Dynapac SD2500W Operation & Maintenance Manual Download Page 1

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01-0111

OPERATION

MAINTENANCE

Paver Finisher

SD2500W

SD2500WS

Type 897 / 898

Keep for later use in document compartment

Article No. for this handbook: 4812037948 (A5) / 4812037953 (A4)

Valid for:
_________________ to _________________
_________________ to _________________

Summary of Contents for SD2500W

Page 1: ...Paver Finisher SD2500W SD2500WS Type 897 898 Keep for later use in document compartment Article No for this handbook 4812037948 A5 4812037953 A4 Valid for _________________ to _________________ _________________ to _________________ ...

Page 2: ...Original spare parts only Everything from one source Your authorised Dynapac dealer ...

Page 3: ...Danger zones 7 4 Safety devices 8 5 Technical data standard configuration 10 5 1 Dimensions all dimensions in mm 10 5 2 Allowed angle of rise and slope 11 5 3 Permissible approach angle 11 5 4 Turning circle 11 5 5 Weights SD2500W all weights in t 12 5 6 Weights SD2500WS all weights in t 12 5 7 Performance data SD2500W 13 5 8 Performance data SD2500WS 14 5 9 Traction driv De chassis 15 5 10 Engine...

Page 4: ...n 1 1 Safety regulations for transportation 1 2 Transportation on low bed trailers 2 2 1 Preparations 2 3 Securing the load 4 3 1 Prepare the low bed trailer 4 3 2 Driving onto the low bed trailer 5 3 3 Lashing equipment 6 3 4 Loading 7 3 5 Preparing the machine 8 4 Securing the load 9 4 1 Securing at the front and at the sides 9 Step 1 fasten lashing chains at the front 9 Step 2 fasten lashing ch...

Page 5: ...ng monitoring 10 Menu 04 external levelling 11 Setting menu 401 external levelling 11 Menu 05 paving thickness 12 Set up menu 501 paving thickness preselection 12 Menu 06 screed parameters 13 Setting menu 600 compacting element frequencies 14 Setting menu 601 delayed screed start 14 Setting menu 602 screed type selection 15 Setting menu 603 screed heater system 15 Menu 07 conveyor auger capacity 1...

Page 6: ... Screed lock mechanical o 13 Screed lock hydraulic o 14 Paving thickness indicator 15 Auger lighting o 16 Engine compartment lighting o 16 Xenon working light o 17 LED working light o 17 500 watt spotlight o 18 Camera o 18 Auger height adjustment ratchet o 19 Auger height indicators 19 Sensor rod sensor rod extension 20 Manual separator fluid spray o 22 Separator fluid spraying system o 23 Conveyo...

Page 7: ...on for transportation 15 Driving and stopping the paver finisher 17 1 3 Preparations for paving 18 Separator fluid 18 Screed heater system 18 Direction marks 19 Loading conveying material 21 1 4 Starting for paving 23 1 5 Checks during paving 24 Paver function 24 Quality of the layer 24 1 6 Paving with screed control at paving stop and screed charging relieving 25 General 25 Screed charging reliev...

Page 8: ...orking width 5 06m 16 Auger upgrading working width 5 70m 16 Auger upgrading working width 6 34m 17 Auger upgrading working width 6 98m 18 Auger upgrading working width 7 62m 19 Auger upgrading working width 8 26m 20 4 3 Mounting the auger brace 21 4 4 Aligning the auger 23 5 Auger extension Auger Type B 24 5 1 Mounting extension parts 25 Mount auger extension 25 Mounting support tube extensions 2...

Page 9: ...switches left and right mounting the PLC version 56 9 Screed 57 10 Electrical connections 57 10 1 Machine operation without remote control side board 58 F10 Maintenance 1 1 Notes regarding safety 1 F24 Maintenance review 1 1 Maintenance review 1 2 Optional assemblies 2 F31 Maintenance conveyor 1 1 Maintenance conveyor 1 1 1 Maintenance intervals 2 1 2 Points of maintenance 3 Chain tension conveyor...

Page 10: ... system 2 6 Engine fuel system 3 8 Engine air filter 4 10 Engine cooling system 5 12 Engine drive belt 6 14 F61 Maintenance hydraulic system 1 1 Maintenance hydraulic system 1 1 1 Maintenance intervals 2 2 Safety instructions for working on the hydraulic system 4 Sfety instructions hydraulic reservoir 4 2 1 Points of maintenance 5 Hydraulic oil tank 1 5 Suction return flow hydraulic filter 2 7 Ble...

Page 11: ...in terminal box C 11 Relays in the engine compartment E 13 F90 Maintenance lubricating points 1 1 Maintenance lubricating points 1 1 1 Maintenance intervals 2 1 2 Points of maintenance 3 Central lubrication system 1 3 Bearing points 2 7 F100 Tests stopping 1 1 Tests checks cleaning stopping 1 1 1 Maintenance intervals 2 2 General visual inspection 3 3 Inspection by an expert 3 4 Cleaning 4 4 1 Cle...

Page 12: ...emblies 2 2 1 Capacities 4 3 Lubricant specifications 5 3 1 Engine 5 3 2 Cooling system 5 3 3 Hydraulic system 5 3 4 Pump distribution gear 5 3 5 Travel drive planetary gear 6 3 6 Auger drive planetary gear type A 6 3 7 Auger box type A 6 3 8 Auger bevel gear type B 6 3 9 Grease 6 3 10 Hydraulic oil 7 ...

Page 13: ...opriate to the vehicle option is used Safety instructions and important notes are identified by the following pictograms f Precedes safety instructions that must be observed in order to prevent danger to per sonnel m Precedes notes that must be observed to prevent damage to equipment A Precedes general notes and explanations t Used to indicate standard equipment o Used to indicate optional equipme...

Page 14: ... information prohibitions and instructions can result in life threatening injuries A The Guidelines for the Correct Use and Application of Paver Finishers compiled by Dynapac must also be observed 1 2 Warnings Warning on a dangerous area or hazard Failure to observe the warnings can result in life threatening inju ries Warning on danger of being pulled in m In this working area on this element the...

Page 15: ...nts are carried out Always make sure that there are no persons within the endangered areas Warning on hand injuries Warning on hot surfaces or hot liquids Warning on danger of falling Warning on dangers posed by batteries Warning on hazardous or irritating substances Warning on substances which constitute a fire hazard Warning on gas bottles ...

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

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

Page 18: ... Hydraulic oil Diesel fuel Coolant Cleaning liquids must not get into the soil or sewer system during cleaning maintenance and repair work Substances must be caught stored transported and brought to pro fessional disposal sites in suitable containers Environmentally hazardous substance 1 6 Fire prevention A Locally applicable regulations may require suitable extinguishing agents to be carried on t...

Page 19: ...turer s documentation and additional doc umentation A For example the maintenance instructions of the engine manufac turer m Description depiction applicable when equipped with gas heater m Description depiction applicable when equipped with electric heat er ...

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

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

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

Page 23: ... 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 24: ...A 2 ...

Page 25: ...ion The Dynapac SD2500W SD2500WS paver finisher is a wheeled paver finisher which is used for paving bituminous mixed material roll down or lean mixed concrete track laying ballast and unbound mineral aggregates for foundations for paving ...

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

Page 27: ...is considerably facilitated by the automatic mate rial handling system the independent travel drives and the clearly structured operat ing components and controls The following extra equipment option is available o Automatic levelling slope control system o Ultrasonic sensors for material transfer controller o Additional cut off shoe o Larger working widths o Automatic central lubrication system f...

Page 28: ... traction drive pumps are connected to the traction motors by means of high pressure hydraulic hoses These hydro motors can drive the drive wheels through a planetary gear The multi stage planetary gear produces the various movement ranges and the brake function Steering system operator s platform The fully hydraulic steering system ensures easy manoeuvrability The small turning radius permits qui...

Page 29: ...tuated independently from the conveyors The left hand and the right hand half of the auger can be controlled separately The drive system is fully hydraulic The conveying direction can be changed towards the centre or towards the outside This ensures that there is always a sufficient supply of material even if an excessive amount of material is required at one side The auger speed is continuously c...

Page 30: ...acility on the crossbeam Depending on the paving condition requirements the crossbeam can be moved backwards or forwards This adjustment enlarges the material space between the au ger and screed Automatic paving stop and screed charging relieving The automatic paving stop prevents the formation of any screed marks caused by a stopped screed When the paver finisher stops during a truck change the s...

Page 31: ...s m In these vehicle working areas there may be a risk of drawing in or crushing during normal operation caused by rotating and conveying elements or by components in motion Danger of being pulled in Danger of crushing ...

Page 32: ...B 8 4 Safety devices 4 5 6 7 10 7 8 9 12 3 2 1 5 11 7 13 14 ...

Page 33: ...lar intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation 1 Hopper transport safeguard 2 Screed lock mechanical hydraulic o 3 Main switch 4 Emergency stop button 5 Horn 6 Ignition key 7 Lights 8 Protective roof latch o 9 Fire extinguisher o 10 Screed warning light o 11 Covers lateral flaps coverings 12 Foot brake 13 Hazard ...

Page 34: ...l data standard configuration 5 1 Dimensions all dimensions in mm A For screed technical data refer to the screed operating instructions R65 6380 2240 6100 1670 2690 3100 3820 3460 3350 2550 2055 302 495 2125 500 425 ...

Page 35: ...on gradient slope lateral inclina tion which is above the specified limit value please consult the customer service de partment for your vehicle 5 3 Permissible approach angle 5 4 Turning circle Internal turning cycle 2 47 m External turning cycle 6 06 m max 15 max 15 max 15 max 15 max 16 max 16 ...

Page 36: ...he operating instruc tions for the screed Paver finisher without screed approx 13 2 14 7 Paver finisher with screed V5100 approx 16 5 18 0 With extension parts for max working width additionally max With filled hopper Additionally max approx 13 0 Paver finisher without screed approx 13 2 14 7 Paver finisher with screed V5100 approx 16 5 18 0 With extension parts for max working width additionally ...

Page 37: ...ydraulically adjustable up to maximum paving widths with extension parts V5100TV E 2 55 2 00 5 10 7 30 m V5100TV 2 55 2 00 5 10 7 30 m V6000TV E 3 00 2 45 6 00 7 50 m V6000TV 3 00 2 45 6 00 7 50 m Transport speed 0 20 km h Operating speed 0 30 m min Paving height 100 300 mm Max grain size 40 mm Theoretical paving performance 700 t h ...

Page 38: ...hydraulically adjustable up to maximum paving widths with extension parts V5100TV E 2 55 2 00 5 10 8 10 m V5100TV 2 55 2 00 5 10 8 10 m V6000TV E 3 00 2 45 6 00 9 00 m V6000TV 3 00 2 45 6 00 9 00 m Transport speed 0 20 km h Operating speed 0 30 m min Paving height 100 300 mm Max grain size 40 mm Theoretical paving performance 750 t h ...

Page 39: ...ontrol Brakes Running gear brake hydraulic brake Make type Cummins QSB 6 7 C173 Version 6 cylinder diesel engine water cooled Performance 129 KW 175PS at 2200 rpm Pollutant emissions in co ordination with EU 3A Tier 3 Fuel consumption full load Fuel consumption 2 3 load 36 0 l h 24 0 l h Fuel tank capacity See chapter F Make type Cummins QSB 6 7 C173 Version 6 cylinder diesel engine water cooled P...

Page 40: ...inlet height outside 585 mm Hopper width outside open 3 460 mm Type Dual conveyor belt Width 2 x 580 mm Conveyors Left and right auger separately controllable Drive Hydrostatic continuously controllable Conveying volume controller Fully automatic via configurable switching points Auger diameter 380 mm Drive Hydrostatic central drive o hydrostatic external drive o Continuously variable regardless o...

Page 41: ... Screed stop with pretensioning max pressure 50 bar During paving Screed charging Screed relieving max pressure 50 bar Levelling system Mechanical grade control Optional systems with and without Slope control system On board voltage 24 V Batteries 2 x 12 V 88 Ah Generator o 19 kVA 400 V 25 kVA 400 V Operation 5 C 45 C Storage 5 C 45 C ...

Page 42: ...B 18 6 Location of instruction labels and identification plates 22 21 22 21 22 21 52 11 53 4 5 72 6 52 51 50 2 1 26 27 28 29 25 3 32 31 30 6 3 54 20 24 60 23 8 22 22 ...

Page 43: ...B 19 71 70 40 41 42 xxxxxxxxxxxxxxxxx 10 9 10 73 12 12 13 9 ...

Page 44: ...ngine and remove the ignition key before per forming any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause se vere or fatal injuries Switch the engine off and remove the ig nition key 3 Warning Danger of crushing Crushing points can cause severe or fa tal injuries Maintain a safe distance from the dan ger area 4 Warning Hot surface Danger ...

Page 45: ...atal injuries The traction system brakes must be re leased before towing Always observe the operating instruc tions 9 Caution Possible collision of parts The ratchet lever must always be swiv elled in Always observe the operating instruc tions 10 Caution Possible collision of parts The Powermoon tripod must be mount ed correctly Always observe the operating instruc tions 11 Warning Danger from run...

Page 46: ...hydraulic oil under pressure can pierce the skin and enter into the body causing severe or fatal injuries Always observe the operating instruc tions 13 Warning Danger from tyres filled with water Handling tyres filled with water incorrect ly can cause severe to fatal injuries Always observe the operating instruc tions ...

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

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

Page 49: ...tive symbols warning symbols No Pictogram Meaning 40 CE sound output level No Pictogram Meaning 50 Wear ear protection devices 51 Do not enter the area 52 Do not spray the area or part with water 53 Warning on dangers posed by batteries 54 First aid kit ...

Page 50: ...ma tions Avoid contact with the human body also avoid inhaling the vapours and seek medical advice if feeling unwell N Environmentally hazardous sub stance May cause immediate or delayed danger to the 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 51: ... enter or work under screed only secured with screed lock for transportation 71 Caution Danger of high voltage in vehicle electrical system Disconnect batteries and electronics dur ing welding work or when charging the batteries or use a service watchdog D978000024 in accordance with the cor responding instruction manual 72 Important Only use approved radiator anti freeze Never mix different grade...

Page 52: ...B 28 No Pictogram Meaning 73 Overview Tyre pressure working width speed preselection 73 Overview Tyre pressure working width speed preselection ...

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

Page 54: ...A 106 1 dB A Sound pressure level at the vehicle 7 2 Operating conditions during measurement The diesel engine was running at maximum speed The screed was lowered into working position Tamper and vibration unit were operated at min 50 while the au gers were operated at a minimum of 40 and the conveyors were operated at a min imum of 10 of their maximum speed 7 3 Measuring point configuration Hemis...

Page 55: ... dB A Sound pressure level at the vehicle 7 5 Operating conditions during measurement The diesel engine was running at maximum speed The screed was lowered into working position Tamper and vibration unit were operated at min 50 while the au gers were operated at a minimum of 40 and the conveyors were operated at a min imum of 10 of their maximum speed 7 6 Measuring point configuration Hemispherica...

Page 56: ...the EMC di rective 2004 108 CE Interference emission according to DIN EN 13309 35 dB μV m for frequencies of 30 MHz 1 GHz measured at a distance of 10 m 45 db μV m for frequencies of 30 MHz 1 GHz measured at a distance of 10 m Interference immunity against electrostatic discharge according to DIN EN 13309 CE ESD The paver finisher did not show any discernible reactions to contact discharges of 4 K...

Page 57: ... must not be transported on the paver finisher or on the screed Disconnect the gas bottles from the gas system and protect them with their caps Use a separate vehicle to transport them When loading via ramps there is a risk that the machine will slip tilt or overturn Drive carefully Keep people away from the danger area Additional stipulations for transportation on public roads m Note local regula...

Page 58: ...n into consideration when selecting the attachment and loading equipment 2 1 Preparations Prepare the paver finisher for transportation see chapter D Remove all overlaying or loose parts from finisher and screed see also Operating instructions for the screed Store these parts in a safe place m Move the auger to the uppermost position to avoid collisions f When the screed is operated with the optio...

Page 59: ...ock Activate set up mode Close the hopper lids Engage both hopper transport safe guards Lift the screed Extend levelling cylinders completely Retract the screed parts until the screed matches the basic width of the paver fin isher Deactivate set up mode ...

Page 60: ... for securing loads positive fit force connection diagonal lashing etc in accordance with the specific transport ve hicle m The low bed trailer must have the necessary number of lashing points with lashing strength of LC 4 000 daN m The total height and total width must not exceed the maximum permissible dimen sions m The ends of lashing chains and straps must be secured to prevent them working lo...

Page 61: ...C 13 5 3 2 Driving onto the low bed trailer f Make sure that there are no persons in the danger area during loading Use the work gear and low engine speeds to drive onto the low bed trailer ...

Page 62: ...ce and load rating m Always tighten the lashing chains and straps handtight 100 150daN m Lashing equipment must be checked by the user for any signs of damage before use On detecting any signs of damage that impact on safety the lashing equipment must be withdrawn from any further use Lashing chain permissible lashing force LC 4 000 daN Lashing straps permissible lashing force LC 2 500 daN Shackle...

Page 63: ...e of gravity of the paver finisher Comply with the following if the paver finisher has to be placed in the front section of the low bed trailer B for load distribution reasons or on account of the length of the paver finisher The paver finisher must stand freely if the push rollers would only touch the goose neck half way up C There must be a positive fit between the paver finisher push rollers an...

Page 64: ... non slip mats under the screed across the whole width of the vehicle 3 and lower the screed Switch off the paver finisher Attach and secure the protective hood 4 to protect the operating panel Lower the roof and set the retainers 5 properly on both sides For machines without roof remove the exhaust extension pipe after it has cooled down Fold up the walkway plates of the screed and fasten on both...

Page 65: ...lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown m The lashing angles should be ß between 6 55 and a between 20 65 Step 2 fasten lashing chainsat the side m Diagonal lashing secures the wheeled paver at the front and sides using the lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown ...

Page 66: ...using the lashing points on the paver finisher eyebolts and on the low load trailer Fasten the lashing straps as shown Screw the supplied eyebolts 7 first of all in the holes provided in the arms A Alternatively additional lashing points 8 are provided on the chassis at the rear These should be used preferably for transports without screed without arms 7 8 ...

Page 67: ...finisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing straps as shown Step 2 fasten lashing chains m Diagonal lashing secures the paver finisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown ...

Page 68: ...porting the vehicle on trans porters the control panel must be se cured in the central position Remove the locking pin 1 from its storage compartment press pushbut ton and insert into locking aperture 2 m To be able to set the lock the panel must be positioned centrally above the ma chine frame 2 1 ...

Page 69: ...nisher without roof Mount the exhaust extension pipe Lift the screed to the transportation position Start the engine and drive from the trailer at a low engine traction speed Park the paver finisher in a secure spot lower the screed and switch off the engine Remove the key and or cover the operating panel with the protective hood and se cure it ...

Page 70: ...e released Raise the roof The locks 4 on both sides of the roof must be released Set the adjustment lever 5 to the Raise or Lower position Raise the roof The lever points for wards Lower the roof The lever points backwards Operate the pump lever 1 until the roof has reached the upper or lower limit posi tion Roof in uppermost position Set the locks 3 on both sides of the roof Roof lowered Set the ...

Page 71: ...instructions for the screed Store these parts in a safe place f When the screed is operated with the optional gas heat ing system Remove the gas bottles for the screed heating system Close main shut off valves and bottle valves Turn off the valves on the bottles and remove the gas bottles from the screed Transport the gas bottles on a second vehicle heed all applicable safety regula tions m For tr...

Page 72: ...lock Activate set up mode Close the hopper lids Engage both hopper transport safe guards Lift the screed Extend levelling cylinders completely Retract the screed parts until the screed matches the basic width of the paver fin isher Deactivate set up mode ...

Page 73: ... Operation Buttons Set the fast slow switch to Hare if neces sary Turn the preselector to zero Swivel the drive lever to maximum f The machine already advances slightly on deflecting the drive lever Adjust required vehicle speed with the preselector To stop the machine swivel the drive le ver to the middle setting and set the preselector to zero 76 ...

Page 74: ...t can bear the load See chapter B for weights and dimensions m Attachment and loading equipment must meet the conditions of the applicable acci dent prevention regulations m The vehicle s centre of gravity is dependent on the screed which is mounted 1 2 3 ...

Page 75: ...any attachments and extension parts from the paver finisher and the screed until the basic width has been attained Take off all protruding or loose parts and the gas bottles of the screed heater see chapters E and D Lower the protective roof o A See section entitled Protective roof Attach lifting gear to the four attachment points 1 2 mThe max permissible attachment point load is 73 5 kN mThe perm...

Page 76: ... finisher and the screed until the basic width has been attained A Two high pressure cartridges 6 are located on both of the travel drive pumps 5 The following activities must be carried out to activate the towing function Loosen lock nut 7 half a turn Screw in the bolt 8 until increased re sistance occurs Then screw the bolt a further half turn into the high pressure cartridge Tighten the lock nu...

Page 77: ... tow bar to the coupling 9 located in the bumper A Now carefully and slowly tow the paver finisher out of the construction area m Only ever tow the shortest distance to the means of transport or the next park ing possibility m The max permissible towing speed is 10 m min In hazardous situations a towing speed of 15 m min is only permitted temporari ly m The max permissible towing eye 9 load is 200...

Page 78: ...e secured in such a way that unauthorised persons or playing children cannot dam age the vehicle Pull off the ignition key and the main switch 1 and take it with you do not hide them somewhere on the ma chine Protect the operating panel with the dust cover 2 and lock it Store loose parts and accessories in a safe place 1 2 ...

Page 79: ...hem from tilling over and rolling or sliding away f Roller type jacks must not be moved when under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequately dimensioned and be able to take the corresponding weight f There must not be anyone on the vehicle while it is being lifted f All raising and lowering work must be carried out uniformly with all h...

Page 80: ...C 13 24 ...

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

Page 82: ...D 13 2 2 Controls 2 1 Operating panel 3 1 A 4 B 2 ...

Page 83: ...the handle A and allow latch to engage again in one of the intended detent positions f Only adjust the operating panel position whilst the vehi cle is stationary A The operating panel can only be swivelled beyond the outer edge of the vehicle if a telescopic control panel is fitted 2 Latch Shift operating panel The operating panel can be shifted to several positions on the left and right hand side...

Page 84: ...D 13 4 10 13 16 15 17 11 12 8 7 9 ...

Page 85: ...creed or other actions are then no longer possible Danger of accidents The emergency stop button does not shut off the gas heat er system o Close the main shut off valve and the valves on the bottles by hand To restart the engine the button must be pulled out again 11 Ignition lock To activate the ignition voltage by turning the key Switch off by turning the key back to its starting position A Aft...

Page 86: ...D 13 6 10 13 16 15 17 11 12 8 7 9 ...

Page 87: ...on 2 position Screed motion tamper vibration on travel drive on increase speed until the stop is reached A Use the preselector to set the maximum speed f The vehicle speed cannot be reduced to 0 with the preselector The machine advances slightly with de flected drive lever even if the travel drive preselector is set to zero A If the engine is started with the drive lever pivoted out the travel dri...

Page 88: ...D 13 8 10 13 16 15 17 11 12 8 7 9 ...

Page 89: ... flected drive lever even if the travel drive preselector is set to zero 16 Steering wheel The steering wheel movement is transferred hydraulically to the front wheels f Take the special steering ratio into consideration when transporting the machine through tight curves approx 3 turns for a full steering lock Danger of ac cidents 17 Horn Press in the case of emergencies and to indicate when the v...

Page 90: ...D 13 10 18 19 20 21 22 23 ...

Page 91: ...F o Button with detent switch function and LED feedback For switching on the rotary beacon Switch OFF by pressing the button again A Switch on for safety on roads and in the construction site area 21 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 22 Filling pump Fuel tank ON OFF o Button with deten...

Page 92: ...D 13 12 24 25 26 27 28 29 ...

Page 93: ...o the left m The platform lock must be released before moving the control panel f On actuation note danger zones of moving parts of the vehicle 25 Move control panel to the right Pushbutton function with LED feedback To move the control panel to the right f On actuation note danger zones of moving parts of the vehicle 26 not used 27 not used ...

Page 94: ...D 13 14 24 25 26 27 28 29 ...

Page 95: ... extend the screed lock m Before retracting and extending lift the crossbeams slightly over the locking bolts lift screed 29 Retract screed lock o Pushbutton function with LED feedback To hydraulically retract the screed lock m Before retracting and extending lift the crossbeams slightly over the locking bolts lift screed ...

Page 96: ...D 13 16 30 31 32 33 34 35 ...

Page 97: ...system Switch OFF by pressing the button again 34 Windscreen wip ers ON OFF o Detent switch function and LED feedback For switching on the windscreen wipers Switch OFF by pressing the button again 35 Windscreen washer system Windscreen wiper ON OFF o Detent switch function and LED feedback To actuate the windscreen washer system windscreen wipers Switched OFF with time control ...

Page 98: ...D 13 18 36 38 39 37 ...

Page 99: ...e there is only limited space at one side or when obstacles obstruct truck unloading f On actuation note danger zones of moving parts of the vehicle 38 Left hopper Open Pushbutton function To open the left half of the hopper A If the hoppers are hydraulically actuated at the same time both the left and the right switch can be used for actuation f On actuation note danger zones of moving parts of t...

Page 100: ...D 13 20 41 40 42 43 ...

Page 101: ...le configurations with a screed which cannot be extended f On actuation note danger zones of moving parts of the vehicle 42 Left screed Retract Pushbutton function To retract the left half of the screed A This function is not used in vehicle configurations with a screed which cannot be extended f On actuation note danger zones of moving parts of the vehicle 43 Right screed Retract Pushbutton funct...

Page 102: ...D 13 22 45 44 46 47 ...

Page 103: ...st be switched to AUTO or MANUAL A On manual triggering the automatic function is overrid den with reduced delivery capacity 46 Left auger MANUAL conveyingdirection inwards Pushbutton function To manually trigger the conveying function for the left half of the auger conveying direction inwards A For manual triggering the auger function must be switched to AUTO or MANUAL A On manual triggering the ...

Page 104: ...D 13 24 49 48 50 51 ...

Page 105: ...e A The main function switch locks the conveying function f On actuation note danger zones of moving parts of the vehicle 49 Right conveyor AUTO Button with detent switch function and LED feedback The conveying function of the right conveyor is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switch es in the material tunnel Switch OFF by pres...

Page 106: ...D 13 26 49 48 50 51 ...

Page 107: ...e A The main function switch locks the conveying function f On actuation note danger zones of moving parts of the vehicle 51 Right conveyor MANUAL Conveyor conveyor o Button with detent switch function and LED feedback The conveying function of the right conveyor is switched on continuously with full delivery capacity without material control via the limit switches in the material tunnel Switch OF...

Page 108: ...D 13 28 53 52 54 55 ...

Page 109: ... function switch locks the conveying function f On actuation note danger zones of moving parts of the vehicle 53 Right auger AUTO Button with detent switch function and LED feedback The conveying function of the right half of the auger is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switch es in the material tunnel Switch OFF by pressing t...

Page 110: ...D 13 30 53 52 54 55 ...

Page 111: ...e A The main function switch locks the conveying function f On actuation note danger zones of moving parts of the vehicle 55 Right auger MANUAL Button with detent switch function and LED feedback The conveying function of the right half of the auger is switched on continuously with full delivery capacity without material control via the limit switches Switch OFF by pressing the button again A The ...

Page 112: ...D 13 32 59 56 57 61 60 58 ...

Page 113: ...n the displayed arrow direction A This function is also activated when the remote control is not connected 57 Auger Lift lower o Button with detent switch function and LED feedback For hydraulic adjustment of the auger height Switch OFF by pressing the button again A The height can be read on the scales to the left and the right of the auger crossbeam support Rule of thumb Paving thickness plus 5 ...

Page 114: ...D 13 34 59 56 57 61 60 58 ...

Page 115: ...djust the selected function in the corresponding direction f On actuation note danger zones of moving parts of the vehicle 60 Adjustment button Extend lower on left Pushbutton function To adjust the selected function in the corresponding direction f On actuation note danger zones of moving parts of the vehicle 61 Adjustment button Extend lower on right Pushbutton function To adjust the selected fu...

Page 116: ...D 13 36 62 63 ...

Page 117: ...ssed for longer than 1 5 seconds LED ON The screed is lowered as long as the button is pressed When the button is re leased the screed is held in the stop paving relief pressure position LED ON m Screed may lower slowly Resting function Press the button briefly LED ON the screed is lowered Press the button briefly again LED OFF the screed is stopped Screed floating position Pressing the button swi...

Page 118: ...D 13 38 64 65 ...

Page 119: ...ton again or by swiv elling the drive lever out to the paving position On reaching the adjusted material height material sensor the filling function is automatically switched off f On actuation note danger zones of moving parts of the vehicle 65 Set up mode Detent switch function and LED feedback When the vehicle is stationary this function enables all operating functions which can only be activat...

Page 120: ...D 13 40 67 69 71 73 66 68 70 72 74 ...

Page 121: ...on again A The main function switch must be set to the OFF posi tion A The function is preset in conjunction with the Set up mode button 68 Lift screed Pushbutton function with LED feedback For lifting the screed LED ON and for switching off the Screed floating position function m Check whether the screed transport safeguard is insert ed f On actuation note danger zones of moving parts of the vehi...

Page 122: ...D 13 42 67 69 71 73 66 68 70 72 74 ...

Page 123: ...eed relieving and screed charging To preset the hydraulic oil pressure switch this button and the Set up mode button to ON 71 Screed charging Button with detent switch function and LED feedback For relieving the screed to influence the traction force and compaction ratio Switch OFF by pressing the button again or switching between screed relieving and screed charging To preset the hydraulic oil pr...

Page 124: ...D 13 44 67 69 71 73 66 68 70 72 74 ...

Page 125: ...tes the lock m Trailer deactivation is only permissible for short jour neys between two sections within the roadworks 73 Travel drive slow tortoise Working gear Buttons with detent switch function and LED feedback To preselect the speed level operating speed A The differential lock is automatically activated in this speed level A On restarting the buttons are set to operating speed tortoise 74 Par...

Page 126: ...D 13 46 75 ...

Page 127: ...ly set up by the drive lever and preselector when activated m After pressing the foot brake the cruise control read justs the last speed level A After the function has been deactivated the drive lever has to be returned to the zero position to change speed A On reducing speed to stationary the cruise control has to be deactivated to drive the vehicle away again ...

Page 128: ...D 13 48 STOP 83 84 85 86 87 88 89 76 77 78 79 80 81 82 ...

Page 129: ...ly 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 cool ing down to normal temperature the engine will run with full performance again A Indicates the fault together with the Error message lamp 80 Indicator lamp hydraulic filter Lights up w...

Page 130: ...D 13 50 STOP 83 84 85 86 87 88 89 76 77 78 79 80 81 82 ...

Page 131: ...checking purposes 86 Oil pressure indica tor lamp for the die sel engine red m Lights up when the oil pressure is too low Switch off the engine immediately For further possible faults see Engine operating in structions A Indicates the fault together with the Error message lamp 87 Oil pressure indica tor for the hydraulic travel drive red Must go out right after the engine has been started Observe ...

Page 132: ...D 13 52 2 2 Special functions Reversible conveyor 1 2 2 ...

Page 133: ...g material losses to be avoided during transportation Switch the main function switch 1 to the off position LED off Keep one or both buttons 2 depressed for approx 1 second The conveyor moves a distance of approx 1 metre towards the hopper A If necessary this process can be repeated as often as required to allow the conveyor to run further in the reverse direction ...

Page 134: ...D 13 54 A A B B C ...

Page 135: ...on blocks A and B are assigned to either the auger or the conveyor control system The relevant element which is con trolled is indicated by an illuminated symbol C m Important Do not disconnect remote controls during operation This causes the paver finisher to be shut down ...

Page 136: ...D 13 56 121 120 ...

Page 137: ... Making way lifting the screed or other actions are then no longer possible Danger of accidents The emergency stop button does not shut off the gas heat er system Close the main shut off valve and the valves on the bottles by hand To restart the engine the button must be pulled out again 121 Remote control connection cable Connect the plug to the screed A Whether this involves the left hand or the...

Page 138: ...D 13 58 122 124 123 125 ...

Page 139: ...on when the drive lever is swiv elled out and is continuously controlled via the mate rial limit switches Switch OFF by pressing the button again A The function is shut off by pressing the EMERGENCY STOP button or restarting the vehicle A The main function switch operating panel locks the conveying function 124 Auger Reversing mode Pushbutton function The auger s conveying direction can be reverse...

Page 140: ...D 13 60 122 124 123 125 ...

Page 141: ...y Pushbutton function Plus minus buttons for adjusting the delivery capacity The delivery capacity is slowed down or speeded up depending on the length of time for which the button is pressed A For adjustment purposes the auger function must be switched to AUTO or MANUAL ...

Page 142: ...D 13 62 126 128 127 129 ...

Page 143: ...the conveyor 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 A The function is shut off by pressing the EMERGENCY STOP button or restarting the vehicle A The main function switch operating panel locks the conveying function 128 Conveyor Reversing mode Pushbutton function The conveying direct...

Page 144: ...D 13 64 126 128 127 129 ...

Page 145: ...y Pushbutton function Plus minus buttons for adjusting the delivery capacity The delivery capacity is slowed down or speeded up depending on the length of time for which the button is pressed A For adjustment purposes the conveyor function must be switched to AUTO or MANUAL ...

Page 146: ...D 13 66 131 132 133 130 ...

Page 147: ...nt Left levelling cylinder Pushbutton function To retract and extend the levelling cylinder on the cor responding side of the vehicle A On adjustment note the levelling display in the remote control display A For direct adjustment the levelling function must be set to MANUAL In AUTO operating mode adjustment is carried out af ter confirming the enter button 133 133 Enter Pushbutton function For co...

Page 148: ...D 13 68 135 136 137 134 ...

Page 149: ...nt Right levelling cylinder Pushbutton function To retract and extend the levelling cylinder on the cor responding side of the vehicle A On adjustment note the levelling display in the remote control display A For direct adjustment the levelling function must be set to MANUAL In AUTO operating mode adjustment is carried out af ter confirming the enter button 137 137 Enter Pushbutton function For c...

Page 150: ...D 13 70 140 138 140 139 ...

Page 151: ...emote control display 139 Screed retract extand Pushbutton function To retract and extend the screed half on the corre sponding side of the vehicle A This function is not used in vehicle configurations with a screed which cannot be extended f On actuation note danger zones of moving parts of the vehicle 140 Horn Press in the case of emergencies and to indicate when the ve hicle starts to move A Th...

Page 152: ...D 13 72 ...

Page 153: ...yout on the display A encoder rotary actuation To scroll in the menu To select various parameters within a menu To change parameters B G function buttons To trigger the commands assigned in the display area H To select the menus assigned in the display area I B C A D E F G I H Y ...

Page 154: ... menus upstream and down stream of the currently shown menu item are displayed A The centrally positioned symbol J indicates the currently displayed menu Command Symbol in the display Call up sub menu call up parameter for adjustment Save setting acknowledge the display Exit menu Cancel ...

Page 155: ...D 20 3 1 1 Menu operation B A F G B A G ...

Page 156: ...positioned over the desired parameter to be adjusted Press button B to activate the selected parameter to be adjusted Set the desired parameter by turning the encoder A Press button F to exit parameter adjustment without saving Press button B to confirm the set value Press button G to exit the setting menu A The set up menus stored in various menus can be called up directly by pressing the relevan...

Page 157: ... 20 5 Menu structure of the setting and display options The following illustration shows the menu structure and serves to simplify operation and the procedure in the case of various settings and displays ...

Page 158: ...overed with a red cross the function is deactivated C drive engine eco mode The engine speed is constantly regulated to 1600 rpm D automatic steering unit The vehicle is steered automatically via corresponding sensing along a reference e g cable m When the automatic steering unit is activated the steering potentiometer is deactivat ed A If the driver carries out a steering movement this overrides ...

Page 159: ...Hare Transportation gear active Tortoise Working gear active STOP Machine stop 20km h Important Machine speed too high Reduce travel Snow flake hydraulic oil temperature too low Let machine run up to tem perature with stationary acceleration A The engine speed cannot be increased when the hydraulic oil temperature is too low Hare with wheels Trailer o connected A When the trailer o is connected al...

Page 160: ...peed Menu for setting the engine speed Set up menu 101 diesel engine speed 1 nominal speed display and adjustment parame ters 2 actual speed display A Adjustment is carried out in steps of 50 the engine speed is adapted directly 1 2 ...

Page 161: ...u for querying various drive engine measured val ues Sub menu 201 drive engine measured value display Display of the following measured values 1 on board voltage V 2 engine coolant temperature C 3 engine oil pressure bar 4 operating hours h 1 2 3 4 ...

Page 162: ...ring monitoring 1 current paving distance Reset set value to zero button C 2 steering monitoring is used for distance control scanning reference automatic steering unit ON OFF button E A Ideal distance scanning reference is the value 0 in display 2 Excursions indi cate increased or reduced distances A If necessary carry out correction via slight steering movement A If the driver carries out a stee...

Page 163: ... right levelling display and adjustment parame ters Internal levelling parameter 0 External levelling parameter 1 A When External levelling is selected the toggle switches of the system s own remote control remain active Only for pavers with wheel drive 3 advance display and adjustment parameters with front wheel drive switched on A Additional traction power is made available by a increased speed ...

Page 164: ...ameters foundation parameter 1 binder course parameter 2 wearing course parameter 3 m On switching to a different type of course the screed parameters in setting menu 600 are automatically switched to the values last set up for the corresponding type of course C Delayed tamper start When the drive lever is deflected the tamper function is only activated once the time set in the relevant menu has e...

Page 165: ...for setting various screed parameters B compacting element frequencies setting menu 600 C delayed screed start setting menu 601 D screed type selection setting menu 602 E screed heater system temperature preselection setting menu 603 B C D E ...

Page 166: ... and auxiliary compactor adjustment range depending on screed type Follow screed manual m On switching to a different type of course in set up menu 501 the screed parameters are automatically switched to the values last set up for the corresponding type of course Setting menu 601 delayed screed start Menu for setting the screed starting delay 1 delay duration sec display and adjustment pa rameters...

Page 167: ...out Setting menu 603 screed heater system Menu for setting the screed heater system 1 nominal screed heater system temperature C display and adjustment pa rameters 2 actual temperature left hand main screed C 3 actual temperature right hand main screed C 4 actual temperature left hand extendable part extension parts C 5 actual temperature right hand extendable part extension parts C A Setting rang...

Page 168: ...ctual left hand conveyor capacity display 3 nominal right hand con veyor capacity display and adjustment parame ters 4 actual right hand conveyor capacity display 5 nominal left hand auger capacity display and adjustment parameters 6 actual left hand auger capacity 7 nominal right hand auger capacity display and adjustment parameters 8 actual right hand auger capacity A Setting range 0 100 1 2 3 4...

Page 169: ...wing infor mation 1 time hh mm ss 2 date dd mm yyyy 3 software version travel drive computer 4 software version terminal 5 operating hours h A If consultation with Technical Support is required for your vehicle always specify the software version 1 4 5 2 3 ...

Page 170: ...D 20 18 Menu 09 service Password protected menu for various service settings ...

Page 171: ...r messages again Query menu 111 error memory C query menu Active errors display of currently present error messages F query menu Error his tory display of all previ ously occurred error messages A The number of stored errors is displayed at positions 1 2 C F 1 2 ...

Page 172: ... each error message The error message is dis played by pressing the button B A All error messages can be identified in the section Ter minal error displays A If consultation with Technical Support is required for your vehicle always specify the number 1 of the error mes sage B 1 ...

Page 173: ... bright ness display and adjustment parame ters A Setting range 0 100 A When the working lights are switched on the system auto matically switches to the night time operation settings 3 beep display and adjustment parameters warning signal for error messages until the error has been acknowledged beep ON parameter 1 beep OFF parameter 0 A Press button E to call up the system menu 1 2 3 E ...

Page 174: ...splay and ad justment parameters hh mm 3 Date display and adjust ment parameters DD MM YYYY 4 Monitor brightness dis play and adjustment pa rameters 5 Button brightness dis play and adjustment parameters A The display brightness is adjusted directly the buttons light up briefly to check 1 E 2 3 4 5 ...

Page 175: ...g panel but tons Test menu 120 button function test On pressing the individual buttons the relevant button symbol is shown to confirm the function A The function test can only be carried out when the drive en gine is not running An error message is produ ced if the engine is running ...

Page 176: ...ra 1 2 dis play button C Menu 13b camera display camera 1 Menu for displaying the cam era images camera 2 o show camera 1 display button B show camera 1 2 display button C Menu 13c camera display camera 1 2 Menu for displaying the cam era images camera 1 2 o show camera 1 display button B show camera 2 display button C C B C B C B ...

Page 177: ...required for your vehicle specify this number together with all other visible informa tion relating to the error message Error No meaning Display Error message 102 Fan control valve Error message 103 Emergency stop button actuated or communication display master Error message 104 Communication engine electronics master ...

Page 178: ...ing Display Error message 105 Communication operating panel keyboard master Error message 106 Communication remote control master Variable left remote control 1 right remote control 2 Error message 107 Error drive lever 1 2 ...

Page 179: ...or drive unit sensor Variable left sensor 1 right sensor 2 Error message 109 Battery voltage too low Error message 110 Conveyor drive valves Variable left conveyor drive 1 right conveyor drive 2 reverse left conveyor 3 reverse right conveyor 4 1 2 1 2 3 4 ...

Page 180: ... 1 right auger drive 2 Reverse left auger 3 Reverse right auger 4 Error message 112 Auger lift valves Variable lift left auger 1 lift right auger 2 lower left auger 3 lower right auger 4 Error message 113 Tamper vibration drive valves Variable tamper drive 1 vibration drive 2 1 2 3 4 1 2 3 4 1 2 ...

Page 181: ...g Display Error message 114 Pump distribution gear engine separating clutch valves Variable separating clutch valve 1 separating clutch valve 2 Error message 115 Drive unit brake valve Error message 116 Error tank sensor 1 2 ...

Page 182: ...20 30 Error No meaning Display Error message 117 Auger material sensors Variable left sensor 1 right sensor 2 Error message 118 Communication master slave Error message 119 Error steering angle sensor 1 2 ...

Page 183: ...ssage 120 Error central lubrication system relay Error message 121 Error road speed potenti ometer Error message 122 Levelling valves Variable Levelling Lift left 1 Levelling Lift right 2 Levelling Lower left 3 Levelling Lower right 4 1 2 3 4 ...

Page 184: ...t 2 extendable part right 4 Error message 124 Conveyor limit switches Variable Left limit switch paddle 1 Right limit switch paddle 2 Left limit switch ultrasound 3 Right limit switch ultrasound 4 Error message 125 Screed extending retracting valves Variable extend right screed 1 retract left screed 2 retract right screed 3 extend left screed 4 1 2 3 4 1 2 3 4 ...

Page 185: ... Variable Screed lift lower left 1 Screed lift lower right 2 floating position pressure valve 3 4 screed non return valve 5 Error message 128 Open close hopper front hopper valves Variable open left hopper 1 open right hopper 2 close left hopper 3 close right hopper 4 close front hopper 5 open front hopper 6 1 2 3 5 4 3 4 1 2 6 5 ...

Page 186: ...ay Error message 130 Calibration not carried out or completed Variable pump flows 1 potentiometer 2 Error message 131 Error system check Internal error in the master Error message 132 Parameter error Wrong machine type select ed 1 2 ...

Page 187: ...rror message 133 Valves movement of opera tor s platform Variable move operator s platform to the left 1 move operator s platform to the right 2 Error message 134 Error hazard warning flash ers Error message 135 Error rotary beacon 1 2 ...

Page 188: ... No meaning Display Error message 136 Error travel drive Pump or engine failure Error message 137 drivelimp Drive controll dis turbance A Driving mode limited in the event of an error Error message 138 System error ...

Page 189: ...D 20 37 Error No meaning Display Error message 139 Error brake pedal f Machine must not be operated any more Error message 140 Battery voltage too high ...

Page 190: ...rror message 141 Communication Display master Error message 142 Data error Data missing for alternator oil temperature service hours Engine speed Error message 143 Remote control Variable Left remote control 1 Right remote control 2 1 2 ...

Page 191: ...onductor break valve or temperature sensor hydrau lic data missing for engine charge air Error message 145 Contamination indicator air fil ter A Proceed with air filter maintenance Error message 146 Retarder valves Variable Left valve 1 Right valve 2 1 2 ...

Page 192: ...ror No meaning Display Error message 147 Valves front axle Error message 149 Start inhibit A Drive lever must be in neutral position when starting Error message 150 Error system check Internal error in the master ...

Page 193: ...D 20 41 Error No meaning Display Error message 151 Power supply master Error message 152 Error braking light Error message 153 Auger ultrasound sensors Variable Left sensor 1 Right sensor 2 ...

Page 194: ...en trailer function active A The transport gear can not be selected if the trailer is not connected Error message 156 Valves safe impact system Variable Extend push roller crossbar 1 Retract push roller crossbar 2 Error message 157 Valves screed lock Variable Extend screed lock 1 Retract screed lock 2 1 2 1 2 ...

Page 195: ...alves crowning adjuster Variable Extend crowning 1 Retract crowning 2 Error message 159 Valves auxiliary compactor Variable Lift auxiliary compactor 1 Lower auxiliary compactor 2 Activate auxiliary compactor 3 Error message 160 Error extraction 1 2 1 2 3 ...

Page 196: ...D 20 44 Error No meaning Display Error message 161 Error hydraulic brake sensor ...

Page 197: ...ns several numerical codes which uniquely define the fault after decoding ENGINE WARNING display 3 indi cates that there is a fault on the drive engine The vehicle can continue to be operated on a temporary basis How ever the fault should be remedied quickly to prevent further damage STOP ENGINE display 4 indicates a serious fault on the drive engine in which the engine is stopped or has to be sto...

Page 198: ...ary engine shut down Display SPN 157 FMI 3 OC 1 Cause Cable break on sensor for rail pressure Effect Engine shut down Frequency Fault occurs for the 1st time m Notify customer service of the error number displayed on your paver finisher the cus tomer service department will then discuss the further procedure with you STOP ...

Page 199: ...D 20 47 2 2 Error codes ...

Page 200: ...D 20 48 ...

Page 201: ...D 20 49 ...

Page 202: ...D 20 50 ...

Page 203: ...D 20 51 ...

Page 204: ...D 20 52 ...

Page 205: ...D 20 53 ...

Page 206: ...D 20 54 ...

Page 207: ...r the roof The locks 3 on both sides of the roof must be released Raise the roof The locks 4 on both sides of the roof must be released Set the adjustment lever 5 to the Raise or Lower position Raise the roof The lever points for wards Lower the roof The lever points backwards Operate the pump lever 1 until the roof has reached the upper or lower limit posi tion Roof in uppermost position Set the ...

Page 208: ...ows The side windows can be swivelled out to the side at the bracket 1 Press the lock 2 to unlock Windscreen wiper Activate the windscreen wiper 3 screen wash on the operating panel if necessary A Ensure that the washer fluid tank 4 is always adequately filled m Replace worn wiper blades immediately 1 3 2 4 ...

Page 209: ...ns on the left and right hand sides of the vehicle Release panel latch 1 and slide panel console to the desired position using the handle 2 Insert panel latch 1 into one of the detent positions 3 m Make sure it is latched properly f Only adjust the operating position whilst the vehicle is stationary 2 1 3 ...

Page 210: ...he control platform has been moved the windows 1 additionally offer a good view of the paving area A Refer to the operating panel for actuation of the platform movement function m Shifting the platform increases the basic width of the paver finisher f If the platform is moved ensure that there is no one in the vehicle s danger area f Only adjust the operating position whilst the vehicle is station...

Page 211: ...tion beyond the outer edge of the vehicle Press latch 5 swivel operating panel to the required position using the handle 3 and allow latch to engage again in one of the intended detent positions m Make sure it is latched properly f Only adjust the operating position whilst the vehicle is stationary Control platform lock o f During transportation in road traffic and when transporting the vehicle on...

Page 212: ...draulically it can be pushed back to its central position by hand Remove the screw cap 1 next to the right footwell window Remove screw 2 A This undoes the connection between the platform and the frame so that the plat form can be moved Restore the original status after eliminating the fault 1 2 ...

Page 213: ...eat console to the desired position and allow latch to engage again m Make sure it is latched properly f Only adjust the operating position whilst the vehicle is stationary Seat console storage compartment A Beneath both seat consoles there is a storage compartment which can be locked 1 A Lock the storage compartments at the end of work 1 1 ...

Page 214: ...ly 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 suppor...

Page 215: ...t height adjustment 4 The seat height can be individually adjusted Turn the handle in the desired direction to adjust the seat height Backrest adjustment 5 The backrest inclination can be continuously adjusted Turn the handle in the desired direction to adjust Armrest inclination 6 The armrest s longitudinal inclination can be adjusted by turning the hand wheel Turning outwards raises the front of...

Page 216: ...f the travel drive is automatically re duced regardless of the drive lever po sition A If the vehicle was brought to a standstill with the service brake it cannot be driv en away again until after the drive lever has been put into neutral m For transportation the driver s seat must be on the same side as the service brake 76 ...

Page 217: ...l box which contains all fus es and relays etc is located beneath the central control platform floor panel A An assignment plan for fuses and relays can be found in chapter F8 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 ...

Page 218: ... instructions see section Starting the paver finisher external starting starting aid Main battery switch The main battery switch separates the current circuit from the battery to the main fuse A For the assignment of all fuses see chapter F To interrupt the battery s current cir cuit turn the key pin 3 to the left and pull it out A Do not lose the key pin as in this case the paver finisher can no ...

Page 219: ...r during transportation Screed lock mechanical o A The screed locks must additionally be engaged on both sides of the vehicle pri or to transportation with the screed lifted f Transportation with an unsecured screed leads to a risk of accidents Lift the screed On both sides of the paver finisher slide the screed lock beneath the crossbeams using the lever 1 place the lever in the detent position m...

Page 220: ...ation with an unsecured screed leads to a risk of accidents Lift the screed Activate the function on the operating panel A The two screed locks 1 extend hydrau lically m ATTENTION Insert screed lock only at crown adjustment zero Screed lock only for transportation Do not enter or work under screed only secured with screed lock for transportation Danger of accidents 1 ...

Page 221: ... situations the same paving thickness should be set on both sides of the vehicle Other displays o are on the crossbeam guide To change the reading position the scale 2 can be raised and lowered again in one of the adjacent locating bores 3 The pointer 4 can be swivelled to different positions using the locking knob 5 m The scale 2 and pointer 4 must be swivelled in completely to transport the mach...

Page 222: ...ompartment They are engaged together with the working lights A These are activated together with the other working lights on the operating panel Engine compartment lighting o A The engine compartment lighting can be activated when the ignition is switched on On off switch 1 for the engine com partment lighting 1 1 ...

Page 223: ...aution environmentally harmful waste Working lights with Xenon lamps have a gas discharge lamp containing mercury Hg A defective lamp is deemed to be hazardous waste and must be disposed of in accordance with the local regula tions LED working light o There are two LED spotlights 1 at the front of the machine and also at the back f Always align the working lights to avoid dazzling the operating pe...

Page 224: ...get very hot Do not touch working lights that are switched on or hot A When equipped with an electric screed it is possible for the lamps to flicker irreg ularly during the heating up phase with simultaneous operation of 500 watt spot lights o and the power moon o Preferably only one type of lighting should be used during the heating up phase Camera o There is a camera 1 at the front of the machin...

Page 225: ... and right ratchets A The current height can be read on both auger height indicators A Observe the notes on adjusting the auger height in the chapter Set up and modifica tion Auger height indicators A scale 1 on which the currently set auger height can be read off is located on the left and right sides of the ladder A Display in cm Loosen the clamping bolt 2 to change the position of the indicator...

Page 226: ...ases the basic width of the paver finisher f If the sensor rod or sensor rod extension are used ensure that there is no one in the vehicle s danger area A The sensor rod is adjusted when the vehicle is positioned with its set working width on the paving route and the reference marking running parallel to the paving route has been set up Adjusting the sensor rod The sensor rod 1 is located on the f...

Page 227: ...After releasing the wing nuts 5 the end section of the sensor rod extension 6 can be set to the desired length the angle can additionally be changed by swivel ling on the joint 7 A Either the adjustable indicator or the chain can be used as an aid to orientation m Tighten all assembly parts properly after setting up A The sensor rod extension s joint 7 can be mounted on both sides of the vehicle i...

Page 228: ... Remove the spray 1 from its bracket Build up pressure by actuating the pump lever 2 The pressure is indicated on the ma nometer 3 Actuate the manual valve 4 to spray On completion of work secure the manual spray in its bracket with a lock 5 f Do not spray into open flame or on hot surface Danger of explosion 5 2 1 2 2 3 4 ...

Page 229: ... When released the hose automatically engages here The hose is automatically retracted into the guide after pulling and discharging again Actuate button 4 to activate and de activate the pump The indicator lamp 5 lights up when the emulsion pump is running Actuate the manual valve 6 to spray f Do not spray into open flame or on hot surface Danger of explosion A The spraying system is fed by a cani...

Page 230: ...ntrol the material flow on the relevant half of the conveyor The conveyors should stop when the materi al has roughly reached the area below the auger tube A This requires that the auger height has been adjusted correctly see chapter E A In vehicles with a PLC control system the deactivation point is set on the re mote control 1 2 ...

Page 231: ...e conveyor The conveyors should stop when the material has roughly reached the area below the au ger tube A This requires that the auger height has been adjusted correctly see chapter E To set the deactivation point release the two mounting screws 2 and set the switch to the required height After adjusting retighten all mounting parts properly 1 2 ...

Page 232: ...or s angle After adjusting retighten all mounting parts properly A The connection cables 4 are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed over the full working width A We recommend adjusting the limit switch positions during material distribut...

Page 233: ...set the sensor height the deacti vation point loosen the star handles 4 and adjust the linkage to the re quired length After adjusting retighten all mounting parts properly A The connection cables are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed...

Page 234: ... socket 1 is located beneath the left right seat consoles Additional working lights can be con nected here for example Right seat console 12V socket Left seat console 24V socket A Voltage is present when the main switch is switched on 1 ...

Page 235: ... stop with relieving This is used to set the pressure for Screed control with paver finisher stop floating stop with relieving Switching on see screed stop paving stop Chapters Operating panel Operation For pressure indication see manometer 3 Manometer for screed charging relieving The manometer 3 indicates the pressure for Screed charging relieving when the drive lever is in the third position pr...

Page 236: ... as the drive engine is started Pumping time 4 min Pause time 2 h m It is prohibited to change the factory set durations of pumping and break without consulting the technical customer serv ice A Changing the duration of lubrication and breaks may be necessary when laying mineral or cement bound material mix ...

Page 237: ...l screed to the desired position using the lever 3 and engage the locking knob again A If the levelling unit is connected to a height controller this has the function of balanc ing out any rapid rise in the screed position The levelling cylinders are extended until the correct height is reached The change in approach angle can only take place slowly and uniformly on both sides at once during pavin...

Page 238: ...e locking plate 3 on the lower side of the crossbar Remove insert plate 5 Move the push roller crossbar as far as it will go to the front rear position A Shift the push roller crossbar at the tow ing eye 6 or use a suitable assembly le ver in its guide left and right to push it into the corresponding position Turn the insert plate 5 180 and rein sert into the groove in the front or rear position P...

Page 239: ...t remote controls and other accessories A Lock the storage box at the end of work Fire extinguisher o A The paver finisher personnel must be fa miliarised with fire extinguisher 2 oper ation A Observe the inspection intervals for the fire extinguisher 2 1 ...

Page 240: ...t 1 Slide the rotary beacon with the tube 2 out to the desired height and se cure with the clamping bolt 3 Vehicle version with protective roof Raise the bracket 4 swivel to the outer position and allow to engage there Activate the function on the operating panel as necessary A The rotary beacon is easy to remove and should be stored securely at the end of work o 2 3 1 2 1 3 2 ...

Page 241: ... 2 into the container which is to be emptied A To enable the container to be emptied completely the suction hose must reach down to the floor of the container Activate the function on the operating panel as necessary m The fuelling pump does not shut off automatically Therefore never leave the pump unattended when fuelling m Never operate the pump without pumping a fluid The risk of damaging your ...

Page 242: ... be maintained from combustible materials f A safety distance of at least 50 m must be maintained from high voltage lines and at least 2 5 m from railway track volt age lines f The power moon must not be operated if the electric supply cables or connectors are damaged Hold the handle 1 tightly and pull the detent pin 2 out Press the handle down until the detent pin engages m Before starting up che...

Page 243: ...n the power moon has been fully assembled and secured the power moon connector 11 can be connect ed to its current supply The power moon is switched off by re moving the power connector 11 from the socket m On assembly make sure that the lower part of the tripod projects max 15 cm out of the bracket Risk of collision A When equipped with an electric screed it is possible for the lamps to flicker i...

Page 244: ...D 31 38 ...

Page 245: ...esel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector Two filled propane gas bottles Shovel and broom Scraper spatula for cleaning the auger and the hopper infeed area Parts that may become necessary for extending the auger Parts that may become necessary for extending the screed Percentage spirit level levelling rail 4 m long Levelling wire Protective clo...

Page 246: ...mediately Steering The paver finisher must immediately fol low every steering wheel movement in a precise manner Check straight ahead travel Horn on the operating panel on both remote controls Briefly press the horn button Horn signal must sound Lights Switch on with the ignition key walk around the paver finisher to check and switch off again Screed hazard flasher with vario screeds With the igni...

Page 247: ...y seated Screed transport safeguard When the screed is lifted it must be pos sible to push the retaining pins beneath the crossbeams 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 Lateral flaps Check that the hoods and flaps are securely...

Page 248: ...D 43 4 13 11 12 10 15 120 ...

Page 249: ...es 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 10 120 is de pressed Error shown on the display Press the sta...

Page 250: ...D 43 6 13 11 12 10 15 120 ...

Page 251: ...the engine Switch on the ignition 11 set the drive lever 13 to the centre position and the travel drive preselector 15 to minimum Use appropriate cables to connect the external power source m Observe the polarity Always connect the negative cable last and disconnect it first A It is impossible to start the vehicle if an emergency stop button 10 120 is de pressed Error shown on the display Press th...

Page 252: ...D 43 8 13 65 ...

Page 253: ...ter starting To increase the engine speed Press button 65 to increase engine speed A The engine speed is increased to the preset value m Let the paver finisher warm up for approx 5 minutes if the engine is cold ...

Page 254: ...D 43 10 13 STOP 83 84 85 86 87 88 89 76 77 78 79 80 81 82 ...

Page 255: ...rottled down automatically Driving mode remains possible After cooling down to normal temperature the engine will run with full performance again Battery charge indicator 83 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 pos...

Page 256: ...D 43 12 65 55 51 54 50 STOP 83 84 85 86 87 88 89 76 77 78 79 80 81 82 ...

Page 257: ... could be damaged When the hydraulic oil is cold Activate set up mode function 65 Set the conveyor function 50 51 to manual and the auger function 54 55 to manual Conveyor and auger 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 malfunctions refer to the section Malfunctions ...

Page 258: ...D 43 14 37 36 15 13 16 68 58 56 59 43 42 126 130 65 ...

Page 259: ...preselector 15 to zero Activate set up mode function 65 Fully extend the levelling cylinders with switch 56 58 59 A To extend the levelling cylinders levelling operating mode 126 130 must be switched to MANUAL LED OFF on the remote controls Use switch 42 43 to adjust the screed to the basic width of the paver finisher m Lift the auger if necessary A If the engine is started with the drive lever pi...

Page 260: ...D 43 16 2 15 13 16 10 72 A ...

Page 261: ... Adjust the speed with the preselector 15 Carry out steering movements with the steering wheel 16 f In case of an emergency press the emergency stop button 10 To stop press the service brake A set the preselector 15 to 0 and move the drive lever 13 into its centre position A If the vehicle was brought to a standstill with the service brake it cannot be driven away again until after the drive lever...

Page 262: ...r push roller with a separator fluid m Do not use diesel fuel as it dissolves the bitumen prohibited in Germany Screed heater system Switch on the screed heater approx 15 30 minutes depending on the ambient tem perature before paving begins Warming up prevents the material from sticking to the screed plates F0147_A1 TIF ...

Page 263: ...traight paving a direction mark must be present or established road edge chalk lines or similar Slide the operating panel to the de sired side and secure it Pull the direction indicator out of the bumper arrow and adjust it accord ingly ...

Page 264: ...D 43 20 62 64 37 36 55 51 54 50 A B ...

Page 265: ...Auto Activate function 64 to fill the vehicle for the paving process Switch the conveyors on The conveyor limit switches A B must switch off when the material has approx imately reached the area beneath the auger crossbeam Check that the material is transferred properly Manually switch on or off the conveyor if the material is not conveyed properly until a sufficient amount of material lies in fro...

Page 266: ...D 43 22 63 53 49 52 48 66 67 73 15 123 127 126 130 126 130 13 ...

Page 267: ...eels as the screed tends to level an uneven ground The reference points for the layer thickness are the caterpillar chains or drive wheels The basic setting of the screed must be corrected when the actual layer thickness de viates significantly from the values indicated by the scales see the operating instruc tions for the screed A The basic setting is for asphalt material Item Travelling directio...

Page 268: ... the way Uniform material transport and distribution or supply to the screed may require cor rections to settings of the material switches for conveyor and auger A See the section Malfunctions when paver functions fail Quality of the layer Paving height Slope Evenness in the driving direction and at right angles to it check with 4 m levelling rod Surface structure texture behind the screed A See s...

Page 269: ...elief when the paver finisher is halting floating paving when the paver finisher is driving floating paving with screed charging or relieving when the paver finisher is driving A Relieving reduces the screed weight and increases the traction force Charging increases the screed weight reduces the traction force but increases the compaction ratio To be used with light weight screeds in exceptional c...

Page 270: ...D 43 26 71 70 63 13 15 68 ...

Page 271: ...g on operating status Paving stop when the paver finisher is stationary The screed is held by the relief pressure and the counter pressure of the material Floating paving during paving operation Lower screed to the floating position with preselected screed charging relieving function A Function for paving operation To lift the screed press switch 68 To lower the screed Resting function Keep button...

Page 272: ...moves on again A pressure greater than 10 15 bar neutralises the screed weight thus preventing the screed from sinking into the material A When combining the paving stop and screed relieving functions make sure that the pressure difference between the two functions does not exceed 10 15 bar m Especially in those cases where the screed relieving function is only briefly used as a start up aid there...

Page 273: ...D 43 29 71 70 63 13 15 ...

Page 274: ...ssure using pressure regu lating valve A read it off at the ma nometer B A When screed charging relieving is nec essary and automatic levelling is used grade control and or slope control the compacting performance changes layer thickness A The pressure can also be set or corrected during paving Max 50 bar Setting pressure for screed control with paving stop relieving Set the drive lever 13 to the ...

Page 275: ...D 43 31 13 15 11 ...

Page 276: ...sher empty and create an edge like the end of a lay er Set the drive lever 13 to the centre position During longer breaks e g lunch break Drive lever 13 into centre position RPM speed adjustment 15 to minimum posi tion Switch off the ignition 11 Switch the screed heater system off With a screed with gas heating system o close the bottle valves A The screed must be heated up to the correct paving t...

Page 277: ...D 43 33 13 11 15 68 ...

Page 278: ...position and the speed adjuster 15 to minimum Switch the screed heater system off Switch off the ignition 11 With a screed with gas heating system o close the main shut off valves and the bottle valves Remove the levelling units and stow them away in the boxes close all flaps Remove all parts that extend beyond the paver finisher contour or secure them if the paver finisher is to be transported ov...

Page 279: ... surface long waves change in the material temperature demixing roller has stopped on the hot material roller has turned or roller speed has been changed too fast incorrect operation of the roller incorrectly prepared foundation truck brake is applied too tight long standstill times between loads grade control reference line is not suitable incorrect installation of the grade control limit switch ...

Page 280: ... screed extendable parts are incorrectly installed cold screed bottom plates are worn or warped screed is not operated in the floating position paver finisher speed is too high auger is overloaded changing material pressure against the screed Marks in the surface truck hits too much against the finisher while aligning to the finisher too much play in the mechanical screed link suspension truck bra...

Page 281: ...r augers run too slowly Hydraulic oil level in the tank is too low Top up the oil Power supply interrupted Check fuses and cables replace if necessary Switch is defective Replace the switch One of the pressure limiting valves is defective Repair or exchange the valves Pump shaft broken Replace the pump Limit switch does not switch or regulate correctly Check the switch replace and adjust the switc...

Page 282: ...supply interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote con trol is set to Auto Set the switch to Manual Power supply interrupted Check fuse and cables replace if necessary Switch on the operating panel defective Replace Excess pressure valve defective Replace Flow rate regulator defec tive Replace Seals defective Replace Crossbeams...

Page 283: ... servo unit Insufficient supply pressure Check and adjust if necessary Check the suction filter replace the supply pump and the filter if necessary Drive shaft of hydraulic pumps or engines broken Replace pump or engine Irregular engine speed engine stop function does not work Fuel level too low Check the fuel level refill fuel if necessary Fuse engine speed control defective Replace fuse strip on...

Page 284: ...D 43 40 ...

Page 285: ...ehicle parts e g screed or hopper against lowering by means of mechanical safeguards Replace parts or have them replaced as stipulated f When connecting or disconnecting hydraulic hoses and when working on the hydrau lic system hot hydraulic fluid may spurt out at high pressure Switch off the engine and depressurise the hydraulic system Protect your eyes Mount all protective devices before re comm...

Page 286: ...different auger systems are available as options Check which auger type is used in your machine and comply with the corresponding installation operation and maintenance instructions Auger Type A Central drive Auger Type B External drive ...

Page 287: ...ng thickness 10 cm Min height setting 18 cm from the ground A An incorrect height setting can result in the following problems during paving Auger too high Too much material in front of the screed material overflow When operating with larger working widths demixing and traction problems may occur Auger too low Not enough material that can be precompacted by the auger Irregularities resulting from ...

Page 288: ...t by alternately adjusting the right hand and the left hand side The current height can be read at the scale 2 3 3 Hydraulic adjustment o Determine the currently set height of the auger crossbeam left and right on the scale 2 m Actuate both of the corresponding func tion buttons on the operating panel evenly to prevent the auger crossbeam from jamming Check whether the heights on the left and on t...

Page 289: ...s from the attaching point on the material shaft Carry out height adjustment Push the slewing brackets with braces onto the attaching point on the material shaft Install the split pin 1 and retaining pin 2 again A If the retaining pins 2 cannot be inserted in the new position the braces must be extended or shortened by rotating the adjustment rods until a continuous bore ena bles the retaining pin...

Page 290: ...ng the adjustment rods 5 until the retaining pins can be inserted Retighten the lock nuts 4 Install the split pin 1 and retaining pin 2 m Each time the height is adjusted the auger must be realigned via the braces A See section Aligning the auger ...

Page 291: ...e fork heads of the braces from the support shackles Carry out height adjustment Push the fork heads of the braces onto the support shackles Install the split pin 1 and retaining pin 2 again A If the retaining pins 2 cannot be set in the new position extend or shorten the braces by turning the adjustment rods until a through hole is available to set the retaining pin 2 Loosen lock nuts 4 A The adj...

Page 292: ...ng the adjustment rods 5 until the retaining pins can be inserted Retighten the lock nuts 4 Install the split pin 1 and retaining pin 2 m Each time the height is adjusted the auger must be realigned via the braces A See section Aligning the auger ...

Page 293: ... For working widths of more than 3 00 m the auger should be fitted with extension parts on both sides to improve material distribution and to reduce the wear f The diesel engine must be switched off whenever work is performed on the auger Danger of injuries A If the operating conditions on the construction site permit an auger extension to be fitted or render this necessary always additionally fit...

Page 294: ...arts 2 bolts washers nuts Dismantle the assembly parts 3 of the adjacent auger blade remove plug 4 Insert the auger shaft extension into the auger shaft Reinstall the previously removed assembly parts 3 and simultaneously tighten the auger shaft bolts Insert the plug 4 at the end of the auger A Depending on the operating width the outer auger bearing and or auger end bearing must be installed 2 4 ...

Page 295: ...aring to the brace shaft with the relevant assembly parts 4 bolts washers pins A If necessary insert fitted plates 5 Reinstall the previously removed assembly parts 1 and simultaneously tighten the auger shaft and bearing shaft bolts Mount the auger half 5 on the outer side of the bearing with the relevant assembly parts 6 bolts washers nuts Insert the plug 2 at the end of the auger 4 1 6 7 2 3 5 ...

Page 296: ... Dismantle the assembly parts 5 of the adjacent auger blade remove plug 6 Insert the auger end bearing 7 into the auger extension Secure the auger end bearing to the material shaft with the relevant assembly parts 8 bolts washers nuts Reinstall the previously removed assembly parts 5 of the auger blade and simul taneously tighten the auger shaft and bearing shaft bolts Insert the plug 6 at the end...

Page 297: ...ght 640L Auger extension part 640mm right 640R Auger extension part 640mm right 960L Auger extension part 960mm left 960R Auger extension part 960mm right 320 Material shaft 320mm 640 Material shaft 640mm 960 Material shaft 960mm 960BL Material shaft 960mm with brace left 960BR Material shaft 960mm with brace right 160L 160R 320L 320R 640L 640R 960L 960R 320 640 960 960BL 960BR ...

Page 298: ...E 13 14 Symbol Meaning Outer auger bearing Auger end bearing ...

Page 299: ...E 13 15 Auger upgrading working width 3 14m Auger upgrading working width 3 78m Auger upgrading working width 4 42m 320 R 320 L 320 320 640 640 640 R 640 L 640 640 640 R 640 L 320 R 320 L 320 320 ...

Page 300: ...E 13 16 Auger upgrading working width 5 06m Auger upgrading working width 5 70m 320 L 320 320 R 320 960 R 960 L 960 960 960 R 960 L 960 960 640 640 640 R 640 L ...

Page 301: ...E 13 17 Auger upgrading working width 6 34m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960 ...

Page 302: ...E 13 18 Auger upgrading working width 6 98m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960 320 L 320 320 R 320 ...

Page 303: ...E 13 19 Auger upgrading working width 7 62m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960 ...

Page 304: ...E 13 20 Auger upgrading working width 8 26m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960 320 L 320 320 R 320 ...

Page 305: ...E 13 21 4 3 Mounting the auger brace 11 8 12 20 19 15 14 26 16 18 21 1 10 13 17 27 23 1 2 3 4 5 6 7 18 22 23 24 25 26 ...

Page 306: ...acket 10 into the brace bracket 8 and secure with the retain ing pin 11 Secure the retaining pins 11 with a split pin 12 Mount the slewing bracket 14 at the brace shaft 13 with retaining pins 15 Secure the retaining pins 15 with a split pin 16 Mount the braces 17 on the fulcrum bracket 10 with the assembly parts 18 A The braces must be mounted on the outer side of the fulcrum bracket 10 Remove the...

Page 307: ...just the length of the adjustment rod here The rotational direc tion for extending or shortening the adjustment rod is determined by the left hand thread L or right hand thread R A A cord which aligns with the screed or the rear wall of the vehicle can be tensioned e g to provide assistance during alignment Extend the upper and lower adjustment rods until the material shafts are aligned vertically...

Page 308: ...ng instruc tions for the screed screed extension chart To obtain the desired working width the corresponding screed extensions auger width extensions guides or cut off shoes must be mounted A Refer to the auger extension chart to determine which parts of the conveyor system are required for the desired paving width in which position f The diesel engine must be switched off whenever work is perform...

Page 309: ...he clamping bolts 1 on the support tube Then turn in the centre expan sion bolt 2 to expand the clamping joint Pull the telescopic tube 3 out of the support tube 4 m Collision between the hydraulic hoses and the steel cable of the height display Remove the steel cable A from the bracket B After the support tube has been pulled out hang the steel cable back in position again 1 2 3 4 5 6 B A ...

Page 310: ...t be in line A A cord which aligns with the screed or the rear panel of the vehicle can be used e g to provide assistance during alignment Remove the expansion bolt 2 Then tighten the clamping bolts 1 Finally tighten the expansion bolt 2 by hand m Before the clamping bolts 1 can be tightened again the expansion bolt 2 must be sufficiently turned back Otherwise the telescopic tube cannot be safely ...

Page 311: ... out of the support tube as otherwise it can fall down The support tube extension 4 of the auger crossbeam consists of two halves Put the upper and lower part over the telescopic tube and bolt together with the support tube using the relevant assembly parts 5 Bolt the two extension parts together using the relevant assembly parts 6 Only tighten the bolts lightly on the clamping piece 7 Mount the r...

Page 312: ...ery for this working width f When connecting or disconnecting hydraulic hoses hydraulic fluid can spurt out at a high pressure Switch off the paver finisher and de pressurize the hydraulic circuit Protect your eyes m When installing the hoses make sure that the area around the connections is clean Any dirt that enters the hydraulic system can cause malfunctions ...

Page 313: ...rts 5 After loosening the bolts 6 adjust the end piece to the required width Then retighten the bolts 6 A For larger working widths additional supports 7 must be attached to the telescopic tube to stabilise the guides Depending on the working width supports with shackles may have to be fitted for fastening the braces Dismantle support lower part 8 Set the support 7 on the telescopic tube and mount...

Page 314: ...nsion part 868m right 345L Guide end piece 345mm extension left 345R Guide end piece 345mm extension right 300L Guide 300mm left 300R Guide 300mm left 300L Guide 300mm left 300R Guide 300mm left 700L Guide 700mm left 700R Guide 700mm left AL Support left AR Support right AL Support with shackles left AR Support with shackles right 290L 290R 434L 434R 868L 868R 300R 345R 300L 345L 300L 300R 300R 50...

Page 315: ...E 13 31 Symbol Meaning RL Extension pipe left RR Extension pipe right RL RR ...

Page 316: ...ding working width 3 06m Auger upgrading working width 3 35m Auger upgrading working width 3 93m 290 R 290 L 300L 300R 300L 300R 434 R 434 L 300L 300R 345L 345R 434 R 434 L 290 L 290 R 500L 500R 300L 300R 345L 345R AL AR ...

Page 317: ...er upgrading working width 5 08m Auger upgrading working width 5 66m 868 R 868 L 500L 500R 300L 300R 345L 345R AR AL 868 L 868 R 434 L 434 R 700L 700R 500L 500R 345R 345L AL AR 868 R 434 R 290 R 290 L 434 L 868 L 700L 700R 500L 500R 345R 345L AR AL ...

Page 318: ...E 13 34 Auger upgrading working width 6 53m 868 R 868 L m m 868 R 290 R 290 L 868 L ALR ALL 300L 300R 300R 700R 700R 345R 300L 700L 700L 345L RR RL ...

Page 319: ...E 13 35 Auger upgrading working width 7 40m 434 L 434 R 500L 500R 868 R 868 L m m 868 R 290 R 290 L 868 L AR AL 300R 700R 700R 345R 300L 700L 700L 345L RR RL ALR ALL ...

Page 320: ...E 13 36 Auger upgrading working width 8 00m 434 L 434 R 500L 500R 868 R 868 L m m 868 R 290 R 290 L 868 L AR AL 300R 700R 700R 345R 300L 700L 700L 345L RR RL ALR ALL 290 R 300R 290 L 300L ...

Page 321: ...E 13 37 5 3 Mounting the auger brace 12 10 13 17 16 20 26 18 11 14 27 21 19 26 1 2 3 4 5 9 23 24 25 8 15 6 7 ...

Page 322: ...int of the bracket and se cure with a pin 8 and split pin 9 A The brace bracket 10 is secured to the central panel of the machine using the cor responding assembly parts Insert the fulcrum bracket 11 into the brace bracket 10 and secure with the re taining pin 12 Secure the retaining pins 12 with a split pin 13 Mount braces 14 to the bracket 11 using the relevant assembly parts 15 A The braces mus...

Page 323: ...st the length of the adjustment rod here The rotational direc tion for extending or shortening the adjustment rod is determined by the left hand thread L or right hand thread R A A cord which aligns with the screed or the rear panel of the vehicle can be used e g to provide assistance during alignment Extend the upper and lower adjustment rods until the guides and auger segments are aligned vertic...

Page 324: ...ue to screed retraction Mount the left right material shafts on the auger box with the relevant assembly parts 1 A If a terminal bearing is mounted for the existing auger width the adapter plate 2 also has to be fitted Fit the plate 3 to the hinge 5 using the hinge rod 4 A The hinged material shaft can be secured with the assembly parts 6 in swivelled in position when transporting the machine in i...

Page 325: ... hopper scrapers 1 must be adjusted at both hopper halves Loosen the mounting screws 2 Adjust a gap of 6 mm across the whole length of the scraper Retighten the mounting screws 2 properly f Risk of injury due to sharp edged parts Wear suitable safety gloves to protect your hands 1 2 ...

Page 326: ...e between the auger and screed Loosen the four mounting screws 1 Remove the screws and move the ve hicle forwards The crossbeam remains in its position on slide rails now tighten the screws 1 back down A When paving thin layers the material can settle in front of the screed if the screed is set to the rear position When paving thick layers the screed then climbs better 1 ...

Page 327: ...s are provided for mounting on the sensor s retaining plate A The digital slope controller must be mounted in such a way that the marking arrow on the housing points in the direction of travel A The analogue slope controller must be mounted in such a way that the displays for the operator visibly point backwards Connect the left or right connection cable to the intended handset or vehicle socket A...

Page 328: ...rd Tighten the pin 2 so that the sensor arm is just still able to swivel A The sensor arm can be secured on the side board with the lock 3 7 3 Mounting the grade control system Insert the grade control system into the clamp bracket 1 and secure with the clamping bolt 2 to prevent rotation Tastarm wmf 3 2 1 F0258_A1 TIF 1 2 ...

Page 329: ...e at the lock 5 Height adjustment for analogue grade sensors is carried out by means of a crank 6 To lock it the crank is inserted into one of the available notches following the adjustment work A All assembly parts and clamping points must be tightened properly to ensure safe and precise sensor arm operation Connect the left or right grade control system connection cable to the intended handset o...

Page 330: ...extensions A The big ski enables the alignment of the individual sensors at the front and rear to be shifted over the reference The sonic ski can actually be positioned in front of and be hind the vehicle in order to guarantee safe reference sensing even on cornering A Before starting paving the big ski must be set with the grade control system mount ed to its reference cable kerb etc The big ski ...

Page 331: ... side next to the screed or also above the screed This is dependent on the paving width required in each case A The procedure for mounting the big ski is the same in both cases A So that the big ski can be operated as parallel to the ground as possible during pav ing it must be attached according to the subsequent paving conditions To do this the screed should be lowered to the desired course thic...

Page 332: ...ket directly at the existing bores or as described in the following to secure it to the crossbeam using clamp ing plates A The front bracket is mounted directly be hind the traction point the rear bracket is mounted at approximately the height of the auger Place both brackets 1 over the crossbeam at the corresponding point and mount with bolts 2 and sleeves 3 A For different crossbeam thicknesses ...

Page 333: ... s 45 chamfer must point upwards Then slide the two swivel arms 3 onto the tube of the big ski bracket A The rear swivel arm is positioned rotat ed by 180 on the big ski bracket Slide a fixing ring 4 flat version onto the front swivel arm and secure with the relevant star handle bolt 1 3 4 2 MBS3a bmp MBS3c bmp ...

Page 334: ... centre element together with the rear swivel arm until the front sliding part 4 can be pushed onto the front swivel arm from above Then secure the rear sliding part with a fixing ring 5 and the relevant star handle bolt A Once the first part of the beam has been assembled it is initially aligned The centre element is now aligned horizontally using the fixing rings on the swivel arms and also with...

Page 335: ...oth the 9 m and 13 m versions A Structure of the 9 m version Extension part at the front rear each Structure of the 13 m version Two extension parts at the front rear each Place the extension module 1 onto the centre element 2 and secure with a bolt 3 1 3 2 MBS1 bmp ...

Page 336: ...ance away from it A Extendable sensor brackets 1 are mounted in the two outer positions the normal sensor bracket 2 is mounted in the centre Place the sliding bracket 3 over the corresponding big ski element from the inner side Insert the sensor bracket 4 into the sliding bracket 5 from below and se cure with the relevant star handle bolts Place the clamping ring 6 onto the sensor bracket tube and...

Page 337: ...ables the two outer sensors to be swivelled during paving for diverse requirements e g cornering By loosening the star handle bolts 5 the length of the extension arm can be adjusted The sensor bracket with extension arm can be swivelled by loosening the star handle bolts 3 A If a sensor extension arm is swivelled to the side it must be ensured that the attached sensor is subsequently aligned in th...

Page 338: ...sed to initially mount the distributor box 1 on the mounting plate 2 A The input connector always points in the direction of travel Then mount the mounting plate on one of the two sliding brackets 4 on the centre element using a star handle bolt 3 m Mounting the big ski on the right hand side of the vehicle To meet the requirement that the input connector always points in the direction of travel t...

Page 339: ...ion diagram A The three sensors are connected to the distributor box and the distributor to the machine according to the following scheme Sensors Front 1 Centre 2 Rear 3 Distributor box 4 Machine interface 5 4 1 2 3 5 ...

Page 340: ...ecure with a clamping lever 4 Connect the left or right sensor s con nection cable 5 to the intended re mote control bracket sockets A The connection cables are connected to the relevant sockets on the remote control bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed over the full working width A We recomme...

Page 341: ...ts 1 when the mechanical assemblies have been mounted and set up PLC version Auger limit switches 2 Remote control 3 Grade control system 4 External levelling system 5 A When using an external levelling sys tem this must be logged in using the re mote control menu Conventional version Remote control 6 Auger limit switches 7 Automatic levelling system 8 A Always seal unused sockets with the rel eva...

Page 342: ...responding bridge connectors have been fitted on both sides of the machine Side board with mounted remote bracket Fit bridge connector 1 in the socket of the remote control and secure with cap Check that the connection box is plugged in 2 Side board removed Fit bridge connector 3 in the socket of the connection box and secure with cap 1 2 3 ...

Page 343: ...manufacturer f Re commissioning Mount all protective devices before re commissioning the paver finisher f Cleaning Cleaning must not be carried out while the engine is running Do not use any inflammable substances such as petrol Avoid directly cleaning electrical parts and insulation material with a steam jet cover them up beforehand f Working in enclosed environments Exhaust fumes must be conduct...

Page 344: ...F 10 2 ...

Page 345: ...F 24 1 F 24 Maintenance review 1 Maintenance review 72 40 51 83 90 100 33 61 41 ...

Page 346: ...different auger systems are available as options Check which auger type is used in your machine and comply with the corresponding installation operation and maintenance instructions Auger Type A Central drive Auger Type B External drive ...

Page 347: ...ce hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F33 q q q Auger Type A F40 q q q q q q q Auger Type B F41 q q q q q q Engine F51 q q q q q q Hydraulic system F61 q q q q q q Wheel chassis F72 q q q q q q Electrical system F83 q q q q q Lubrication points F90 q q q q Checking stopping F100 q q q Maintenance required q ...

Page 348: ...F 24 4 ...

Page 349: ...F 31 1 F 31 Maintenance conveyor 1 Maintenance conveyor ...

Page 350: ...If necessary 1 q Conveyor chain Check tightness q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Conveyor drive drive chains Check chain tightness q Conveyor drive drive chains Adjust chain tightness 3 q Replace conveyor deflectors conveyor plates Maintenance q Maintenance during the running in period g ...

Page 351: ... An excessively taut chain can cause the chain to be stopped or to break when material falls into the space between the chain and the sprocket An excessively slack chain may catch on protruding objects and be destroyed Adjustment of chain tension A The chain tension is adjusted with grease tensioners The filling connec tions A are located behind the bumper on the left and right sides Add grease wi...

Page 352: ...ng the chains would lead to the destruction of the drive wheels m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyor deflectors Conveyor plates Deflector plates Conveyor chain reversing rollers Conveyor drive chain sprockets A Your Dynapac customer service will be happy to provide support during maintenance repai...

Page 353: ...n has been set properly the chain must be able to move freely approx 10 15 mm To re tension the chains Unfasten mounting screws A and lock nut B slightly Use the tensioning screw C to set the required chain tightness Retighten mounting screws A and lock nuts B correctly A A B D ...

Page 354: ...deflectors with new bolts A At the latest the conveyor plates B must be replaced when the wear limit of 5 mm in the rear area beneath the chain has been reached m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyor deflectors Conveyor plates Deflector plates Conveyor chain reversing rollers Conveyor drive chain sp...

Page 355: ...F 40 1 F 40 Maintenance auger assembly 1 Maintenance auger assembly ...

Page 356: ...planetary gear Check oil level q Auger planetary gear Top up oil g q Auger planetary gear Change oil 3 q Auger drive chains Check tension q Auger drive chains Adjust tension 4 q Auger box Check oil level q Auger box Top up oil q Auger box Change oil 5 q Seals and sealing rings Check wear q Seals and sealing rings Replace seals Maintenance q Maintenance during the running in period g ...

Page 357: ...0 If necessary 6 g Gearbox bolts Check tightening q Gearbox bolts Tighten to correct torque 7 g g Outer bearing bolts Check tightening q Outer bearing bolts Tighten to correct torque 8 q Auger blade Check wear q Auger blade Replace auger blade Maintenance q Maintenance during the running in period g ...

Page 358: ... any bitumen res idues which may have entered and to supply the bearings with fresh grease when warm A If the auger is extended the outer rings should be loosened slightly when initially greasing the outer bearing points in or der to improve ventilation on greasing The outer rings must be properly se cured again after greasing A New bearings must be filled with 6 strokes of grease using a grease g...

Page 359: ... oil into the filler bore at B until the oil level has reached the lower edge of the inspec tion bore A Screw the filler B and inspection screws A back in To change oil A The oil should be changed when at oper ating temperature Unscrew the filler screw B and drain plug C Drain the oil Screw the drain plug C back in Unscrew the inspection screw A Fill the specified oil into the filler bore at B unt...

Page 360: ... augers outer circumference should be 10 mm f Risk of injury due to sharp edged parts To re tension the chains Release the mounting screws A Set the chain tension correctly using the threaded pins B Tighten the threaded pins to 20 Nm using a torque wrench Subsequently loosen the threaded pins again by one full revolution Retighten the bolts A C A A B ...

Page 361: ...Change oil A The oil should be changed when at oper ating temperature Place a suitable collecting container under the auger box Loosen bolts D from the circumfer ence of the worm shaft flange A The oil runs out between the flange and auger box Drain out all oil Correctly retighten flange bolts D di agonally Pour the specified oil in through the open top cover C of the auger box until the oil level...

Page 362: ... sealing rings 5 A After reaching operating temperature check the gearbox for leaks m In case of visible leaks e g between the flange surfaces A of the gearbox re placement of the seals and sealing rings is necessary A ...

Page 363: ... has attained the full tightening torque and note the corre sponding tightening pattern whilst doing so Mounting screws Outer auger bearing Check tightening 7 m Following the running in period the tightening torques of the outer auger bearing mounting screws must be checked Tighten to the following torques if nec essary F 210 Nm m If the auger s working width is changed the tightening check must b...

Page 364: ...ced and the blades B have to be replaced Remove the bolts C washers D nuts E and auger blade B f Risk of injury due to sharp edged parts m Auger blades must be installed play free the contact surfaces must be dirt free Install the new auger blade B re place the bolts C washers D and nuts E if necessary A B C D E B ...

Page 365: ...F 41 1 F 41 Maintenance auger assembly 1 Maintenance auger assembly external drive version ...

Page 366: ...necessary 1 q Outer auger bearing Lubricate 2 q Auger centre bearing Lubricate 3 q Auger gear neck bearing Lubricate 4 q Auger bevel gear Check oil level q Auger bevel gear Top up oil q Auger bevel gear Change oil 5 q Auger blade Check wear q Auger blade Replace auger blade Maintenance q Maintenance during the running in period g ...

Page 367: ...side at the top of the outer auger bear ings These nipples must be lubricated each time work is finished A Lubricate the outer auger bearing while they are warm to force out any bitumen residues A Manual lubrication no longer applies when equipped with the optional central lubrication system 5x ...

Page 368: ...g 2 The centre bearing A must be lubricat ed on the left hand side of the auger To do so the bevel gear unit must be pulled off A The centre bearing must be lubricated when in a warm state to force out any bi tumen residues A 5x ...

Page 369: ...lug A on the gear neck and replace the screw located underneath with an M10x1 grease nipple Using a grease gun inject 10 strokes into it A Remove the grease nipple and screw both screws back in The gear bearing is sealed underneath and lubricated only with grease A 10x ...

Page 370: ...d inspection bore A until the oil level has reached the lower edge of the bore A Screw the inspection bolt filler screw A back in To change oil A The oil should be changed when at oper ating temperature Unscrew and remove the inspection bolt filler screw A and drain plug B Drain the oil Tighten the drain plug B back in Pour the specified oil into the filler and inspection bore A until the oil leve...

Page 371: ...ger is reduced and the blades have to be replaced Dismantle nuts B and bolt C and re move the worn auger blade f Risk of injury due to sharp edged parts m Auger blades must be installed play free the contact surfaces must be dirt free Install the new auger blade D re place the bolts C and nuts B B A C D ...

Page 372: ...F 41 8 ...

Page 373: ...ce engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work and service intervals itemised here are binding in nature ...

Page 374: ...ean the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel system Fuel filter drain the water separa tor q Engine fuel system Replace fuel pre filter q Engine fuel system Replace fuel filter q Engine fuel system Bleed fuel system Maintenance q Maintenanceduring...

Page 375: ... filter Air filter cartridge Replace 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system Top up coolant q Engine cooling system Check coolant concentration q Engine cooling system Coolant concentration Adjust q Engine cooling system Change coolant Maintenance q Maintenanceduringtherun...

Page 376: ...e 10 50 100 250 500 annually 1000 annually 2000 every 2 years If necessary 6 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt Maintenance q Maintenanceduringtherunning inperiod g ...

Page 377: ... run 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 plugs B in both tanks and drain about 1 l fuel into a collection pan When fastening the screw again after draining make sure to use a new seal A B B ...

Page 378: ... in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use dipstick to check level again Oil change A The oil drain screw is accessed via the cover C in the vehicle s material tunnel Remove the bolts D from the frame and pull the cover C out in the direc tion of travel After completing the maintenance work reinstall the cover C properly...

Page 379: ...icle s centre wall Remove the screws G from the inner side of the frame and remove the serv ice flap F After completing the maintenance work reinstall the service flap F properly 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 ...

Page 380: ...pleting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two fil ters Prefilter with water separator C Main filter D Prefilter draining of water A Drain 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 381: ...lunger is now pressed out via the spring Pump until a very high resistance is perceptible and pumping can only be carried out very slowly Now continue pumping a few more times The return line must be 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 simultaneo...

Page 382: ...ty dust collector Empty the dust removal valve A on the air filter housing by compressing the discharge slot Remove any dust deflectors by press ing together the upper valve section A Clean the dust removal valve from time to time A ...

Page 383: ...or Open the air filter housing B at the clips C Move filter element D to the side a lit tle and then pull it out of the housing Pull out the safety element E and check for signs of damage A Replace the 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 384: ...em is under pressure When it is opened there is danger of scalding m Use only approved coolants A Observe the instructions in the chapter entitled Operating substances Remove the drain screw B on the 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 385: ...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 386: ... 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 387: ...F 61 1 F 61 Maintenance hydraulic system 1 Maintenance hydraulic system ...

Page 388: ...Hydraulic oil tank Check maintenance indicator q q Hydraulic oil tank Intake return hydraulic filter change vent 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 Clean b...

Page 389: ...very 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 Replace filter element o Maintenance q Maintenanceduringtherunning inperiod g ...

Page 390: ...aulic reservoirs A are on the frame crossbeam at the rear axle Sfety instructions hydraulic reservoir f The hydraulic reservoir may only be as sembled maintained and repaired by authorised trained and familiarised per sonnel f Risk of explosion during welding and soldering work f Mechanical treatment leads to the risk of bursting and loss of the operating li cence f Improper mounting can cause sev...

Page 391: ...d on the side of the tank For filling in the oil Remove cap B Fill in oil through the filling opening un til the oil level rises to the centre of the sight glass A 5mm Screw cap B on again A Regularly 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 ...

Page 392: ...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 393: ...r mounting screws A and lift off cover Disassemble the removed unit into Cover B Separating plate C Filter D Dirt trap E Clean the filter housing cover sepa rating plate and dirt trap Check the O rings F replace if nec essary Coat the sealing surfaces and O rings with clean operating fluid m The filter must be bled following filter re placement F E D C B A ...

Page 394: ...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 395: ... cartridge Clean the filter housing Insert the new filter cartridge Replace the seal ring of the filter hous ing Turn on the filter housing by hand and tighten it using a wrench Start trial operation 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 396: ... for a moment as the oil which has been poured in first has to flow off m Make sure to clean the screw and the vi cinity of the drain bore Oil change Place the end of the oil drain port hose C in the 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 prescribed quality of oil through the dipstick open...

Page 397: ...F 61 11 Bleeder A The bleeder A can be found on the rear of the pump distribution gear housing The functioning of the bleeder must be ensured If soiling has occurred the bleeder should be cleaned A ...

Page 398: ...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 399: ...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 400: ...noth er and always ensure that they are at the correct pressure In individual cases the period of use can be stipulated according to experience and may differ from the following general indications When producing the hose pipe the hose purchased by the meter should not be more than four years old The period of use of a hose pipe should not exceed six years including any possi ble storage period Th...

Page 401: ...n the filter then close the non return valve again Replace filter element B and sealing ring C Turn filter element clockwise with the help of carrier straps and at the same time raise it slightly Wait for a moment until the oil has escaped downwards then remove the filter element Check inlet and outlet in filter housing D As required top up hydraulic oil level in filter housing then screw down the...

Page 402: ...F 61 16 ...

Page 403: ...F 72 1 F 72 Maintenance travel drive steering 1 Maintenance travel drive steering ...

Page 404: ... point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality Maintenance q Maintenance during the running in period g ...

Page 405: ...tyres q Drive wheels Check air pressure q Drive wheels Adjust air pressure g Drive wheels Check wheel nuts q Drive wheels Tighten wheel nuts 3 q Lubrication points Lubricate king pins q Lubrication points Lubricate steering q Lubrication points Lubricate floating axle q Lubrication points Lubricate o wheel bearings Maintenance q Maintenance during the running in period g ...

Page 406: ...nto the filler 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 rear wheel 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 407: ...eels 2 Check tyres replace tyres Check the tyres on a daily basis for signs of damage cracks or blister for mation Regularly check compliance with the minimum profile depth m Replace damaged or worn tyres immediately ...

Page 408: ...n under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequately dimensioned and be able to take the corresponding weight f There must not be anyone on the machine while it is being lifted Dismantle the arm Lift the machine with the jack at the intended position 1 under the machine frame Place the wooden block 2 under the wheel as a safeguard Place a...

Page 409: ...heck the tyre pressure in cold condi tion A slight increase in tyre pressure during operation is normal and there is no need to relieve pressure f Only ever set the tyre pressure using a self regulating filler connection Never stand directly in front of the tyres when filling them with air f Please comply with the safety instructions for checking and adjusting the air pressure A Bear in mind that ...

Page 410: ... operating speed C Max min air pressure at transportation speed D Screed type E Max air pressure for screed without extension parts F Max air pressure for screed with extension parts G Max air pressure A Ascertain the tyre type before adjusting the pressure Pressures for equipment Bandag on Michelin XHA Pressures for equipment Michelin XGC Techking ETGC B C D F E D E A G G ...

Page 411: ...heel nuts tighten wheel nuts A Following wheel replacement check the wheel nuts after the running in time Check tighten all wheel nuts using a torque wrench as shown A Adjust the torque to 510Nm 8 4 9 5 1 7 3 10 6 2 ...

Page 412: ...ng nipples B are on the rear axle of the main frame and supply the steering linkage with grease via a lu brication line Floating axle A The lubricating nipples C are located on the left and right of the floating axle s centre bearing Wheel bearings o A Each of the wheels is equipped with a lubricating nipple D on the wheel hub In the case of front wheel drive the drive wheels have no lubricating n...

Page 413: ...F 83 1 F 83 Maintenance electrical system 1 Maintenance electrical system ...

Page 414: ... electrolyte check q Top up with distilled water q Apply grease to battery terminals 2 q Alternator Electrical system insulation moni toring Check function o q Alternator Visual check for pollution or dam age Check the cooling air openings for pollution or clogging clean if nec essary o 3 q Electric Fuses Maintenance q Maintenance during the running in period g ...

Page 415: ...fluid level should come up to the top mark If re quired top up the battery but only use distilled water to do so m The battery terminal clips must be free of oxide and protected with a special termi nal grease m When removing the batteries always first remove the negative terminal en suring that the battery terminals cannot be short circuited ...

Page 416: ...s conducted successfully work may be undertaken with the screed and external consumers may be used If the insulation fault indicator lamp displays a fault even before the test button is pressed or if no fault is displayed during the simulation work must not be undertaken with the screed or with connected external equipment f The screed and equipment must be checked or repaired by a specialist elec...

Page 417: ...ried out If the indicator lamp goes out the switches of the heating system and external equipment can be switched back to ON one after another until a message again appears and the system is shut down The equipment found to be faulty must be removed or must not be engaged and the reset button must be pressed for at least 3 seconds to delete the fault A Operation may now be continued without the fa...

Page 418: ...nerator m The generator must be regularly checked for excessive dirt and must be cleaned if necessary The air intake 1 and fan shroud 2 must be kept free of dirt m Cleaning with a high pressure cleaner is not permissible 2 1 ...

Page 419: ...3 7 Electrical fuses relays 3 Main fuses A A Main fuses B Fuses in terminal box C Relays in terminal box F A F1 1 Main fuse 50 F1 2 Main fuse 50 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 C B A ...

Page 420: ...F 83 8 Fuses in terminal box B 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 ...

Page 421: ...Keyboard voltage supply 10 F19 Engine compartment lighting 10 F20 Rotary beacon 7 5 F21 Travel drive computer voltage supply 25A F22 Travel drive computer voltage supply 25A F23 Horn 15 F24 Engine start 10 F25 Windscreen wiper 5 F26 Engine control unit 30 F27 Keyboard display constant positive 2 F28 Hazard flashers 10 F29 Ignition 3 F30 Reverse buzzer 5 F31 Diesel pump 7 5 F32 Travel drive compute...

Page 422: ...F 83 10 F A F39 Left hand parking lights 5 F40 Parking lights right 5 F41 Parking light 5 F42 Low beam headlights 10 F43 High beam headlights 10 ...

Page 423: ...F 83 11 Relays in terminal box C 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 ...

Page 424: ...ont working lights 8 Rear working lights 9 Horn 10 Start inhibit emergency stop 11 Start inhibit 12 Rotary beacon 13 Seat heating 14 Windscreen wiper 15 Windscreen washer system 16 Reverse buzzer 17 Diesel pump 18 High beam headlights 19 Lights 20 Flashers 21 Brake light 22 not used 23 not used 24 not used 25 not used 26 not used 27 not used 28 not used 29 Central lubrication ...

Page 425: ...F 83 13 Relays in the engine compartment E K 0 Engine start ...

Page 426: ...F 83 14 ...

Page 427: ...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 428: ...em 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 429: ...k of injury due to escaping lubricant as the system operates at high pressures f Ensure that the diesel engine cannot be started when working on the system f Observe safety regulations for handling hydraulic systems m Ensure maximum cleanliness when working on the central lubrication system The following assemblies lubricating points can be automatically supplied with grease by the central lubrica...

Page 430: ...in a fill level above the MIN mark a on the tank Top up lubricant tank A lubricating nipple b is located on the lubricant tank a for filling purposes Connect the grease gun c enclosed on delivery to the filling nipple b and fill the lubricant tank a up to the MAX mark Alternatively unscrew cover d and fill tank from above A When the lubricant tank is completely empty the pump may have to run for u...

Page 431: ...bricant has emerged Check all connections and lines for leaks Check pressure limiting valve m If lubricant emerges at the pressure lim iting valve a this indicates a malfunc tion in the system The consumers are no longer adequate ly supplied with lubricant Release all distribution lines b leading from the distributor c to the consumers in succession If lubricant emerges from one of the released di...

Page 432: ...e Remove the lubrication line a and install a normal lubricating nipple b Connect the grease gun c en closed on delivery to the lubricating nipple b Operate the grease gun until the lu bricant visibly emerges Rectify any faults in the flow of lubri cant Reinstall the lubrication lines Check all connections and lines for leaks c a b ...

Page 433: ...F 90 7 Bearing points 2 A One lubricating nipple A is located at each hydraulic cylinder bearing point top and bottom A One lubricating nipple B is located at each push roller bearing point 2x A 2x B ...

Page 434: ...F 90 8 ...

Page 435: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping ...

Page 436: ...Maintenance point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q General visual inspection 2 q q Inspection by an expert 3 q Cleaning 4 q Preserving the paver finisher Maintenance q Maintenance during the running in period g ...

Page 437: ...Are all fastening points conveyor auger screed etc in order m Immediately take actions to correct any detected malfunction to avoid damages dan gers or environmental hazards 3 Inspection by an expert A Have finisher screed and optional gas or electric system checked by a trained spe cialist when required according to the operating conditions and the nature of application however at least once a ye...

Page 438: ...l lube points acc to specification Clean the vehicle with water after laying mineral aggregates lean mixed concrete etc m Do not spray bearing points electrical or electronic components with water Remove residual paving material m After cleaning work with the high pres sure cleaner grease all lube points acc to specification f Danger of slipping Ensure that all steps and ladders are free of grease...

Page 439: ...y with further instructions in the safety manual 4 2 Cleaning the conveyor and auger m Clean the conveyor and auger regularly If necessary let the conveyor and auger run at low speed during cleaning f Danger of being pulled in by rotating or conveying vehicle parts f Rotating or conveying vehicle parts can cause severe or fatal injuries Do not enter the danger zone Do not reach into rotating or co...

Page 440: ...oved batteries every 2 months Protect all bare metal components e g piston rods on hydraulic cylinders with a suitable corrosion inhibitor If it is not possible to park the vehicle is an enclosed building or under cover it must be covered with a suitable size of tarpaulin In all cases seal all air intake and ex haust apertures with plastic film and adhesive tape 5 2 Shutdowns lasting from 6 months...

Page 441: ...isposal must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oily or greasy parts hydraulic hoses lube pipes etc must be treated separately A Electric devices accessories and packaging should be recycled in an env...

Page 442: ...F 100 8 ...

Page 443: ...ts 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 paver finisher failure m Never mix synthetic oils with mineral oils ...

Page 444: ... different auger systems are available as options Check which auger type is used in your machine and comply with the corresponding installation operation and maintenance instructions Auger Type A Central drive Auger Type B External drive ...

Page 445: ...F 111 3 2 1 6 5 7 4 3 6 8 ...

Page 446: ... reservoir Hydraulic oil 220 litres 5 Pump distribution gear Gearbox oil 7 0 litres 6 Planetary gear Travel drive Gearbox oil 2 5 litres 7 Planetary gear augers on each side Auger Type A Gearbox oil 1 5 litres 7 Auger box Auger Type A Gearbox oil 4 0 litres 7 Outer auger bearing per bearing Auger Type A Hot bearing grease 115 grams 8 Auger bevel gear on each side Auger Type B Gearbox oil 0 6 litre...

Page 447: ...o Exxon Fuchs Mobil Shell Engine Oil 100 Rimula R6LM 10W 40 Dynapac AGIP Chevron Caltex Delo Mobil Shell Coolant 200 Antifreeze Spezial Extended Life Coolant Extended Life Coolant Extended Life Coolant Atlas Copco AGIP Chevron Caltex Fuchs Mobil Shell Hydraulic 100 Rando HDZ 46 Rando HDZ 46 Tellus Oil S2 V46 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Titan ATF 6000 SL Spirax S4 ATF HDX Spirax S4...

Page 448: ...ed Atlas Copco Aral BP Esso Exxon Fuchs Mobil Shell Traction Gear 100 Omala Oil F 220 Atlas Copco Aral BP Esso Exxon Fuchs Mobil Shell Traction Gear 100 Omala Oil F 220 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Omala S4WE460 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 300 Spirax S2 G 80W 90 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Chevron Paver Grease Gadus S5 T460 1 5 High Temp P...

Page 449: ... pressure fluids to biodegradable pressure fluids please contact our factory advisory service Manufacturer ISO viscosity class VG 46 Atlas Copco Hydraulic 120 Shell Naturelle HF E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 Manufacturer ISO viscosity class VG 46 Atlas Copco Hydraulic 100 Shell Tellus S2 V46 Chevron Rando HDZ 46 Caltex Rando HDZ 46 ...

Page 450: ...F 111 8 ...

Page 451: ...n ter FACTORY ADVISORY SERVICE If ever for any reason our dealership network encounters limits to what it is able to do for you please always feel free to contact us di rectly Our team of technical advisers is on hand to assist you gmbh service dynapac com TRAINING INSTRUCTIONS We offer our customers training cours es on DYNAPAC equipment in our ded icated factory training centre We hold regular t...

Page 452: ...Don t hesitate to contact your local dealer for service spare parts wearing parts additional documentation accessories and the complete Dynapac paver finisher range ...

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Dynapac SD2500W, Operation & Maintenance Manual

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