over the fil ter head Tighten the screws D properly Then mount the supply lines B and con nect up to the power supply plug C m After installation check correct sealing during a trial run E B C D ...

Page 496: ...ng screw F of the filter Pull the used filter G from the suction pipe Fit the new filter onto the suction pipe and fasten with a new fastening screw F A Ensure correct alignment of filter and holders Lightly grease the O ring H of the multi head F G F H ...

Page 497: ...push the parts with force directly into the tank opening This will cause damage Position the head in the required align ment Ensure that the two noses I at the flange of the filter head fit in the corre sponding recesses at the tank Press on the top until the head fits completely in the tank opening Place the retaining ring E over the fil ter head I E ...

Page 498: ...F 52 28 Tighten the screws D properly Then mount the supply lines B and connect up to the power supply plug C m After installation check correct sealing during a trial run B C D ...

Page 499: ... cleaned as follows Loosen the retaining tab A and un screw the tank cover B from the tank Put the cover in a vessel filled with wa ter so that the water comes up to half the height of the blue edge large di ameter Leave the cap to soak for about five minutes m Make sure that the cover is not com pletely covered with water as this inter feres with the ventilation function Shake the cap to let any ...

Page 500: ...F 52 30 Wipe the gasket with a damp cloth to remove any remaining DEF crystals or dirt Then connect the tank cover with the previously loosened retaining tab and screw onto the tank ...

Page 501: ...he filter with a click A Use the side of the service tool with the same colour markings as the filter m Depending on their condition the com pensation element and filter must be re placed after they have been removed A Check the cover A cover thread and thread D of the dosing unit for any damage and replace if necessary Clean the cover A the cap thread and the dosing unit with warm water and a cle...

Page 502: ... 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 503: ...n the filter cover with warm soapy water E and dry it with compressed air f Wear protective goggles when using working with compressed air Never blow compressed air towards other people f Use personal safety equipment when cleaning with solvents Avoid contact with skin Apply a little fresh engine oil to the O rings F of the new filter and set the filter correctly on its contact surface Fit the cov...

Page 504: ...hot surfaces During system cleaning the exhaust temperature and the surface temperature of the exhaust system is very hot and can cause severe injuries The exhaust and exhaust com ponents remain hot after the engine has stopped Let the exhaust system cool down before starting inspection work Make sure that no flammable materials can come into contact with the exhaust system Wear your personal safe...

Page 505: ... V o 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 506: ... engine and remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with engine combustion gases 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 ...

Page 507: ... Fuel tank 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 Maint...

Page 508: ...q Engine air filter Empty dust collector q q Engine air filter Exchange air filter insert 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system Top up coolant q Engine cooling system Change coolant flush radiator Maintenance q Maintenance during the running in period g ...

Page 509: ...q AdBlue DEF tank Top up AdBlue DEF i q q AdBlue DEF tank Replace suction filter q AdBlue DEF tank Check tank cover q AdBlue DEF tank Clean tank cover q AdBlue DEF dosing unit Inspection and cleaning q q AdBlue DEF dosing unit Replace filter q Check hoses and lines for damage Maintenance q Maintenance deviating interval in dusty environment i Maintenanceduringtherunning inperiod g ...

Page 510: ...000 every 2 years 4000 every 3 years 6500 If necessary 7 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt 8 q Exhaust system Inspect diesel oxidation catalytic converter Maintenance q Maintenanceduringtherunning inperiod g ...

Page 511: ...sk of combustion from static electricity than earlier grades of die sel that contained more sulphur An explosion or combus tion can cause severe to fatal injuries When refuelling vehicles always ensure that the fuel pump is earthed with equipotential bonding to the vehicle When a fuel pump has correct equipotential bonding there is a continuous electrically conductive connection between all compon...

Page 512: ...ing port until the required fill lever is achieved Replace the cover A Clean the tank and system Unscrew the drain plug B at the bot tom of the tank and drain into a collec tion pan about 1 l fuel When fastening the screw again after draining make sure to use a new seal B A ...

Page 513: ...s of the dip stick A A Only check the oil level when the vehicle is in a horizontal position m Too much oil in engine damages gas kets too little oil results in overheating and engine destruction For filling in the oil Remove cover B Fill up oil to correct level Return cover B Use dipstick to check level again B A ...

Page 514: ...eplace the screw cap and tighten properly Fill in the specified quality of oil through the filler opening B on the engine until the oil level rises to the correct mark on the sensor rod A A Oil change s n XXXX Unscrew seal cap C Screwing on the oil drainage hose D 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 com pletely Unscrew ...

Page 515: ...rly A The new filter is inserted during an oil change once the used oil has been drained out Loosen the filter H with a filter wrench 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 installing the oil filter attention must be paid to the oil pressure disp...

Page 516: ...mpleting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two filters Prefilter with water separator C Main filter D Prefilter draining of water A Drain the collecting vessel at regular in tervals or in response to an error mes sage from the engine control unit Drain off separated water at the cock E and collect then close the cock again B A D C A G E...

Page 517: ...plunger 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 filled Start the engine and operate for approx 5 minutes at idle speed or low load Check the prefilter for leaks whilst doing this Lock the manual fuel pump s G bayonet lock by pressing and simultane...

Page 518: ... by compressing the discharge slot Remove any dust deflectors by press ing together the upper valve section Open the collector housing B at the clips C and remove dust accu mulations Properly reposition the collector hous ing and lock at the clips C A Clean the dust removal valve from time to time C C A B ...

Page 519: ...A Clean the filter element F 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 emergency only A Do not damage cartridge when doing so Check the soundness of the filter pa pers of the filter cartridge by exposing to light and the soundness of the seals Replace them as required A Replace the safety element G after the filter has be...

Page 520: ...nly approved coolants A As well as changing the coolant the ra diator should be flushed with an ap proved cooling system cleaner Observe engine s operating instructions A Observe the instructions in the chapter entitled Operating substances Remove the drain screw B on the radiator and let the coolant drain com pletely Reinstall the drain screw B and tight en properly Fill in coolant through the fi...

Page 521: ...ry 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 522: ...0 The storage temperature for AdBlue DEF is between 5 C and 25 C 23 F and 77 F Store in sealed containers to avoid impurities No direct sunlight It is not advisable to store in a vehicle for longer than 6 months Seal the tank breathers when stored in the urea tank If AdBlue DEF is spilt on painted surfaces or alumin ium surfaces when topping up rinse the affected areas immediately with water Do no...

Page 523: ...get AdBlue DEF in your eyes rinse your eyes immediately and thoroughly for at least 15 minutes with clear water Seek medical advice immediately Wash AdBlue DEF off your skin immediately with soap and water If you have swallowed AdBlue DEF rinse your mouth out with water and drink plenty of water Seek medical advice immediately Change any clothing soiled with AdBlue DEF immediately Comply with all ...

Page 524: ...Only fill the AdBlue DEF tank in well ventilated areas Always be careful when opening the AdBlue DEF as this can cause pressure to be released AdBlue DEF may leak as a result Do not inhale the ammonia vapours Ammonia vapours have a biting smell and cause irrita tion above all to the skin mucous membranes and eyes Consult a doctor immediately if injured Comply with all further instructions in the A...

Page 525: ... To change the filter the supply lines B at the AdBlue DEF multi head A must be dismantled and the electrical connection plug C dis connected A Use a suitable container or cloth to take up any leaked residues Loosen screws D and remove retain ing ring E B A C D E ...

Page 526: ...ge Pull the head at the same time m Do not pull the connection cable or con nection port Carefully pull the multi head up until the lower part is beneath the tank opening Carefully tilt the lower part up and turn the head until the lower part is at the tank opening Carefully pull the lower part out of the tank opening A ...

Page 527: ...filter for soiling particles and cracks m On finding particles or cracks also check the filter of the dosing unit Fit the O ring H in the groove on the intake pipe Insert the inlet connection of the new filter into the tank intake pipe Fit the clip F over the groove on the filter inlet connection F G F H ...

Page 528: ... about 45 Gradually insert the lower part in the tank opening proceeding carefully m Do not push the parts with force directly into the tank opening This will cause damage Position the head in the required align ment and press on the top until the head fits completely in the tank opening I ...

Page 529: ... the retaining ring E over the fil ter head Tighten the screws D properly Then mount the supply lines B and connect up to the power supply plug C m After installation check correct sealing during a trial run E B C D ...

Page 530: ...ws Remove the drain plug A to empty the tank Collect the remaining contents in a suitable container and then dispose of them properly To remove the filler neck filter B turn the filter a quarter of a turn counter clockwise and pull out of the filler neck strainer m To avoid damage do not use a sharp object to remove the filler neck filter Remove the filler neck filter A To avoid soiling place the ...

Page 531: ...lter for cracks and other damage On finding any damage re place the filter Clean the filter with warm water and a soft brush Dry with compressed air to avoid soiling Check the tank cover and the ventila tion cap for cracks and holes check the condition of the thread On finding any damage replace the tank cover and or the ventilation cap Check the thread of the DEF tank On finding any damage replac...

Page 532: ...nk drain plug and screw tight 5 Nm Fit the filler neck strainer B in the tank Insert the filler neck unit in the tank Turn counter clockwise until the unit locks Fit the tank cover and tighten by hand until it locks E B ...

Page 533: ...ill possible for residual pressure to remain in the system Before disconnecting any connections open the fittings slowly to let any pressure escape Disconnect the batteries The DEF dosing unit filter consists of the following components DEF dosing unit A Filter element of the DEF dosing unit B Anti freeze membrane of the DEF dosing unit C Housing of the DEF dosing unit filter D C A B C D ...

Page 534: ... with a clean damp cloth to ensure no soiling can land in the DEF dosing unit m Even tiny quantities of dirt particles and soiling can damage the DEF dosing sys tem No dirt or other foreign bodies may land in the DEF dosing unit Place a suitable container under the filter housing to catch any AdBlue DEF residues Unscrew housing D 46 mm wrench Remove anti freeze membrane C and proceed with visual i...

Page 535: ... the DEF dosing sys tem check the DEF filter prior to dis posal Check the filter of the dosing unit for signs of soiled DEF Use the appearance and smell of the filter to ascertain whether soiled fluid has flowed through the dosing system Contact the service department if nec essary Check the DEF filter for soil ing On finding soiling check the following DEF tank filter Inlet connection of the DEF ...

Page 536: ... unit is damaged replace the complete DEF dosing unit Check that the groove of the anti freeze membrane is clean and free of soiling Clean with a clean damp cloth warm water and a mild cleaner A Never drive the vehicle when the DEF fil ter or filter housing is removed Clean the cover of the new filter housing of the DEF dosing unit and the thread of the dosing unit Use warm water and a clean cloth...

Page 537: ...e notch of the pump housing A Use the supplied lubricant when fitting the filter housing Spray the supplied lu bricant on the threads of the pump hous ing and the sealing bead of the anti freeze membrane Install the filter hous ing and screw tight Use a 46 mm socket wrench insert Torque 80 Nm Final jobs of work Connect the battery m Let the engine run for at least 15 minutes so that the system rea...

Page 538: ... 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 539: ...hot surfaces During system cleaning the exhaust temperature and the surface temperature of the exhaust system is very hot and can cause severe injuries The exhaust and exhaust com ponents remain hot after the engine has stopped Let the exhaust system cool down before starting inspection work Make sure that no flammable materials can come into contact with the exhaust system Wear your personal safe...

Page 540: ...F 53 36 ...

Page 541: ...F 60 1 F 60 Maintenance hydraulic system 1 Maintenance hydraulic system ...

Page 542: ...any maintenance work 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 engine combustion gases can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the vehic...

Page 543: ...ower limit position Move front hopper cylinder to lower limit position Turn diesel engine off and secure to prevent it starting up again without authorisation Disconnect battery from vehicle electrical system Let the hydraulic oil cool down Allow a waiting period to relieve residual pressures After depressurising open screwed connections slowly and carefully Continue to loosen the screwed connecti...

Page 544: ... 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 q Pump distribution gear Check oil level q Pump distribution gear Top up oil q Pump distribution gear Change oil q Pump distribution gear Check bleeder q Pump distribution gear C...

Page 545: ...ry 2 years If necessary 5 g q Hydraulic hoses Visual inspection g q Hydraulic system Leak test q Hydraulic system Retighten screw connections q q Hydraulic hoses Replace hoses 6 q q Auxiliary flow filter Change filter element o Maintenance q Maintenance during the running in period g ...

Page 546: ... on the side of the tank For filling in the 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 dirt from the oil tank vent C Clean the surfaces of the oil cooler m Use only the recommended hydraulic oils see section Recommended hy draulic oils A When filling for the first time al...

Page 547: ...lug D at the bottom of the tank Collect the oil in a container using a funnel When fastening the screw again after draining make sure to use a new seal A The oil should be changed when at oper ating temperature m When changing the hydraulic oil also change the filter D ...

Page 548: ...er securing 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 F replace if nec essary Coat the sealing surfaces and O rings with clean operating fluid m The filter must be bled following filter replacement F E D C B A ...

Page 549: ...ht en the cover mounting screws A Open the bleed screw G Place 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 therefore free of air bubbles A The process from assembling the filter cover to starting the drive engine should take place in less than 3 minu...

Page 550: ...r 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 r...

Page 551: ...s 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 A The oil should be changed when at operating temperature Oil change s n XXXX 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 Pour in the prescr...

Page 552: ...lace the end of the hose in the col lecting vessel and let the oil drain com pletely Unscrew the drainage hose and return the screw cap 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 C D A ...

Page 553: ...ing 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 manuf...

Page 554: ...ening of the hoses prevents them from chafing on components or on each other components with sharp edges must be covered when installing hydraulic hoses bending radii are not smaller than the permitted values When hydraulic hoses are connected to moving parts the length of the hose must be dimensioned to ensure that the bending radii are not smaller than the permitted smallest values right across ...

Page 555: ...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 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 The...

Page 556: ... the filter then close the non return valve again Replace filter element B and sealing ring C Turn filter element clockwise with the help of carrier straps and at the same time raise it slightly Wait for a moment until the oil has escaped downwards then remove the filter element Check inlet and outlet in filter housing D As required top up hydraulic oil level in filter housing then screw down the ...

Page 557: ...F 71 1 F 71 Maintenance drive units 1 Maintenance drive units ...

Page 558: ...s The vehicle may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces i...

Page 559: ...500 1000 annually 2000 every 2 years If necessary 1 q Chain tension Check q Chain tension Adjust q Chains Relieve 2 q Bottom plates Check wear q Bottom plates Replace 3 q Rollers Check for leaks q Rollers Check wear q Rollers Replace Maintenance q Maintenance during the running in period g ...

Page 560: ...y 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 Check screw connections q Planetary gear Tighten screw connections 5 q Lubrication points Grease the track guide Maintenance q Maintenanceduringtherunning inperiod g ...

Page 561: ...ant 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 ma...

Page 562: ...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 Checking adjusting chain tension The chain tension is adjusted with grease tensioners The filling ports A are located on the RH and LH sides of the drive unit frame x A ...

Page 563: ...tension ensure that the position of the chain to the idler wheel is as shown in diagram A A Correct if necessary by moving the vehicle a little The correct setting has been adjusted when the pressure gauge C shows a value between 65 85 bar A B C ...

Page 564: ...he tension is too high see section Relieving the chain A Repeat this procedure on both drive units Relieving the chain f The grease in the tensioning element is under pressure Carefully and slowly un screw the filling valve but not too far Unscrew the filling connection A us ing a tool until the grease is able to emerge from the lateral hole A The idler wheel moves back independ ently or must be r...

Page 565: ...te with the front edge A over the chain links bolt eye B Lubricate the threads and the contact surfaces beneath the bolt heads with a thin film of oil or grease Insert the bolts C into the holes and screw them into the nuts D a few turns Tighten the bolts without applying significant torque Tighten the bolts diagonally E to the required torque 155 8 Nm m Check that each bolt has attained the full ...

Page 566: ...measures when rais ing and securing loads Remove the defective roller Install the new roller using new as sembly parts Tighten the bolts without applying sig nificant torque Tighten the bolts diagonally to the re quired torque Tighten to the following torques Small rollers A 220 Nm Large rollers B 87 Nm m Check that each bolt has attained the full tightening torque Lower the track chassis and tens...

Page 567: ...r bore at A until the oil level has reached the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at oper ating temperature m Ensure that no dirt or foreign bodies are able to enter the gear Turn the conveyor chain sprocket so that the drain plug B is located at the bottom Unscrew and remove the drain plug B and filler screw A and drain off ...

Page 568: ...arbox mount ing screws are firmly seated m Improperly tightened screws may lead to increased wear and to the destruction of components The correct torque for the gear track chassis connecting screws B is 500Nm 50Nm The correct torque for the hydraulic motor gear connecting screws C is 410Nm B C ...

Page 569: ...F 71 13 Lubrication points 5 Drive unit guide A There is a grease nipple A on both sides of the drive unit guide 15x A ...

Page 570: ...F 71 14 ...

Page 571: ...F 81 1 F 81 Maintenance electrical system 1 Maintenance electrical system ...

Page 572: ...e caused by touching live parts directly or indirectly 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 Comply with all further information in these instructions and in the safety manual Danger from batteries Incorrect handling of the batteries poses a danger...

Page 573: ...ce point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Check fill level of battery acid q Top up with distilled water q Apply grease to battery terminals 2 q Electrical fuses Maintenance q Maintenance during the running in period g ...

Page 574: ...ries usually depends on the operating conditions such as e g temperatures number of starts operating time be tween starting and stopping etc If a battery has to be topped up with increasing fre quency this indicates overloading If a battery does not have to be topped up at all over a long period of operation the battery may be underloaded e g due to poor ca ble connections m The battery terminal c...

Page 575: ...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 capaci...

Page 576: ...F 81 6 2 Electrical fuses relays 2 1 Main fuses A F A F1 1 Main fuse 1 50 F1 2 Main fuse 2 50 F1 3 Preheater 125 F1 4 Engine T4f O 30 F1 5 Illuminated balloon 30 A ...

Page 577: ...F 81 7 2 2 Fuses in terminal box B B ...

Page 578: ...3 T4F system O 15 F14 Emulsion sensor central lubrication 7 5 F15 24V socket 10 F16 24V socket 10 F17 Telematic 10 F18 Operating panel 3 F19 Interface 2 F20 Interface 2 F21 Power supply Slave A11 25 F22 Power supply Master A1 5 F23 Engine sensor 7 5 F24 Power supply Master Slave 5 F25 Power supply Master A1 25 F26 Fuel pump 10 F27 Operating panel 2 F28 Horn 10 F29 Spare 10 F30 Power supply Slave A...

Page 579: ...F 81 9 F Usage A F36 Windscreen wiper 10 F37 Central lubrication 7 5 F38 Spare 10 F39 Main conveyor belt emulsion 10 F40 Conveyor belt working lights 5 ...

Page 580: ...F 81 10 Relays in the engine compartment K 0 Engine start 30 Preheater O 31 Illuminated balloon O K31 K30 K0 ...

Page 581: ...F 81 11 Relays in terminal box C C ...

Page 582: ...1 Addblue preheater 12 Addblue preheater 13 Emulsion spraying system hand piece 14 Addblue system 15 Reversing alarm 16 Hazard flashers 17 Seat heating 18 Windscreen wiper 19 Windscreen wiper water pump 20 Video system 21 Central lubrication chain 22 Light signalling system 23 Light signalling system 24 Emulsion spraying system slewing belt O 25 Spare 26 Lights 27 Stage V engine 28 Stage V engine ...

Page 583: ...0 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 read there ...

Page 584: ...os 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 585: ...ing 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 oil by the...

Page 586: ... minutes until the full delivery rate is achieved after filling Bleed central lubrication system Bleeding the lubrication system is nec essary if the central lubrication system has been operated with an empty lubri cant tank Release the main lubrication line a at the distributor b Start up the central lubrication sys tem with the filled lubricant tank c Allow the pump to run until lubricant emerge...

Page 587: ...e of the blockage which has triggered the pressure limiting valve After rectifying the malfunction and reconnecting all lines again check the pressure limiting valve a for lu bricant emergence Check all connections and lines for leaks Check the flow of lubricant at the consumers Each lubrication channel at the consum ers must be checked as regards clear ance A A pair of oil brushes which apply the...

Page 588: ...F 90 6 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 589: ...F 95 1 F 95 Maintenance special equipment 1 Maintenance special equipment ...

Page 590: ...s The vehicle may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces i...

Page 591: ...250 500 1000 annually 2000 every 2 years If necessary 1 q Hopper augers Grease the bearing 2 q Hopper augers Drive chains Check tension q Hopper augers Drive chains Adjust tension 3 q Hopper augers Check wear q Hopper augers Replace augers Maintenance q Maintenance during the running in period g ...

Page 592: ... q Scraper Check function q Scraper Adjust distance q Scraper Replace blades 5 q Auger Grease the bearing 6 q Auger Drive chains Check tension q Auger Drive chains Adjust tension 7 q Auger Check wear q Auger Replace auger 8 q Cutting wedge Wear check Blades q Cutting wedge Replace blades Maintenance q Maintenance during the running in period g ...

Page 593: ...ers Grease the bearing 1 Remote the maintenance flap A and take out the seal B A There is a grease nipple C at both bearings Fill with grease using a grease gun Then replace the seal B and mainte nance flap A in the correct position B A 2x C ...

Page 594: ... must be able to move freely ap prox 10 mm To re tension the chains Slightly loosen the mounting screws C and lock nut D Adjust the required chain tension us ing the tensioning screw E Tighten fastening bolts C and lock nuts D again correctly Regrease the chain with a suitable grease Then replace the seal B and mainte nance flap A in the correct position B A C C E D 10mm ...

Page 595: ...er augers check wear 3 A The auger must be replaced if the sur face of the auger flight A becomes sharp edged the diameter of the auger is reduced or the plating is worn f Risk of injury due to sharp edged parts A ...

Page 596: ...pe off material residues A If the scraper blades are worn they must be replaced as complete sets on the en tire scraper A The correct spacing between the scrap er blade and the conveyor is 10 mm Adjust if necessary Slightly loosen the nuts B along the whole length of the scraper Unfasten the lock nuts on the two adjusting screws C Turn the screws C to adjust the height Then tighten the lock nuts o...

Page 597: ...emove the protective hood A of the auger drive A Proceed on both sides of the vehicle A There is a lubricating nipple B at each bearing Fill with grease using a grease gun Then put the protective hood A back in the proper position A 2x B ...

Page 598: ...e chain must be able to move freely approx 10 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 Regrease the chain with a suitable grease Then put the protective hood A back in the proper position A B B C D 1 0 m m ...

Page 599: ...F 95 11 Auger check wear 7 A The auger must be replaced if the surface of the auger flight A becomes sharp edged and the diameter is reduced f Risk of injury due to sharp edged parts A ...

Page 600: ... top of the remixer unit The part is located directly in the material flow with the risk of great er wear and tear Remove the spring cotter pin and re taining bolt B to pull the cutting wedge out of the remixer unit The blades C must be replaced if they are worn B A C ...

Page 601: ...F 100 1 F 100 Checking shutdown cleaning 1 Tests checks cleaning shutdown ...

Page 602: ... 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 Check ladders steps 5 q q Cleaning 6 q Preserving the feeder Maintenance q Maintenance during the running in period g ...

Page 603: ...responding 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 the spare parts catalogue Screws locked with screw cement must be cemented in again if found to have come loose...

Page 604: ...at least once a year check that they are all in good operational condition 5 Ladders steps A The surface structure of steps and ladders becomes worn over time The surfaces of areas and components designed to be non slip must be checked to ensure that they are safe to operate at least once a year f Components which are no longer sufficiently non slip must be exchanged immediately ...

Page 605: ...e all 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 gr...

Page 606: ...ion key before any maintenance work Comply with all further information in these instructions and in the safety manual Caution Possible destruction of parts The conveyor belt is fitted with parts that are sensitive to heat Damage can be caused when using a blowtorch or similar equipment for cleaning Hot surfaces Surfaces including those behind covering parts together with engine combustion gases c...

Page 607: ...adjust if necessary see Maintenance Conveyor Maintenance slewing belt Check that the conveyor side shields are correctly adjusted readjust if necessary see Maintenance Conveyor Maintenance slewing belt Use the spray lance to apply separator emulsion to all machine parts and compo nents coming in contact with asphalt This applies particularly to Hopper Conveyor side shields Push roller Stone guard ...

Page 608: ...shields A Use the spraying system to apply separator emulsion to the emptied conveyor belt After the end of the construction site Remove any remaining asphalt adhering to the conveyor side shields A Remove any remaining asphalt adhering to the scraper B still in working position Remove any material adhering to the conveyor chain A B ...

Page 609: ...r must be checked for any unwanted material incursions and for material adhering to the segments of the conveyor belt This material must be loosened with a suitable tool and removed from the con veyor belt m Do not clean with sharp objects The rubber conveyor belt must not be damaged A B A B D C ...

Page 610: ...ove the unwanted material A Material deposits under the conveyor belt segments are indicated by bumps on the outer surface of the conveyor belt example C While the belt runs round complete ly once a second person should check the entire outer surface for any signs of bumps If there is material under the segments loosen the screwed connections D of the segment remove material under the segment Rest...

Page 611: ...rotect 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 m Move the conveyor belt s 2 to 3 meters every 2 months 8 2 Shutdo...

Page 612: ...e impaired Corresponding preventive treatment must be applied to the machine This should be repeated at appropriate intervals when necessary All possible harmful influences must be taken into consideration This includes high salt content in the air near the coast together with the use of de icing agents on the roads or strong UV radiation The vehicle should be treated with corrosion and surface pr...

Page 613: ...isposal must be carried out after replacing wear and spare parts and after the vehicle has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oily or greasy parts hydraulic hoses lube pipes etc must be treated separately A Electric devices accessories and packaging should be recycled in an env...

Page 614: ...1 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 ...

Page 615: ... 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 616: ...F 100 16 ...

Page 617: ...icants 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 or lubricant levels promote rapid wear and feeder failure m Never mix synthetic oils with mineral oils ...

Page 618: ...F 110 2 3 2 1 6 6 7 8 4 5 9 ...

Page 619: ...ooling liquid 32 litres 4 Hydraulic oil reservoir Hydraulic oil 240 litres Tier 3 Tier4F 215 litres Stage V 5 Pump distribution gear Gearbox oil 7 0 litres 6 Planetary gear drive unit Gearbox oil 2 5 litres 7 Emulsion spraying system Emulsion 100 litres 8 Chain lubricating system Chain oil 2 0 litres 9 AdBlue DEF tank o AdBlue DEF fluid 19 litres Tier 4F 37 litres Stage V Separator fluid tank Sepa...

Page 620: ...r of explosion Never mix diesel fuel with ethanol petrol or alcohol m Diesel fuel contaminated with water or dirt can cause serious damage to the fuel system Keep fuel and fuel system free of water and impurities m Observe the instructions for fuel recommendations and the specification in the main tenance instructions of the engine manufacturer 2 2 Drive engine TIER 3 4F Stage V o lubricating oil ...

Page 621: ...e Coolant 200 Antifreeze Special Extended Life Coolant Antifreeze G12 Aviaticon Finkofreeze P12 Dynapac AGIP Chevron Caltex Fuchs Mobil Shell Finke Hydraulic 100 Rando HDZ 46 Rando HDZ 46 Tellus Oil S2 V46 Tellus S2 VX46 Aviaticon HV 46 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 400 Titan ATF 6000 SL Spirax S4 ATF HDX Spirax S6 ATF VM Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oi...

Page 622: ...sed to the vehicle by using separator emulsions and other cleaning agents not approved by the factory without prior consultation The use of separator emulsions and cleaning agents that are not approved makes the vehicle guarantee null and void Only use approved separator emulsions cleaning agents and operating substances Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Chevron Chain fluid D956921561 D...

Page 623: ...uid is prescribed pursuant to ISO 22241 1 respectively DIN 70070 For vehicles operating in North America the use of a DEF fluid with API approval is urgently recommended m Observe the instructions for the AdBlue DEF recommendations and specification in the maintenance instructions issued by the engine manufacturer Dynapac ...

Page 624: ... contact our factory advisory service Caution Do not mix Panolin When using Panolin it must not be mixed with other hydraulic fluids Keep Panolin in stock for topping up Heed the marking at the filling point 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 4...

Page 625: ......

Page 626: ...www dynapac com ...

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