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Dynapac Svedala Demag DF 115 P/D, Operation & Maintenance Manual

Get your hands on the Operation & Maintenance Manual for the Dynapac Svedala Demag DF 115 P/D for free download. This essential manual provides detailed instructions for the operation and maintenance of this heavy-duty machinery. Download it now from manualshive.com and keep your equipment running smoothly.

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125PD_O

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 6-

8

F5.1

Maintenance - Engine  ............................................................. 1

1

Maintenance - engine sub-unit ................................................................... 1

1.1

Maintenance intervals  ................................................................................ 2

1.2

Points of maintenance  ............................................................................... 4

Engine fuel tank (1)  ............................................................................... 4
Engine lube-oil system (2)   .................................................................... 5
Engine fuel system (3)   .......................................................................... 7
Engine air filter (4)  ................................................................................. 9
Coolant system of the engine (5) ......................................................... 10
Engine drive belt (6) ............................................................................. 10
Engine exhaust system (7)   ................................................................. 11

F6.0

Maintenance - Hydraulic system  ........................................... 1

1

Maintenance - hydraulic system  ................................................................ 1

1.1

Maintenance intervals  ................................................................................ 2

1.2

Points of maintenance  ............................................................................... 3

Hydraulic oil tank (1)  .............................................................................. 3
Suction/return flow hydraulic filter (2)  .................................................... 4
Venting the filter: .................................................................................... 5
High pressure filter (3)  ........................................................................... 6
Pump distribution gear (4)  ..................................................................... 7
Hydraulic hoses (5) ................................................................................ 8

F7.4

Maintenance - travel drive, steering  ...................................... 1

1

Maintenance - travel drive, steering  ........................................................... 1

1.1

Maintenance intervals  ................................................................................ 2

1.2

Points of maintenance  ............................................................................... 3

Planetary gear (1)  .................................................................................. 3
Air pressure (driving wheels) (2) ............................................................ 4
Places of lubrication (3)  ......................................................................... 5
Steering ................................................................................................. 5

Summary of Contents for Svedala Demag DF 115 P/D

Page 1: ...34 02 0107 OPERATION MAINTENANCE Paver finisher Svedala Demag DF 115 P D DF 125 P D Typ 34 Keep this manual for future reference Order number for this manual D900981408...

Page 2: ...VALUE QUALITY THE ORIGINAL Your Authorized Dynapac Dealer...

Page 3: ...switch 17 8 4 7 Hopper transport safeguards 18 8 4 8 Screed transport safeguards 19 8 4 9 Latch for protective roof 20 8 5 Technical data standard configuration 10 5 1 Dimensions all dimensions in mm...

Page 4: ...rations acting on hands and arms 23 7 9 Electromagnetic compatibility EMC 23 C1 0 Transportation 1 1 Safety regulations for transportation 1 2 Transportation on low bed trailers 2 2 1 Preparations 2 2...

Page 5: ...switch of flasher 85e 7 230 V On Off switch Connection sockets 85f 7 Locking of the collapsible roof LH and RH on the roofs console 86 7 Hydraulic folding roof 87 o 8 Electric setting of the transpor...

Page 6: ...ontrol stopping of paver finisher and screed loading unloading 14 General 14 Screed charging relieving 15 Screed control with the paver finisher standing still Floating position with and without prest...

Page 7: ...11 3 Auger extension auger type II 12 3 1 Mounting extension parts 13 3 2 Auger modification plan 15 4 Screed 17 5 Electrical connections 17 5 1 Remote controls 17 5 2 Grade control 17 5 3 Auger limi...

Page 8: ...ust system 7 11 F6 0 Maintenance Hydraulic system 1 1 Maintenance hydraulic system 1 1 1 Maintenance intervals 2 1 2 Points of maintenance 3 Hydraulic oil tank 1 3 Suction return flow hydraulic filter...

Page 9: ...x C 19 Fuses on operating panel 20 F9 0 Maintenance Points of lubrication 1 1 Maintenance Points of lubrication 1 1 1 Maintenance intervals 2 1 2 Points of maintenance 3 Central lubrication 1 3 Bearin...

Page 10: ......

Page 11: ...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 Prece...

Page 12: ...e correct and specified appli cation of pavers shall also be observed 1 2 Warning instructions Warning pointing to hazardous place or danger Not observing the warning instructions may lead to injuries...

Page 13: ...k of hand injury Attention hot surfaces or hot liquids Warning risk of falling off Attention hazardous batteries Attention materials harmful to health and irritating substances Attention flammable mat...

Page 14: ...art the engine drive Maintenance and repair works can be carried out only with the Die sel engine turned off Do not sprinkle with water Do not extinguish with water Do it yourself maintenance is prohi...

Page 15: ...Observe these specifications Protect your eyes with googles Wear appropriate head protection Protect your hearing with appropriate ear mufflers Protect your feet with safety footwear Always wear tigh...

Page 16: ...polluting water e g lubricants oils grease hydraulic oil gas oil coolant detergents may not enter the soil or the sewer system These materials shall be collected stored transported in the correct con...

Page 17: ...m Observe the manufacturer s and other instructions A e g the maintenance instructions of the engine manufacturer m Description figure in case of an electrically heated design m Description figure in...

Page 18: ......

Page 19: ...thin the meaning of the present operating instructions is defined as any natural or legal person who either uses the paver finisher himself or on whose behalf it is used In special cases e g leasing o...

Page 20: ......

Page 21: ...plication The Svedala Demag DF115P D DF125P D is a rubber tyre fitted paver finisher that is used for laying bituminous mixed material roll down or lean mixed concrete track laying ballast and unbound...

Page 22: ...inder for paving thickness 6 t Traction roller 7 t Traction arm rail 8 t Paving thickness indicator 9 t Arm 10 t Machine drive 11 t Auger 12 t Screed 13 t Operator s platform 14 t Operating panel can...

Page 23: ...her and or the screed o Protective roof o Further equipment and upgrade options on request Engine The paver finisher is driven by a water cooled Diesel engine For further de tails see the technical da...

Page 24: ...less from its course and paving in curves is made easier Material compartment hopper The hopper inlet is equipped with a conveyor sys tem that empties the hopper and transfers the material to the aug...

Page 25: ...ulically on both sides and can be controlled manually by means of toggle switches or automatically by means of an electronic grade control system The screed lifting system The screed can be lifted to...

Page 26: ...B 6 B_DF115PD_DF125PD_01_GB fm 6 24 3 Danger zones m In these areas of the machine there is a danger of pulling in or crushing due to the rotating transporting or moving parts...

Page 27: ...op button on the operating panel on the two remote control units option m Pressing the emergency stop button switches off the engine the drives and the steer ing system Corrective measures that might...

Page 28: ...24 4 6 Main switch 17 4 7 Hopper transport safeguards 18 4 8 Screed transport safeguards 19 4 9 Latch for protective roof 20 Mainswitch tif Mainswitch_SK eps 17 o Hopperlock2 tif Hopperlock_SK eps 18...

Page 29: ...dges Warning triangle First aid kit Item Designation 25 Fire fighting device 26 Engine hood 27 Lateral flaps 28 Walkway 29 Screed coverings 30 Hazard warning lights of the screed 31 Auger covers 634_s...

Page 30: ...cal data standard configuration 5 1 Dimensions all dimensions in mm A For the technical data of the screed see the operating instructions of the screed 634_side_DEM bmp 634_front_DEM bmp 6500 1962 160...

Page 31: ...sition gradient slope lateral inclina tion which is above the specified limit value please consult with the customer serv ice for your machine 5 3 Allowed angle of driving up 5 4 Turning circle Turnin...

Page 32: ...6 Paver finisher with screed EB 51 about 16 5 Including mounted accessories for max paving width plus max about 0 9 With filled hopper additionally max about 12 5 max front axle load for transportati...

Page 33: ...t off shoes minimum paving width with cut off shoe continuously hydraulically adjustable up to Maximum paving widths with attachments EB 51 2 55 2 00 5 10 7 30 m EB 51 2 55 2 00 5 10 m Travelling spee...

Page 34: ...t off shoes minimum paving width with cut off shoe continuously hydraulically adjustable up to Maximum paving widths with attachments EB 51 2 55 2 00 5 10 8 10 m EB 51 2 55 2 00 5 10 m Travelling spee...

Page 35: ...ydraulic brake Make type Deutz TCD 2013 L04 2V Model 4 cylinder water cooled Diesel engine Performance 116 KW 158 HP at 2100 rpm Volume of fuel tank see chapter F Make type Deutz TCD 2013 L06 2V Model...

Page 36: ...ontrollable Conveying volume controller Fully automatic via configurable switching points Augers Left and right side separately controllable Drive Hydrostatic external drive continuously controlla ble...

Page 37: ...unctions At standstill Screed stop Screed stop with pretensioning max pressure 40 bar During paving Screed charging Screed relieving max pressure 40 bar Levelling system Mechanical grade control optio...

Page 38: ...B 18 B_DF115PD_DF125PD_01_GB fm 18 24 6 Location of instruction labels and identification plates o 10 1 2 4 7 6 3 12 14 11 13 15 16 8 9 5 5 10 21 17 18 19 20...

Page 39: ...nched vehicle identification number 6 Label Securing or fixing points for crane transportation 7 Paver finisher identification label 8 CE noise level plate O 9 Fan danger warning plate 10 Spraying wit...

Page 40: ...identification number 8 No Denomination 1 Type of paver finisher 2 Year of manufacture 3 Serial number of the paver finisher series 4 Max permissible operating weight incl all attachments in kg 5 Max...

Page 41: ...Sound capacity level LWA 108 0 dB A Sound pressure level at the machine 7 2 Operating conditions during measurement The diesel engine was running at maximum speed The screed was in working posi tion...

Page 42: ...capacity level LWA 109 0 dB A Sound pressure level at the machine 7 5 Operating conditions during measurement The diesel engine was running at maximum speed The screed was in working posi tion lowered...

Page 43: ...pulations of the EMC di rective 89 336 EEC 08 95 Interference emission according to DIN EN 50081 1 03 93 40 dB V m for frequencies of 30 MHz 230 MHz measured at a distance of 3 m 47 db V m for frequen...

Page 44: ......

Page 45: ...isher 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 the paver finisher may slip aside...

Page 46: ...see chapter D Remove all protruding or loose parts from the paver finisher and the screed see also the operating instructions of the screed Store these parts in a safe place f When screed is operated...

Page 47: ...ansport safeguards Lift the screed Insert the transportation safe guards of the hopper A Only in case of not connected remote control Turn the preselecting regulator to zero Move the drive lever forwa...

Page 48: ...ed trailer Lower the screed onto wooden blocks on the low bed trailer Switch off the paver finisher Attach and secure the protective hood to protect the operating panel If necessary swing down the pro...

Page 49: ...it and store it 2 4 After transportation Remove the attachment devices Swing up the protective roof take out the bolts push the protective roof forward to raise it and insert the bolts to lock it agai...

Page 50: ...rts from the paver finisher and the screed see also the operating instructions of the screed Store these parts in a safe place f When screed is operated with the optional gas heating system Remove the...

Page 51: ...t safe guards Lift the screed Insert the transportation safeguards of the screed A Only when remote control is not connected Turn the preselecting regulator to ze ro Move the drive lever forward The l...

Page 52: ...out 2 5 3 full steering wheel turns Press the emergency stop button when a dangerous situation arises f When pressing the emergency button the paver the engine stops and steering be comes very difficu...

Page 53: ...the transport safeguards Remove any attachments and accessories from the paver finisher and the screed until the basic width has been attained Take off all protruding or loose parts and the gas bottle...

Page 54: ...hand pump m Only release the traction system brakes when the machine is sufficiently secured against accidental rolling or is already properly connected to the towing vehi cle The two high pressure ca...

Page 55: ...few turns again and lock with the lock nut 2 The high pressure cartridges 1 have to be fully screwed back in to make the ma chine usable again The brakes of the traction drive are now active again an...

Page 56: ...e them somewhere on the ma chine m Do not turn off main switch 1 until 15 seconds after the ignition has been turned off A The engine electronics need this length of time to back up data Protect the o...

Page 57: ...o life and limb Always make sure during operation that no one is endangered by the machine Ensure that all protective covers and hoods are fitted and secured accordingly When damages are detected elim...

Page 58: ...D 1 3 2 D_1 3_01_GB fm 2 24 2 Operating elements 2 1 Operating panel 3 2 B 1 A 4 C B A Bedienpult_konv_Rad_634_2 bmp Element3_konv_Rad_634 bmp Element1_konv_Kette_635 bmp Element2_konv_Rad_634 bmp C...

Page 59: ...knurled screw at the desired location into the des ignated notch and secure with the knurled nut f When not secured the operating panel can move Danger of accidents during transportation 3 Latch for o...

Page 60: ...D 1 3 4 D_1 3_01_GB fm 4 24 Element2_konv_Rad_634 bmp 9 12 9a 5 8 14 A 6 7 13 10 11...

Page 61: ...the paver finisher functions and for continu ously regulating the traction speed forward or reverse Zero position Starting is possible engine at idling speed no traction drive secured against inadvert...

Page 62: ...D 1 3 6 D_1 3_01_GB fm 6 24 Element2_konv_Rad_634 bmp 9 12 9a 5 8 14 A 6 7 13 10 11...

Page 63: ...queried from the machine which means a specific fault Keep pressing the button until a three digit error code is dis played A See Chapter Operating Failures for querying the error code 14 Emergency st...

Page 64: ...D 1 3 8 D_1 3_01_GB fm 8 24 Element1_konv_Kette_635 bmp 27 19 18 17 28 29 B 16 25 26 22 21 20 23 24...

Page 65: ...turned on and continuously regulat ed in the tunnel using the material limit switch B stop turned off C manual continuously turned on full delivery capacity without material mix regulation If the con...

Page 66: ...D 1 3 10 D_1 3_01_GB fm 10 24 Element1_konv_Kette_635 bmp 27 19 18 17 28 29 B 16 25 26 22 21 20 23 24...

Page 67: ...ivearm 9 is in central position in case of stopping the paver the screed is only maintained in floating position controlled f In case of transportation or maintenance operations al ways insert the mec...

Page 68: ...D 1 3 12 D_1 3_01_GB fm 12 24 Element1_konv_Kette_635 bmp 27 19 18 17 28 29 B 16 25 26 22 21 20 23 24...

Page 69: ...limit switch and the o ultrasonic sensor both switches must be in auto position 26 Adjustment of au ger beams on the LH RH sides o In case of hydraulically adjustable auger beams this is the way to ch...

Page 70: ...D 1 3 14 D_1 3_01_GB fm 14 24 l m nt3 konv ad 634 bmp uchtmodul tt 635 bmp 31 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C 47 34...

Page 71: ...ving the drive lever Min position idling speed Max position rated speed A During laying in a normal case the rated speed is se lected while in case of travel the RPM shall be re duced A The automatic...

Page 72: ...D 1 3 16 D_1 3_01_GB fm 16 24 Element3_konv_Rad_634 bmp Leuchtmodul_KONV_Kette_635 bmp 31 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C 47 34...

Page 73: ...her faults All the faults shall be eliminated as soon as possible A The error code can be queried using button 13 A After the ignition is turned on the light is on for a few seconds for check up 39 Hi...

Page 74: ...D 1 3 18 D_1 3_01_GB fm 18 24 Element3_konv_Rad_634 bmp Leuchtmodul_KONV_Kette_635 bmp 31 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C 47 34...

Page 75: ...ferential lock is automatically engaged 46 Battery indicator light red It must go out after start up at a higher speed Stop the engine 47 Parking brake light red It is on when parking brake is active...

Page 76: ...D 1 3 20 D_1 3_01_GB fm 20 24 Element3_konv_Rad_634 bmp Leuchtmodul_KONV_Kette_635 bmp 31 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C 47 34...

Page 77: ...21 24 3 Remote control A With the help of the two remote controls on the RH and LH sides of the screed the functions available on the specific side of the paver can be controlled 58 56 Remote_konv_neu...

Page 78: ...e are similar to the function of the switch 17 on the control panel The switch must be set to auto 59 Auger Its function and use are similar to the function of the switch 25 on the control panel The s...

Page 79: ...utomatic system Connect the cable for the grade control unit here 67 Connection to the end position switch of the auger Connect the cable for the material limit switch here 68 Cable for the remote con...

Page 80: ...D 1 3 24 D_1 3_01_GB fm 24 24...

Page 81: ...the paver finisher externally see section Starting the paver finisher External starting starting aid Battery main switch 72 The main switch interrupting the circuit between the battery and the main fu...

Page 82: ...the transport safe guards for the hopper must be inserted Item a outside on the two half hoppers or b in the feeding hopper o f Do not enter the hopper while the engine is running Danger of being caug...

Page 83: ...ment zero Screed lock only for transportation Use the interlocking of the main girder for transportation only Do not enter or work under screed only secured with screed lock for transportation Danger...

Page 84: ...ides The service brake acts within the ma chine drive A Upon operating the brake the machine drive is regulated to stop automatically regardless of the position of the drive le ver A If the machine wa...

Page 85: ...y will be discharged Switch off after use A A permanent installed hose guide D for the fluid spraying system is available as an option Pull hose out of the guide till there is an audible creak The hos...

Page 86: ...osed spaces Danger to health Have a fire extinguisher ready On off switch special lighting 85b If the machine is equipped with addition al headlights these are actuated by means of the switch a When s...

Page 87: ...t is mounted on the paver finisher 230 V On Off switch Connection sockets 85f In case of being equipped with 230 V ac cessories the connection sockets can be powered through switches In the switch pos...

Page 88: ...crushing Ensure that nobody inserts their fingers or hands into the joint areas or are placed at risk by the lowering roof during the folding proce dure In order to raise the roof again turn the key...

Page 89: ...est adjustable vol ume RH side conveyor 88a LH side conveyor 88b Conveyor limit switches 89 The mechanical conveyor limit switches 89 or the ultrasonic conveyor limit switches 89ao control the materia...

Page 90: ...modify angle height of the sensor The cables must be connected to the re mote control units located at the sides of the screed socket 62 A We recommend to adjust the limit switch positions while the...

Page 91: ...lat form It is used to adjust the pressure for screed stop with pretensioning Activation see screed charging re lieving device Pressure display see pressure gauge 93b Pressure gauge for screed chargin...

Page 92: ...that the driven front wheels do not spin Pressure gauge of the front wheel drive 94a o It shows the drive pressure of the sup plementary front wheel drive Pressure adjustment with valve 94 Experiment...

Page 93: ...ry 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 placing mineral or cement bound materia...

Page 94: ...ee chapter Maintenance for cleaning the particle filter Indicator colour Operating condition Cause action yellow No counterpressure No counterpressure Check the tightness of the system green Within th...

Page 95: ...the tank Fold the front window by its handle A and lock it on the RH and LH sides with the two locks B in the upper po sition Additional functions If necessary turn on the windscreen wipers on the RH...

Page 96: ...en lock nuts B for eccentric adjustment Swivel screed into desired position using lever C then engage the locking knob once again A If the levelling unit is connected to a height controller this has t...

Page 97: ...y become necessary for extending the auger Parts that may become necessary for extending the screed Percentage spirit level and levelling rail 4 m long Levelling wire Protective clothing signal vest g...

Page 98: ...n button The horn must sound Lights Switch on with the ignition key walk around the paver finisher to check and switch off again Hazard warning lights of the screed with vario screeds With the ignitio...

Page 99: ...eguard When the screed is lifted it must be possible to push the locking rods side ways into the recesses in the cross beams using the lever beneath the seat Hopper transport safeguard When the hopper...

Page 100: ...ever 1 to the center posi tion and the speed adjuster 2 to mini mum Insert the ignition key 3 in position 0 The lights should be switched off during starting to reduce the current drain on the battery...

Page 101: ...s cannot be used for external starting To externally start the engine Set the drive lever 1 to mid position and the speed regulator 2 to mini mum Insert ignition switch 3 to position 0 to turn on the...

Page 102: ...harge indicator 1 Must go out after starting when the en gine revs up m Briefly rev up the engine when the lamp does not go out or lights up during oper ation Switch off the engine and determine the c...

Page 103: ...gulator 5 to medium RPM and move the drive lever 6 un til the conveyor belt and the auger start operating Let the hydraulics warm up until the in dicator lamp goes out A The lamp goes out when the pre...

Page 104: ...r Switch on the screed heater ca 15 30 minutes depending on the ambient tempera ture before paving begins Warming up prevents the material from sticking to the screed plates Direction marks To ensure...

Page 105: ...he auger and the switch 3 of the feeder to auto posi tion Set the appropriate auger switch on the remote control and conveyor switch if applicable to auto position Set the engine speed regulator 4 to...

Page 106: ...st switch off when the material has reached the area be neath the auger crossbeam Check that the material is conveyed properly Manually switch on or off the conveyor if the material is not conveyed pr...

Page 107: ...D 4 5 11 D_4 5_01_GB fm 11 34 1 3 Starting for paving Element2_konv_Kette_635 bmp Element1_konv_Kette_635 bmp Tamprev cdr Vibrev cdr Remote_konv_neu1 bmp 3 14 2 1 9 8 6 7 5 4 12 13 B A...

Page 108: ...he check in the area of the drive chains or wheels as the screed tends to level an uneven ground The reference points for the layer thickness are the drive chains or wheels The basic setting of the sc...

Page 109: ...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 pa...

Page 110: ...tain optimum paving re sults Screed stop with and without pretensioning with the paver finisher halted Screed charging or relieving with the paver finisher driving A Relieving reduces the screed weigh...

Page 111: ...g the screed the relieving pressure and the countepressure of the ma terial will provide retention so that the sinking of the screed is avoided when a tempo rary stop occurs Using the switch 2 the fol...

Page 112: ...the first stops until the lower edge of the screed no longer leaves any marks when the paver finisher moves on again A pressure greater than 10 15 bar neutralizes the screed weight thus preventing the...

Page 113: ...rade and or slope transducer the compacting perform ance will be modified layer thickness A Pressure can be adjusted and corrected during paving max 50 bar Screed control pressure with the pav er fini...

Page 114: ...edge like the end of a layer Set the drive lever 1 to the center po sition During extended interruptions e g lunch break Drive lever 1 into centre position RPM speed adjustment 2 to mini mum position...

Page 115: ...mpers at a low speed let any material residues drop out Set the drive lever 5 to the center po sition and the speed adjuster 6 to minimum Switch off the ignition Switch off screed heater system When s...

Page 116: ...need this length of time to back up data Read and check the operating hour meter 8 to determine whether main tenance work must be performed see chapter F Cover and lock the operating panel Remove mat...

Page 117: ...sage can be queried from the ma chine using the diagnostic button 2 which represents a specific fault The flashing code is also displayed by the control light 1 Display of the number code Set the diag...

Page 118: ...sition 0 the warning light which indicated the fault will come on again will flash or will be lit up continuously This will be as long as the fault or problem is eliminated A In order to check if no s...

Page 119: ...2 2 3 Diagnostics according to the error message list Charging air pressure Faulty sen sor input e g short circuit or broken cable t 800ms t 400ms BREAK t 2000ms t 400ms t 400ms t 800ms t 800ms t 400...

Page 120: ...D 4 5 24 D_4 5_01_GB fm 24 34 2 2 Error messages...

Page 121: ...D 4 5 25 D_4 5_01_GB fm 25 34...

Page 122: ...D 4 5 26 D_4 5_01_GB fm 26 34...

Page 123: ...D 4 5 27 D_4 5_01_GB fm 27 34...

Page 124: ...D 4 5 28 D_4 5_01_GB fm 28 34...

Page 125: ...D 4 5 29 D_4 5_01_GB fm 29 34 2 3 FMI codes...

Page 126: ...ng 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...

Page 127: ...lled cold screed bottom plates are worn or warped screed does not work in the floating position paver finisher speed is too high auger is overloaded changing material pressure against the screed Marks...

Page 128: ...veyor or augers run too slowly Hydraulic oil level in the tank is too low Top up the oil Power supply is interrupted Check fuses and cables replace if necessary Switch is defective Replace the switch...

Page 129: ...Power supply is interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote control is set to auto Set the switch to manual Power supply is inter...

Page 130: ...lace the 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 br...

Page 131: ...e battery main switch Secure lifted machine parts e g screed or hopper against lowering by means of mechanical supports Replace parts or have them replaced as stipulated f When connecting or disconnec...

Page 132: ...ixing and traction problems may occur Auger too low Not enough material that can be precompacted by the auger Irregularities resulting from this cannot be completely compensated for by the screed wavy...

Page 133: ...rning clockwise lifts the auger Set the desired height by alternatingly adjusting the right hand and the left hand side The actual height can be read on scale 1 in cm or inch LH side column inch RH si...

Page 134: ...e auger beam does not get into inclined position Check whether the heights on the left and on the right are identical A The height indicating scales 3 may be optionally also along the climbing rungs o...

Page 135: ...cation especially Screed extension chart Auger extension chart To attain the desired working width the respective screed extensions side plates au gers tunnel plates or cut off shoes must be mounted F...

Page 136: ...the drive of the auger gear is slid all the way over the shaft end of the auger extension part and that the threads of the augers match Remove the expansion screw 5 Then tighten the clamping screws 6...

Page 137: ...urs by tightening the screwed connections 9 linking the support tube extension If the working width exceeds 7 50 m the hydraulic hoses 10 for the auger mo tors must be replaced with longer ones These...

Page 138: ...or more combined tun nel plates 13 must be used In this case additional stabilizing sup ports 12 must be attached to the tele scopic tube The tunnel plates must be directly screwed to the receptacles...

Page 139: ...e augers must be provided with an additional support To do so attach two braces on both the left hand and the right hand side be tween the tunnel plate support and the bracket provided on the paver fi...

Page 140: ...E 01 10 E_01_GB fm 10 18 2 10 Auger mounting chart for 310 mm auger from working width of 6 75 m the machine can be operated only with appropriate braces screed auger material pipeline...

Page 141: ...E 01 11 E_01_GB fm 11 18 2 11 Auger mounting chart for 380 mm auger from working width of 6 75 m the machine can be operated only with appropriate braces screed auger material pipeline...

Page 142: ...E 01 12 E_01_GB fm 12 18 3 Auger extension auger type II Auger_DEM bmp...

Page 143: ...E 01 13 E_01_GB fm 13 18 3 1 Mounting extension parts Sch_ver1 tif Sch_ver2 tif 16 5 9 10 8 7 6 14 15 12 11 12 5...

Page 144: ...ing bolts 13 washers 14 and nuts 15 for the extension of the auger and simultaneously bolt the auger shafts firmly together A If the application conditions on the job site allow or demand auger extens...

Page 145: ...3 2 Auger modification plan Marking Meaning Basic auger Auger section to be mounted material shaft 320mm Auger section to be mounted material shaft 640mm Auger section to be mounted material shaft 96...

Page 146: ...Mountable parts bearing Mountable parts bearing 2 5 m 3 7 m 3 2 m 4 4 m 4 1 m 5 0 m 4 1 m 5 0 m 4 8 m 5 7 m 4 8 m 5 7 m 5 4 m 6 3 m 5 4 m 6 3 m 6 0 m 6 9 m 6 0 m 6 9 m 6 7 m 7 6 m 6 7 m 7 6 m 7 3 m 8...

Page 147: ...Establish the following connections when the mechanical components have been mounted and set up 5 1 Remote controls to socket 15 on the screed 5 2 Grade control to socket 16 on the remote control uni...

Page 148: ......

Page 149: ...in doubt contact the 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...

Page 150: ......

Page 151: ...F 2 2 1 F_2 2_01_GB fm 1 2 F 2 2 Maintenance review 1 Maintenance review 4 2 3 5 1 6 8 9 10 7 4...

Page 152: ...e required after the following service hours 10 50 100 250 500 1000 year 2000 2 years 5000 20000 as required Feeder F3 q q q q Auger F4 2 q q q q q Drive engine F5 1 q q q q q q Hydraulics F6 0 q q q...

Page 153: ...F 3 0 1 F_3 0_01_GB fm 1 4 F 3 0 Maintenance Conveyor 1 Maintenance Conveyor...

Page 154: ...ear 2000 2 years as required 1 q Checking the tightness of the conveyor chain q Adjustment of the tightness of the conveyor chain 2 q Checking the oil level of the conveyor drive q Topping up the oil...

Page 155: ...of the floor plate until the lower edge of the chain see the figure m The chains should not be too tight or too slack Material between the chains and the sprocket wheel can lead to stoppage or breakag...

Page 156: ...hrough fill in stub C A On the dipstick about 10 cm corre sponds to about 0 25 l oil to be added The drive of the conveyor is filled in the factory with Optimol Optigear 220 oil Owing to the excellent...

Page 157: ...F 4 1 1 F_4 1_01_GB fm 1 8 F 4 1 Maintenance Auger 1 Maintenance auger sub unit...

Page 158: ...Lubrication 2 q Auger planetary gear oil level check q Auger planetary gear topping up the oil q Auger planetary gear oil change 3 q Auger drive chain checking of tightness q Auger drive chain adjustm...

Page 159: ...A In case of auger extension slightly un tighten the outer rings for the first lubri cation of the outer bearings ensuring better venting Following the lubrication the outer rings shall be retightened...

Page 160: ...rature Unscrew filling plug B and the drain plug C Drain the oil Drive in the oil drain plug C again Remove the inspection plug A Fill oil of the correct specification through the filling hole B until...

Page 161: ...ease locking bolts A Adjust the proper chain tightness with the threaded pins B Tighten the threaded pins to 20 Nm using a torque wrench Thereafter ease back the threaded pins by one full turn Retight...

Page 162: ...F 4 1 6 F_4 1_01_GB fm 6 8 Auger case 4 Checking the oil level A In case of correct oil level the oil is be tween the two notches of the dipstick A...

Page 163: ...ature Place a suitable dish under the auger cases to catch the oil Untighten bolts D on the perimeter of the auger shaft flange A The oil flows out between the flange and the auger housing Fully drain...

Page 164: ......

Page 165: ...1 Maintenance engine sub unit m In addition to these Maintenance Instructions the Maintenance Instructions of the en gine manufacturer must always also be observed All other maintenance work and in t...

Page 166: ...and device 2 q Engine lube oil system oil level check q Engine lube oil system topping up the oil q Engine lube oil system oil change q Engine lube oil system oil filter change 3 q Engine fuel system...

Page 167: ...stem of the engine Cleaning of the radiator fins q Cooling system of the engine Check the level of the coolant q Cooling system of the engine topping up the coolant q Cooling system of the engine chan...

Page 168: ...way the time consuming venting bleeding can be avoided For filling in the fuel Unscrew cap A under the tank cov er Fill in fuel through the filling port until the required filling is achieved Replace...

Page 169: ...ve cap B Fill in oil until the correct level is achieved Return cap B Check the oil level once again using the dipstick Oil change A Change the oil when the engine is at op erating temperature Remove...

Page 170: ...ined Untighten the filter D and clean its resting surface Apply thin coat of oil to the seal of the new filter and fill the filter with oil before mounting Tighten the filter by hand A After mounting...

Page 171: ...r Drain the separated water at the tap C collect it and close the tap again Pull down the connection of the water detector D Untighten the filter cartridge A with the collection sump using a pair of o...

Page 172: ...mount of the manual fuel pump F by pressing and twisting counter clockwise at the same time The pump piston now can be displaced by a spring Until strong resistance is felt and the pump moves already...

Page 173: ...field C is fully visible when the engine is stopped When the engine electronic unit indi cates service need Open the air filter lid Withdraw the filter cartridge C and the safety cartridge D A Clean...

Page 174: ...e system is under pressure When opening there is a danger of scalding If necessary fill in sufficient amount of coolant through the open port A of the compensating tank Changing the coolant A See oper...

Page 175: ...r to the filter edge than 10 cm Carefully blow out all the filter passag es Turn around the filter element and re peat the process on the other side as well Repeat the process until no more carbon res...

Page 176: ......

Page 177: ...F 6 0 1 F_6 0_01_GB fm 1 8 F 6 0 Maintenance Hydraulic system 1 Maintenance hydraulic system...

Page 178: ...ydraulic oil tank Checking of maintenance indica tor q q Hydraulic oil tank Intake return change of hydraulic filter venting 3 q High pressure filter Checking of maintenance indica tor q High pressure...

Page 179: ...arly clean the vent port of the oil tank from dust and pollution Clean the surfaces of the oil cooler m Use only the recommended hydraulic oils see section Recommended hy draulic oils For changing the...

Page 180: ...tor O at the operating position m When changing the hydraulic oil also change the filter Remove the lid fastening screws B and remove the lid Disassemble the withdrawn unit into the following parts li...

Page 181: ...into the housing and tighten the locking screws of the lid B Open the vent screw H Mount a transparent hose l on the vent screw and lead it into an appropriate con tainer Start the traction engine at...

Page 182: ...he new filter cartidge Replace the seal ring of the filter hous ing Turn on the filter housing by hand and tighten it using a wrench Start the trial operation and check the tightness of the filter A R...

Page 183: ...rew plug B m Take care of cleanliness Oil change Change the oil when the engine is at op erating temperature Remove the cover cap of the oil drain port C and screw on the hose provid ed as an accessor...

Page 184: ...red hos es f The aged hoses may become porous and burst Risk of accident A The numbers stamped in the joints of the hoses state the date of manufacture A and the maximum pressure B allowed for that ho...

Page 185: ...F 7 4 1 F_7 4_01_GB fm 1 6 F 7 4 Maintenance travel drive steering 1 Maintenance travel drive steering...

Page 186: ...Checking the oil level of the planetary gear drive q Planetary gear drive Change the oil 2 q Air pressure drive wheels check q Air pressure drive wheels adjust 3 q Lubrication points lubrication of a...

Page 187: ...Replace the inspection plug A and filling plug B Oil change A Change the oil when the engine is at op erating temperature m Make sure that no pollution or foreign matter gets into the drive Stop the m...

Page 188: ...4 6 Air pressure driving wheels 2 Check adjust the belt tightness A The required tyre pressure is stamped in each wheel rim and marked by colour A Check the air pressure in valve B and adjust as requ...

Page 189: ...ight side wall and the steering linkage is supplied with grease through a lubri cation line Swing axle A Grease nipple C is located on the RH and LH sides on the central bearing of the swing axle Whee...

Page 190: ......

Page 191: ...F 8 0 1 F_8 0_01_GB fm 1 20 F 8 0 Maintenance Electronic System 1 Maintenance Electronic System...

Page 192: ...o Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 q Check the level of battery electrolyte q Top up with ion exchanged water q Coat the battery poles with...

Page 193: ...ion or damage Check the cooling air openings for pollution or clogging clean as re quired o q Generator Check the ball bearings by listen ing and replace them as re quired o q q Generator Replacement...

Page 194: ...F 8 0 4 F_8 0_01_GB fm 4 20 No Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 3 q Electric fuses Maintenance q Maintenance during run in period g...

Page 195: ...me of electrolyte in the factory The electrolyte level shall be up to the top mark Top up with ion exchanged water only when required The shoes shall be free of oxyde and coated with special battery p...

Page 196: ...eady before pressing the control button then work cannot pro ceed with the electrical system and the external consumers In case of insula tion fault the connection sockets are au tomatically turned of...

Page 197: ...F_8 0_01_GB fm 7 20 Checking of ball bearings Replace ment of ball bearings A Report the displayed fault code to the customer service of the paver finisher and they will discuss with you the steps to...

Page 198: ...screw A so that the bracket B of the tightening roller comes to position zero scale C 0 For the adjustment of the locking de vice loosen or turn the appropriate nut D or counter nut E until the tight...

Page 199: ...belt Replacement of belt Unfasten both lock nuts A from the clamping lock Rotate and open clamping lock B un til belt C can be replaced A Pre tension newly fitted belt using clamping lock B Checking a...

Page 200: ...28KVA Deflection force min 92 2N Deflection force max 100 5N Belt deflection approx 5 4mm If necessary adjust the belt tension Set belt to correct tension using clamping lock B Retighten both lock nu...

Page 201: ...0 Electric fuses 3 Type of machine Conventional electronics Terminal box Main fuses A A Main fuses B Fuses in terminal box C Relays in terminal box F A 3 1 Main fuse 50 3 2 Reserve auxiliary lighting...

Page 202: ...les 10 5 6 Integrated receptacles 10 5 7 Integrated receptacles 10 5 8 Integrated receptacles 10 5 9 Engine start 10 41 Power supply for engine control 25 51 Diesel spray pump 3 52 Emulsion spraying s...

Page 203: ...18 2 Screed hazard warning flasher right 42 Power supply for travel drive 44 Compactor lift 52 Engine changeover travel drive 53 Engine changeover travel drive 83 Speed raising for screed heater 88 Au...

Page 204: ...screed extending retracting screed power supply screed compactor lift o mov ing cab o lifting lowering auger o 10 8 1 8 Emergency stop 7 5 No F A 1 2 1 Hazard warning flashers flasher right 5 2 2 2 Ha...

Page 205: ...7 Screed function 32 Flasher sensor lighting 33 Engine stop 39 Start interlock 80 Timer relay revers conveyor right 81 Timer relay revers conveyor right 149 1 Priority circuit for extending retracting...

Page 206: ...0_01_GB fm 16 20 Type of machine PLC electronics Terminal box Main fuses A A Main fuses B Fuses in terminal box C Relays in terminal box F A 3 1 Lighting engine 50 3 2 Lighting engine 50 Fuses_635_ko...

Page 207: ...5 3 10 5 4 Screed power supply 10 5 5 Integrated receptacles 10 5 6 Integrated receptacles 10 5 7 Integrated receptacles 10 5 8 Integrated receptacles 10 5 9 Engine start 10 7 1 Slave A51 5 7 2 Slave...

Page 208: ...Diesel tank filler pump 5 54 Rotary beacon 3 55 Lighting on glassfibre reinforced roof 10 59 Working lights o 15 80 Power supply Master A1 5 82 Particulate filter o 3 83 Asphalt fume control system o...

Page 209: ...fm 19 20 Relays in terminal box C K 15 Engine start 30 Horn 42 Travel drive 47 Start interlock 49 Reverse buzzer 52 Engine changeover travel drive 53 Engine changeover travel drive 94 Engine 145 Engi...

Page 210: ...r supply o moving cab 5 8 1 8 Free No F A 1 2 1 Hazard warning flashers flasher left 5 2 2 2 Hazard warning flashers flasher right horn reverse buzzer 3 3 2 3 Brake 3 4 2 4 High beam headlights left r...

Page 211: ...ormation related to the lubrication points of the various sub units are included in the specific maintenance descriptions and additional reading is recommended as follows A In case of applying a centr...

Page 212: ...0 year 2000 2 years as required 1 q Check the filling level of the lubri cant tank o q Fill up the lubricant tank o q Vent the central lubrication unit o q Check the pressure limiting valve o q Check...

Page 213: ...ries as the equipment operates under high pres sure f Make sure that the starting of the diesel engine should be prohibited while work is per formed on the equipment f Observe the rules applicable to...

Page 214: ...Always keep the filling level above the MIN mark of the tank a Fill up the lubricant tank A grease nipple b is mounted for filling on the lubricant tank a Connect the grease gun c supplied with the ma...

Page 215: ...ck the tightness of all the connections and lines Check the pressure limiting valve m If lubricant is discharged at the pressure limiting valve a this refers to failure in the system The consumers rec...

Page 216: ...n pipe a and fit a standard grease nipple b Connect the grease gun c supplied with the machine to the grease nip ple b Keep on operating the grease gun until lubricant is visibly discharged If necessa...

Page 217: ...F 9 0 7 F_9 0_01_GB fm 7 8 Bearings 2 There are grease nipples on the bearing points of the hydraulic cylinder one each at the top and bottom a Zylinder bmp 2x a...

Page 218: ......

Page 219: ...F 10 0 1 F_10 0_01_GB fm 1 6 F 10 0 Checks decommissioning 1 Tests check up cleaning stopping...

Page 220: ...rvals No Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 q General observation 2 q q Checks by a specialist 3 q Cleaning 4 q Conservation of paver finisher...

Page 221: ...locking points secure conveyor auger screed m Repair the detected faults immediately in order to avoid risks of accidents and envi ronmental pollution 3 Checks by a specialist A Subject the paver fini...

Page 222: ...the bearings with grease as spec ified Clean the machine with water after laying mineral mixes lean concrete etc m Do not spray water on the bearings electric or electronic parts Remove the residue of...

Page 223: ...smounted batteries every 2nd month Protect all shiny metal surfaces e g piston rods of the hydraulic cylinder against corrosion using an appropriate agent If the machine cannot be halted in a closed h...

Page 224: ......

Page 225: ...lvania Grease EP LF 2 Retinax A Engine oil See operating instructions for the engine Shell Remula Super FE 10 W 40 has been filled at the factory Hydraulic oils See see section 1 1 Shell Tellus Oil 46...

Page 226: ...l pressure fluids to biodegradable pressure fluids please contact our factory advisors A Use only clean containers inside and outside for pouring oil or fuel in Manufacturer ISO viscosity class VG 46...

Page 227: ...tank Diesel fuel 280 litres Hydraulic oil reservoir Hydraulic oils 175 litres Pump distribution gear Gear oil 90 4 5 litres Planetary gear Travel drive see the section Lubricants and operat ing subst...

Page 228: ...Operating substance Volume Diesel engine with oil filter change Engine oil 10W40 20 0 litres Cooling system of the engine Coolant 20 0 litres Operating substance Volume Diesel engine with oil filter c...

Page 229: ...0 Operating substance Volume Diesel engine with oil filter change Engine oil 10W40 21 5 liters Cooling system of the engine Coolant 20 0 liters Operating substance Volume Diesel engine with oil filter...

Page 230: ...rating substance Volume Auger bevel gear each side Gear oil 90 0 6 litres Operating substance Volume Planetary gear Augers each side Gear oil 90 0 5 litres Auger box Gear oil 460 2 5 litres Outer auge...

Page 231: ...y gear m Never mix synthetic oils with mineral oils Always drain used oil completely A The oil should be changed when at oper ating temperature Flush out assembly with the new grade of oil to be used...

Page 232: ......

Page 233: ...OPERATING ADVICE Anytime when our dealers cannot help you please feel free to contact us directly The team of our Technical Advisors is at your disposal TRAINING EDU CATION We offer our Customers vari...

Page 234: ...Don t hesitate to contact your local dealer for service spare parts documentation accessories and information about the complete Dynapac paving and planing range...

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