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Operating Instructions Manual

Fayat Group DYNAPAC SD2550C, Operating Instructions Manual

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F 54 35

Exhaust system -
diesel oxidation catalytic
converter (9)

Inspect the exhaust system

A

Basically the exhaust system does not
need any maintenance.
Inspection consists of a visual check:

- damaged parts?
- loose screwed connections, plugs or lines?

m

The Atlas Copco Customer Service
must be consulted whenever the ex-
haust system is to be repaired

Risk from hot surfaces!

During system cleaning, the exhaust temperature and the
surface temperature of the exhaust system is very hot and
can cause severe injuries! The exhaust and exhaust com-
ponents remain hot after the engine has stopped.

- Let the exhaust system cool down before starting

inspection work.

- Make sure that no flammable materials can come into

contact with the exhaust system.

- Wear your personal safety gear.
- Do not touch hot parts of the vehicle.
- Comply with all further information in the engine operat-

ing instructions and in the safety manual.

WARNUNG

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Summary of Contents for DYNAPAC SD2550C

Page 1: ...Operating Instructions Paver Finisher SD2550C SD2550CS Type 894 895 10 0118 4812202131...

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

Page 3: ...cription 1 1 Application 1 2 Description of assemblies and functions 2 2 1 Vehicle 3 Construction 3 3 Danger zones 8 4 Safety devices 9 5 Technical data standard configuration 11 5 1 Dimensions all di...

Page 4: ...Measuring point configuration 38 7 4 Continuous sound pressure SD2550CS 39 7 5 Operating conditions during measurement 39 7 6 Measuring point configuration 39 7 7 Vibration acting on the entire body 4...

Page 5: ...enu sub menus 10 Home functions Quick Settings 12 Engine Speed menu Engine measured value display 14 Material Management measured value display 15 Screed Heater adjustment and display menu o 16 Paving...

Page 6: ...13 Fuse box 14 Batteries 15 Main battery switch 15 Hopper transport safeguard 16 Screed lock mechanical o 16 Screed lock hydraulic o 17 Paving thickness indicator 18 Auger lighting o 19 Engine compart...

Page 7: ...fore starting the paver finisher 6 Normal starting 6 External starting starting aid 8 After starting 11 Observe indicator lamps 13 Engine coolant temperature check A 13 Battery charge indicator lamp B...

Page 8: ...7 Mounting the outer auger bearing 8 Mounting the auger end bearing 9 3 2 Auger extension chart 10 Auger upgrading working width 3 14 m 12 Auger upgrading working width 3 78 m 12 Auger upgrading work...

Page 9: ...urement O 53 9 Limit switch 54 9 1 Auger limit switches left and right mount PLC version 54 10 Special accessories 55 10 1 Material bucket 55 Application 55 Description of assemblies and functions 56...

Page 10: ...1 1 Maintenance intervals 3 1 2 Points of maintenance 5 Outer auger bearing 1 5 Auger planetary gear 2 6 Drive chains of the augers 3 7 Auger box 4 8 Seals and sealing rings 5 9 Gearbox bolts Check t...

Page 11: ...ange extraction filter o 14 Engine air filter 4 15 Engine cooling system 5 17 AdBlue DEF tank 6 19 AdBlue DEF tank suction filter 22 Filter change s n 003055 24 Filter change s n 003056 27 AdBlue DEF...

Page 12: ...ricating 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 clea...

Page 13: ...bstances 1 1 Lubricants and operating substances 1 1 1 Capacities 3 2 Operating substance specifications 4 2 1 Drive engine TIER 4i 4F Stage IIIb IV o fuel specification 4 2 2 Drive engine Lube oil 4...

Page 14: ...12...

Page 15: ...xample Page B 2 is the second page of chapter B These operating instructions cover various vehicle options Make sure that during op eration and maintenance work the description appropriate to the vehi...

Page 16: ...sible for compliance with the resulting regulations and measures A The following warnings prohibitive symbols and instructive symbols indicate dangers for persons the vehicle and the environment due t...

Page 17: ...esult in fatal or se vere injuries unless the corresponding actions are taken Caution Indication of a possible danger that result in moderate or mi nor injuries unless the corresponding actions are ta...

Page 18: ...tched off Warning on dangerous electrical voltage m All maintenance and repair work on the screed s electrical system must always be carried out by an electrician Warning on suspended loads m Never st...

Page 19: ...V 5 Warning on danger of falling Warning on dangers posed by batteries Warning on hazardous or irritating substances Warning on substances which constitute a fire hazard Warning on gas bottles...

Page 20: ...tart engine drive Maintenance and repair work may only be carried out with the diesel engine shut down Spraying with water is prohibited Extinguishing with water is prohibited Unauthorised maintenance...

Page 21: ...ggles to protect your eyes Wear suitable head protection Wear suitable hearing protection to protect your hearing Wear suitable safety gloves to protect your hands Wear safety shoes to protect your fe...

Page 22: ...Hydraulic oil Diesel fuel Coolant Cleaning liquids must not get into the soil or sewer system during cleaning maintenance and repair work Substances must be caught stored transported and brought to pr...

Page 23: ...c umentation A For example the maintenance instructions of the engine manufac turer m Description depiction applicable when equipped with gas heater m Description depiction applicable when equipped wi...

Page 24: ...cified in the valid regulations and amend ments together with harmonised standards and other valid provisions 3 Guarantee conditions A The guarantee conditions are included in the scope of supply of t...

Page 25: ...ting range of the machine caused by wrong or improper use of the machine defective or missing safety devices use of the machine by untrained uninstructed staff defective or damaged parts incorrect tra...

Page 26: ...he machine includes presence in the danger zone of the machine transporting persons leaving the operator s platform while the machine is operating removing protection or safety devices starting and us...

Page 27: ...e meaning of these operating instructions is defined as any natural or legal person who either uses the paver finisher himself or on whose behalf it is used In special cases e g leasing or renting the...

Page 28: ...A 2...

Page 29: ...napac SD2550C SD2550CS paver finisher is a paver finisher with a caterpillar drive which is used for paving bituminous mixed material roll down or lean mixed con crete track laying ballast and unbound...

Page 30: ...Levelling cylinder for paving thickness 6 t Traction roller 7 t Crossbeam pull bar 8 t Paving thickness indicator 9 t Crossbeam 10 t Travel drive of the caterpillar drive 11 t Auger 12 t Screed 13 t...

Page 31: ...f the paver finisher is considerably facilitated by the automatic mate rial handling system the independent travel drives and the clearly structured operat ing components and controls The following ex...

Page 32: ...e g of a diesel oxidisation catalytic converter DOC an SCR catalytic converter Selective Catalytic Reducer and an AdBlue DEF injection system The emission of exhaust gases which are harmful to the env...

Page 33: ...roller crossbar can be shifted to two positions The hydraulically extendable push roller crossbar o allows different distances to the rear wheels of material trucks to be infinitely compensated The e...

Page 34: ...wall are used to adjust the height Another variant allows the height to be regulated at the operating panel by means of hydraulic cylinders o Auger segments of different lengths can be attached to eas...

Page 35: ...during a truck change the screed remains in floating position and relief pressure is applied thus preventing the screed from sinking while stationary The screed relieving device puts a higher load on...

Page 36: ...e operator and the screed personnel are allowed on the vehicle or in the danger zone The vehicle operator and screed personnel must keep to the respective driver s seats Make sure that there is no one...

Page 37: ...B 9 4 Safety devices 1 3 5 10 7 9 11 8 12 2 4 5 6 7...

Page 38: ...ese devices at regular intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Description 1 Hopper transport safeguard 2 Screed lock mecha...

Page 39: ...al data standard configuration 5 1 Dimensions all dimensions in mm A For screed technical data refer to the screed operating instructions R65 6880 3360 6625 950 1850 2845 3100 3900 3470 3290 2550 1995...

Page 40: ...ing your vehicle in an inclined position gradient slope lateral inclina tion which is above the specified limit value please consult the customer service de partment for your vehicle 5 3 Permissible a...

Page 41: ...operating instruc tions for the screed Paver finisher without screed approx 15 5 Paver finisher with screed V5100 approx 19 2 With extension parts for max working width additionally max approx xxx Wi...

Page 42: ...up to Maximum paving width with extension parts V5100TV E 2 55 2 00 5 10 8 80 m V5100TV 2 55 2 00 5 10 8 80 m V6000TV E 3 00 2 45 6 00 9 70 m V6000TV 3 00 2 45 6 00 9 70 m R300TV E 3 00 12 00 m R300TV...

Page 43: ...up to Maximum paving width with extension parts V5100TV E 2 55 2 00 5 10 8 80 m V5100TV 2 55 2 00 5 10 8 80 m V6000TV E 3 00 2 45 6 00 9 70 m V6000TV 3 00 2 45 6 00 9 70 m R300TV E 3 00 14 00 m R300TV...

Page 44: ...0 Version 6 cylinder diesel engine water cooled Performance 164 KW 223PS at 2200 rpm Pollutant emissions in accordance with Stage IIIa Tier 3 Fuel consumption full load Fuel consumption 2 3 load 44 8...

Page 45: ...n accordance with Stage IIIb Tier 4i Fuel consumption full load Fuel consumption 2 3 load 44 0 l h 29 4 l h Fuel tank capacity See chapter F Make type Cummins QSB 6 7 C260 Version 6 cylinder diesel en...

Page 46: ...onsumption full load Fuel consumption 2 3 load 42 1 l h 28 1 l h Fuel tank capacity See chapter F AdBlue DEF consumption approx 5 of fuel consumption Make type Cummins QSB 6 7 C260 Version 6 cylinder...

Page 47: ...ating functions Fan Clutch Separate hydraulic circuits for options Hydraulic oil reservoir volume See chapter F Volume Approx 8 0 m3 approx 17 5 t Minimum inlet height centre 525 mm Minimum inlet heig...

Page 48: ...tic via configurable switching points Auger height adjustment Mechanically Auger extension With extension parts see auger extension chart Auger diameter 500 mm Drive Hydrostatic external drive fully v...

Page 49: ...op 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 slo...

Page 50: ...r of injuries Never remove any warnings or information signs from the vehicle Damaged or lost warning or information signs must be replaced immediately Make yourself familiar with the meaning and posi...

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

Page 52: ...B 24 71 70 40 41 42 xxxxxxxxxxxxxxxxx 9 9 7 7...

Page 53: ...engine and re move the ignition key before perform ing any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause severe or fatal injuries Switch...

Page 54: ...injuries Always observe the maintenance instructions 8 Caution danger from incorrect towing Vehicle movements can cause severe or fatal injuries The traction system brake must be released before towin...

Page 55: ...d with water Handling tyres filled with water incorrect ly can cause severe to fatal injuries Always observe the operating instructions 14 Maintenance for the starter batteries Maintenance work has to...

Page 56: ...only permitted at these lifting points 22 Lashing point Lashing the machine is only permitted at these points 23 Main battery switch Position of the main battery switch 24 Diesel fuel Position of the...

Page 57: ...of the filling and control point 28 Hydraulic oil Position of the filling point 29 Hydraulic oil level Position of the control point 30 Engine oil drainage point Position of the drainage point 31 Gea...

Page 58: ...30 6 3 CE marking No Pictogram Meaning 33 Tamper speed adjuster Position of the speed adjuster 34 Vibration speed adjuster Position of the speed adjuster No Pictogram Meaning 40 CE sound output level...

Page 59: ...symbols prohibitive symbols warning symbols No Pictogram Meaning 50 Wear ear protectors 51 Do not enter the area 52 Do not spray the area or component with water 53 Warning on dangers posed by batter...

Page 60: ...mation Avoid contact with the human body also avoid inhaling the vapours and seek med ical advice if feeling unwell N Environmentally hazardous sub stance May cause immediate or delayed danger to the...

Page 61: ...ly at crown adjustment zero Cross beam lock only for transportation Do not enter or work under screed only secured with screed lock for transportation 71 Attention danger of high voltage in vehicle el...

Page 62: ...pressure working width speed preselection 74 Overview Tyre pressure working width speed preselection 75 Engine start all switches in neutral The engine cannot be started when functions are switched on...

Page 63: ...Description 1 Vehicle designation 2 Designation type 3 Year of construction 4 Serial number product identification number PIN 5 Operating weight incl all extension parts in kg 6 Maximum permitted tot...

Page 64: ...B 36 6 8 Explanation of 17 digit PIN serial number A Manufacturer B Family Model C Code letter F Serial number 10002014JHG002076 A B C F...

Page 65: ...ine type plate 1 is affixed on top of the engine The type plate states the engine type serial number and engine data Please state the engine number of the engine when ordering spare parts See also ope...

Page 66: ...LWA 108 3 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 The tamper an...

Page 67: ...2 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 The tamper and the v...

Page 68: ...ents of the EMC Directive 2004 108 EC Interference emission according to DIN EN 13309 35 dB V m for frequencies of 30 MHz 1GHz measured at a distance of 10 m 45 db V m for frequencies of 30 MHz 1 GHz...

Page 69: ...many gas bottles must not be transported on the paver finisher or on the screed Disconnect the gas bottles from the gas system and protect them with their caps Use a separate vehicle to transport them...

Page 70: ...e taken into consideration when selecting the attachment and loading equipment 2 1 Preparations Prepare the paver finisher for transportation see chapter D Remove all overlaying or loose parts from fi...

Page 71: ...lock Activate set up mode Close the hopper lids Engage both hopper transport safeguards Lift the screed Fully extend the levelling cylinder Retract the screed parts until the screed matches the basic...

Page 72: ...able for securing loads positive fit force connection diagonal lashing etc in accordance with the specific transport vehicle m The low loader must have the necessary number of lashing points with a la...

Page 73: ...sure that there are no persons in the danger area during loading Use the work gear and low engine speeds to drive onto the low bed trailer Caution Possible collision of parts When driving up inclines...

Page 74: ...orce and load rating m Always tighten the lashing chains and straps hand tight 100 150 daN m Lashing equipment must be checked by the user for any signs of damage before use On detecting any signs of...

Page 75: ...of gravity of the paver finisher Comply with the following if the paver finisher has to be placed in the front section of the low bed trailer B for load distribution reasons or on account of the leng...

Page 76: ...rt safeguards 2 on both sides Position the non slip mats under the screed across the whole width of the vehicle 3 and lower the screed Switch off the paver finisher Attach and secure the protective ho...

Page 77: ...the paver finisher and on the low load trailer Fasten the lashing chains as shown 4 2 Securing at the front m Diagonal lashing secures the paver finisher at the front using the lashing points on the p...

Page 78: ...ecures the paver finisher at the rear at right angles to the direction of travel using the lashing points on the paver finisher eyebolts and on the low load trailer Fasten the lashing straps as shown...

Page 79: ...inisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing straps as shown Step 2 fasten lashing chains m Diagonal lashing secures the paver fini...

Page 80: ...d Release the latch 1 to move the con trol platform A The latch must be fixed when the control platform is set in the middle and during transport m To be able to set the lock the platform must be posi...

Page 81: ...Protective roof Lift the screed to the transportation position Start the engine and drive from the trailer at a low engine traction speed Park the paver finisher in a secure spot lower the screed and...

Page 82: ...is at the bottom wheeled paver Driver s seats swivelled to middle setting and in lowest position Backrests and armrests of driver s seats tilted forwards Front and side windows closed Engine hood and...

Page 83: ...st pipe is lowered or raised to gether with the roof Connect the pump lever 1 to the pump 2 Tighten bolts 3 on both sides of the roof Operate the pump lever 1 until the roof has reached the upper or l...

Page 84: ...ose parts from finisher and screed see also Screed op erating instructions Store these parts in a safe place f When screed is operated with the optional gas heating system Remove the gas bottles for t...

Page 85: ...ate set up mode Close the hopper lids Engage both hopper transport safeguards Lift the screed Fully extend the levelling cylinder Retract the screed parts until the screed matches the basic width of t...

Page 86: ...fast slow switch to Hare if necessary Turn the preselector to zero Swivel the drive lever to maximum f The vehicle already advances slightly on deflecting the drive lever Adjust required vehicle speed...

Page 87: ...y is dependent on the screed which is mounted Danger from suspended loads Crane and or lifted vehicle can tip when lifted and cause injuries The vehicle may only be raised at the marked lifting points...

Page 88: ...is located in the area of the drive unit s rear reversing roller 3 Secure vehicle wherever it is parked up Engage the transport safeguards Remove any attachments and extension parts from the paver fin...

Page 89: ...ar to the four attachment points 1 2 m The max permissible attachment point load at the attachment points is 73 5 kN m The permissible load applies in the vertical direction m Make sure that the paver...

Page 90: ...for towing heavy con struction machines m The towing vehicle must be capable of securing the paver finisher even on slopes Use only approved tow bars If necessary remove any attachments and accessorie...

Page 91: ...al number 2014 2016 2021 et seq Push knob 3a into the valve body While pumping next step check that the knob remains in the pressed position Actuate lever 4 of hand pump until sufficient pressure has...

Page 92: ...hten the lock nut 7 to a torque of 22 Nm m On completion of the towing process re store the initial status Attach the tow bar to the coupling 9 located in the bumper A Now carefully and slowly tow the...

Page 93: ...tion key and the main switch 1 and take it with you do not hide them somewhere on the machine Protect the operating panel with the dust cover 2 and lock it Store loose parts and accessories in a safe...

Page 94: ...m from tilling over and rolling or sliding away f Roller type jacks must not be moved when under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequatel...

Page 95: ...lways 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...

Page 96: ...or conveying vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries Do not enter the danger zone Do not reach into rotating or conveying parts Only wear close fitting clo...

Page 97: ...er and conveyor conveying function are set to the STOP function in the case of EMER GENCY STOP or restarting the control system If settings are changed when the die sel engine is stopped AUTO or MANUA...

Page 98: ...D 11 4 10 13 16 15 17 11 12...

Page 99: ...off by turning the key back to its starting position A After activating the ignition voltage the input and dis play terminal requires a few seconds for the booting process A On shutting off the vehic...

Page 100: ...D 11 6 10 13 16 15 17 11 12...

Page 101: ...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...

Page 102: ...D 11 8 10 13 16 15 17 11 12...

Page 103: ...elector The vehicle advances slightly with deflect ed drive lever even if the travel drive preselector is set to zero 16 Steering potentiometer The steering wheel movement is transferred electrohydrau...

Page 104: ...D 11 10 18 19 20 21...

Page 105: ...For switching on the rear working lights Switch OFF by pressing the button again f Avoid dazzling other road users 20 Auger compart ment working lights ON OFF o Button with detent switch function and...

Page 106: ...D 11 12 22 23 24 25...

Page 107: ...ipers Switched OFF with time control 24 Move control plat form to the left Pushbutton function with LED feedback To move the control platform to the left m The platform lock must be released before mo...

Page 108: ...D 11 14 26 27 28...

Page 109: ...filling pump Switch OFF by pressing the button again 27 Seat heating ON OFF o Button with detent switch function and LED feedback For switching on the seat heating Switch OFF by pressing the button a...

Page 110: ...D 11 16 29 30 31...

Page 111: ...o Pushbutton function with LED feedback To hydraulically retract the push roller crossbar f On actuation heed danger zones of moving parts of the vehicle 31 Push roller damping ON OFF o Detent switch...

Page 112: ...D 11 18 33 32...

Page 113: ...ted in the working gear travel drive slow speed A If the Turning on the spot function has been inadvert ently activated and the steering is set to straight ahead travel the paver finisher does not mov...

Page 114: ...D 11 20 35 34 36 37...

Page 115: ...there is only limited space at one side or when obstacles obstruct truck unloading f On actuation heed danger zones of moving parts of the vehicle 36 Open hopper left Pushbutton function To open the...

Page 116: ...D 11 22 38 40 41 39 42...

Page 117: ...d understand the system Comply with all further information in the operating instructions and in the safety manual Item Description Brief description LED display 38 Tell truck to reverse Pushbutton fu...

Page 118: ...D 11 24 38 40 41 39 42...

Page 119: ...l truck to End Tipping lower truck hopper tell truck to Detach Depart Pushbutton function with LED feedback To change over to the End Tipping signal YELLOW SIGNAL running light de scending Press butto...

Page 120: ...D 11 26 38 40 41 39 42...

Page 121: ...se for truck to approach GREEN SIGNAL A The truck is detected by a laser sensor at a distance of 6 m between the paver and the material truck GREEN SIGNAL flashing A The flashing frequency of the disp...

Page 122: ...D 11 28 44 43 45 46...

Page 123: ...e configurations with a screed which cannot be extended f On actuation heed danger zones of moving parts of the vehicle 45 Retract left screed Pushbutton function To retract the left half of the scree...

Page 124: ...D 11 30 48 52 50 47 51 49...

Page 125: ...A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 48 Right conveyor AUTO Button with detent switch function and LED feedback The...

Page 126: ...D 11 32 48 52 50 47 51 49...

Page 127: ...A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 50 Right conveyor MANUAL Button with detent switch function and LED feedback Th...

Page 128: ...D 11 34 48 52 50 47 51 49...

Page 129: ...moves towards the hopper for approx 3 5 seconds f On actuation heed danger zones of moving parts of the vehicle 52 Reverse right conveyor Pushbutton function The conveying direction of the conveyor ca...

Page 130: ...D 11 36 54 58 56 53 57 55...

Page 131: ...function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 54 Right auger AUTO Button with detent switch function and LED feedback The conveying funct...

Page 132: ...D 11 38 54 58 56 53 57 55...

Page 133: ...A The main function switch locks the conveying function f On actuation heed danger zones of moving parts of the vehicle 56 Right auger MANUAL Button with detent switch function and LED feedback The c...

Page 134: ...D 11 40 54 58 56 53 57 55...

Page 135: ...e switched to AUTO or MANUAL A On manual triggering the automatic function is overrid den with reduced delivery capacity 58 Right auger MANUAL Conveying direc tion inwards Pushbutton function To manua...

Page 136: ...D 11 42 60 59...

Page 137: ...espite Auto settings in the individual functions these are not activated when the drive lever is swivelled out Switch OFF by pressing the button again A The preset vehicle can be relocated and release...

Page 138: ...D 11 44 64 61 62 66 65 63...

Page 139: ...e displayed arrow direction A This function is also activated when the remote control is not connected 62 Raising lowering auger o Button with detent switch function and LED feedback For hydraulic adj...

Page 140: ...D 11 46 64 61 62 66 65 63...

Page 141: ...just the selected function in the corresponding direction f On actuation heed danger zones of moving parts of the vehicle 65 Adjustment button Extend lower on left Pushbutton function To adjust the se...

Page 142: ...D 11 48 68 67...

Page 143: ...ton again or by swiv elling the drive lever out to the paving position On reaching the adjusted material height material sen sor the filling function is automatically switched off f On actuation heed...

Page 144: ...D 11 50 70 69...

Page 145: ...ssed 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...

Page 146: ...D 11 52 72 71...

Page 147: ...in function switch must be set to the OFF position A The function is preset in conjunction with the Set up mode button 72 Vibration screed specific Button with detent switch function and LED feedback...

Page 148: ...D 11 54 74 73...

Page 149: ...ed relieving and screed charging To preset the hydraulic oil pressure switch this button and the Set up mode button to ON 74 Screed charging Button with detent switch function and LED feedback For rel...

Page 150: ...D 11 56 76 75...

Page 151: ...eam lock m Before retracting and extending the lock raise the crossbeams slightly over the locking bolts raise the screed 76 Retract cross beam lock o Pushbutton function with LED feedback To hydrauli...

Page 152: ...D 11 58 78 77...

Page 153: ...st be fulfilled to use the function Drive lever 13 in neutral position road speed 0 Transport speed 33 OFF Main function switch 59 OFF Set up mode 68 OFF Item Description Brief description 77 Set Set...

Page 154: ...D 11 60 3 Remote control...

Page 155: ...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...

Page 156: ...D 11 62 121 120 121...

Page 157: ...ifting the screed or other actions are then no longer possible Danger of accident The emergency stop button does not shut off the gas heat er system Close the main shut off valve and the valves on the...

Page 158: ...D 11 64 122 124 125 123 125 122 124...

Page 159: ...n 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 ST...

Page 160: ...D 11 66 122 124 125 123 125 122 124...

Page 161: ...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 The auge...

Page 162: ...D 11 68 122 124 125 123 125 122 124...

Page 163: ...he 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 pr...

Page 164: ...D 11 70 122 124 125 123 125 122 124...

Page 165: ...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 The conv...

Page 166: ...D 11 72 131 132 133 130...

Page 167: ...t 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 di...

Page 168: ...D 11 74 135 136 137 134...

Page 169: ...t 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 d...

Page 170: ...D 11 76 140 138 140 139...

Page 171: ...mote control display 139 Extend retract screed 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...

Page 172: ...D 11 78...

Page 173: ...D 22 1 D 22 Operating the display...

Page 174: ...a menu Press to release the adjustment of a parameter to confirm a parameter adjustment to confirm a selection possibility B Home button To show the home menu directly C Upwards button To show the hi...

Page 175: ...status warning or error message A Detailed explanations for the individual displays can be found in the section Symbols for status warning and error messages Colour code Explanation RED error message...

Page 176: ...D 22 4 1 1 Menu operation procedure for adjusting parameters A B C...

Page 177: ...Press button B to open the Screed Heater menu Turn jog dial C to make the cursor appear A A blue frame appears around the temperature parameter Press jog dial C to activate the adjustment Turn jog dia...

Page 178: ...rs around the top adjustment parameter in the menu Turn jog dial C in the corresponding direction until the blue frame is around the required adjustment parameter Press jog dial C to activate the para...

Page 179: ...al to activate the parameter adjustment A A blue frame appears around the top selection possibility in the menu Turn jog dial in the corresponding direction until the blue frame is around the re quire...

Page 180: ...el AdBlue DEF tank o m If the level is too low a warning also appears 4 Paving material conveyor level left right 5 Paving material auger level left right 6 Actual temperature of the screen heater C F...

Page 181: ...o 11 Crowning o 12 Target slope left right o 13 Overall width screed cm inch o A The remote control must be reset to measure the overall width 14 Extension distance levelling cylinder left cm inch o...

Page 182: ...sub menus 1 Show Home functions Quick Settings 2 Call Engine Speed menu Engine measured value display sub menus 3 Paving Parameters menu sub menus 4 Camera display menu sub menus o 5 Error Memory men...

Page 183: ...D 22 11 A If the corresponding function button of an opened sub menu is pressed again the Home menu appears and the sub menu display remains 2x...

Page 184: ...Depending on the vehicle equipment the position 1 can have two different functions 1 1 Eco mode function The engine speed is constantly regulated to 1600 rpm 1 2 Vario Speed function The engine speed...

Page 185: ...heel drive is activated A Front wheel drive Plus o To activate front wheel drive again the drive lever must remain in neutral for 10 seconds The Drive speed fast hare must be deactivated in this case...

Page 186: ...of 50 the engine speed is adapted directly 2 Actual engine speed 3 Engine oil pressure bar 4 On board voltage V 5 Engine coolant temperature C F 6 Engine operating hours h 7 Fuel consumption l h o Op...

Page 187: ...Menu for checking the following parameters 1 Paving material level conveyor left 2 Paving material level conveyor right 3 Paving material level auger left 4 Paving material level auger right 5 Tamper...

Page 188: ...2 Average actual temperature of all screed sections C F 3 Actual temperature basic screed left C F 4 Actual temperature basic screed right C F 5 Actual temperature extendable part extension parts lef...

Page 189: ...seconds during reset 2 Steering monitoring is used for distance control scanning reference Reset reference to zero Select function 2 1 with the job dial and press to reset A As confirmation the displ...

Page 190: ...tched to the existing paving situation A Adjustment is also possible during the driving mode m When the front wheel drive is switched off automatically the related mes sage is shown in the display An...

Page 191: ...ration A Necessary regeneration is indicated by the regeneration warning sign 1a A Please heed the notes in the Terminal error messages section A When the function is activated the HEST warning sign 1...

Page 192: ...er regeneration can occur immediately after being enabled again Danger from particulate filter regeneration Improper particulate filter regeneration can cause severe to fatal injuries Keep the outlet...

Page 193: ...aving speed 1d Binder course high paving speed 1e Foundation A The speeds for every course thickness parameter have been stored in the factory for all conveying and compacting elements Depending on th...

Page 194: ...play and adjustment parameters 6 Nominal tamper speed n min display and adjustment parameters 7 Nominal vibration speed n min display and adjustment parameters A Tamper and vibration range depending o...

Page 195: ...onfirmation the display changes for 5 to 10 seconds during loading 10 Parameter Reset Load Factory Settings function A Firstly the system requests reset confirmation Press the button again for a reset...

Page 196: ...Overview Course Thickness Parameters Menu for viewing the speeds saved for all conveying and compacting elements ac cording to the course thickness parameters Back to the main menu 1 Paving Parameters...

Page 197: ...mera display menu o Machine parts partly concealed from view can be displayed by the camera system A When this function is called up display camera 1 appears 1 Show camera 1 display 2 Show camera 2 di...

Page 198: ...2 Number of vehicle warning messages Open detailed display Vehicle Warning Messages 2 1 3 Number of engine error messages Open detailed display Engine Error Messages 3 1 4 System error display A Poss...

Page 199: ...Error Messages With Travel Drive Stop Display of existing error messages in a table 1 Error code 2 Error description 3 Designation of the faulty part as per BMK EIC list A Press the job dial to scrol...

Page 200: ...ror messages in a table 1 Error code 2 Error description 3 Designation of the faulty part as per BMK EIC list A Press the job dial to scroll through the list Delete list of error messages 4 A As confi...

Page 201: ...ror Messages Display of existing error messages in a table 1 SPN code 2 FMI code 3 OC error frequency A All error messages can be identified in the section Error codes drive engine A Press the job dia...

Page 202: ...d from every menu sub menu or display Menu for opening the following sub menus 1 Home menu Display and quick settings menu 2 Service menu Menu for service technician password required 3 Info Settings...

Page 203: ...D 22 31 Service menu Password protected menu for various service settings...

Page 204: ...f the vehicle 2 Software version of the display 3 Engine operating hours h A If consultation with Technical Support is required for your vehicle always specify the software version Open the following...

Page 205: ...cation system 2 1 Extended lubrication interval 2 2 Standard lubrication interval 2 3 Shortened lubrication interval A If necessary the lubrication interval has to be adjusted to the prevailing paving...

Page 206: ...o A After closing the hopper lids the front hopper is only raised after the adjusted time has expired A Setting range 0 25 sec 2 Selection External Levelling L External levelling left side of the vehi...

Page 207: ...hicle 2 Data display and control of the opposite side of the vehicle 3 Split screen on the remote controls simultaneous data display and operation of both sides of the vehicle possible o 4 Selection S...

Page 208: ...stances paver truck 1 1 Shortened distance 1 2 Medium distance 1 3 Extended distance 2 Selection Set Assist A The selected elements are taken into account in executing the Set Assist function 2 1 Rais...

Page 209: ...usting the illuminance of various control elements 2 Monitor brightness display and adjustment parameters 2 1 daytime light 2 2 nighttime light 3 Truck Assist display and adjustment parameters 3 1 day...

Page 210: ...splay and adjustment parameters h h min min 24h PM AM 4 Date display and adjustment parameters dd mm yyyy Open the following sub menus 5 Camera display set up menu 6 Licence text display of Open Sourc...

Page 211: ...he camera display 1 Brightness display and adjustment parameters 2 Contrast display and adjustment parameters 3 Colour display and adjustment parameters Setting range 0 100 Open the following sub menu...

Page 212: ...D 22 40 Licence text display Display of the software licence text Open the following sub menus 1 Display set up menu 2 Camera display set up 1 2...

Page 213: ...ng status of the vehicle permits Indicator lamp flashes Urgent maintenance level II Particular filter regeneration must be carried out as soon as possible The engine output may be automatically reduce...

Page 214: ...is being cleaned by the engine f Keep the outlet of the exhaust pipe out of the reach of people and of objects that can burn melt or explode f There may not be any people or objects with in a radius...

Page 215: ...temporarily continue to be operated or in the case of serious faults should be shut down immediately to prevent further damage from occurring Each fault should be rectified as soon as possible A An e...

Page 216: ...e to avoid subsequent damage Service overdue A A maintenance interval is overdue m Proceed immediately with maintenance to avoid subsequent damage Heating status ON A xxxxxxxxx m xxxxxxxxx Switching o...

Page 217: ...been pressed Engine coolant temperature The engine temperature is too high m The engine performance will be throttled down automatically Driving mode remains possible Stop the paver finisher drive lev...

Page 218: ...r with Error Message Hydrostatic travel drive oil pressure indicator m The oil pressure is insufficient Switch off the engine immediately For other possible errors see engine s oper ating instructions...

Page 219: ...D 22 47 Command Symbol in the display Engine stop Display for all error messages with machine stop...

Page 220: ...D 22 48 2 1 Drive engine error codes A If a fault is detected on the engine this is shown by the corresponding indication 1 in the display 1...

Page 221: ...fault after decoding A Press the job dial to scroll through the list m It may be possible to continue operating the vehicle depending on the severity of the error The error should however be remedied...

Page 222: ...D 22 50 Example C...

Page 223: ...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...

Page 224: ...D 22 52 2 2 Error codes A Scan QR Code to access failure code chart...

Page 225: ...2 53 3 Menu structure of the setting and display menus The following illustration shows the menu structure and serves to simplify operation and the procedure in the case of various settings and displa...

Page 226: ...D 22 54...

Page 227: ...alling from the vehicle which can cause severe to fatal injuries During operation the operator must be at the intended driver s seat and be seated properly Never jump onto or off a moving vehicle Keep...

Page 228: ...is at the bottom wheeled paver Driver s seats swivelled to middle setting and in lowest position Backrests and armrests of driver s seats tilted forwards Front and side windows closed Engine hood and...

Page 229: ...ever 1 to the pump 2 Tighten bolts 3 on both sides of the roof 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 backw...

Page 230: ...son Set the latch 1 on both sides of the ladder to the intended position f The ladder must not be locked when driving or paving Storage space There are two removable containers 2 under the lockable bo...

Page 231: ...D 30 5 Control platform moveable o 9 6 2 5 7 4 3...

Page 232: ...n see operating panel A To shift the control platform the latch 9 must be released m Shifting the platform increases the basic width of the paver finisher f If the platform is moved ensure that there...

Page 233: ...and slide panel console to the desired position using the handle 3 Insert panel latch 2 into one of the detent positions 4 Swivelling the operating panel Lift latch 5 swivel operating panel to the req...

Page 234: ...D 30 8 Protective roof o A D B C B A C D 1 3 4 5 2...

Page 235: ...close the front window pull the latch 4 and pull the sliding frame at the handle 4 Windscreen wiper Engage the windscreen wiper screen wash on the operating panel if necessary A Ensure that the washer...

Page 236: ...raulically it can be pushed back to its central position by hand Remove the screw cap 1 next to the right footwell window Remove screw 2 A This undoes the connection between the platform and the frame...

Page 237: ...eyond the outer edge of the vehicle Press latch 1 swivel seat console to the desired position and allow latch to engage again Fold hinged step 2 down if necessary m Make sure it is latched properly f...

Page 238: ...dually adjusted Raise the button to adjust the inclination The seat surface in clines to the desired position by simultaneously loading or relieving it Armrest inclination 6 The armrest s longitudinal...

Page 239: ...t height adjustment 4 The seat height can be individually adjusted Turn the handle in the desired direction to adjust the seat height Backrest adjustment 5 The backrest inclination can be continuously...

Page 240: ...box which contains all fus es and relays etc is located beneath the central control platform floor panel A An assignment plan for fuses and relays can be found in chapter F8 15 10 15 25 15 10 15 25 1...

Page 241: ...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 th...

Page 242: ...n dan ger during transportation Screed lock mechanical o A The screed locks must additionally be engaged on both sides of the vehicle pri or to transportation with the screed lifted f Transportation w...

Page 243: ...tion with an unsecured screed leads to a risk of accidents Lift the screed Activate the function on the operat ing panel A The two screed locks 1 extend hydrau lically m ATTENTION Insert screed lock o...

Page 244: ...ituations the same paving thickness should be set on both sides of the vehicle Other displays o are on the cross beam guide To change the reading position the scale 2 can be raised and lowered again i...

Page 245: ...partment They are engaged together with the working lights A These are activated together with the other working lights on the operat ing panel Engine compartment lighting o A The engine compartment l...

Page 246: ...D 30 20 LED working light o There are two LED spotlights 1 at the front and rear of the vehicle f Always align the working lights to avoid dazzling the operating personnel or oth er road users 1...

Page 247: ...quipped with an electric screed it is possible for the lamps to flicker irreg ularly during the heating up phase with simultaneous operation of 500 watt spot lights o and illuminated balloon o Prefera...

Page 248: ...t 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 modification Auger height displays A s...

Page 249: ...ses the basic width of the paver finisher f If the sensor rod or sensor rod extension are used ensure that there is no one in the vehicle s danger area A The sensor rod is adjusted when the vehicle is...

Page 250: ...fter releasing the wing nuts 5 the end section of the sensor rod extension 6 can be set to the desired length the angle can additionally be changed by swivel ling on the joint 7 A Either the adjustabl...

Page 251: ...emove 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 ma...

Page 252: ...hen 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 indica...

Page 253: ...ntrol the material flow on the relevant half of the conveyor The conveyors should stop when the material has roughly reached the area below the auger tube A This requires that the auger height has bee...

Page 254: ...conveyor The con veyors should stop when the material has roughly reached the area below the auger tube A This requires that the auger height has been adjusted correctly see chapter E To set the deac...

Page 255: ...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...

Page 256: ...set the sensor height the deacti vation point loosen the star handles 4 and adjust the linkage to the required length After adjusting retighten all mounting parts properly A The connection cables are...

Page 257: ...socket 1 is located behind the left right seat consoles Additional working lights can be con nected here for example Right seat console 12V socket Left seat console 24V socket A Voltage is present wh...

Page 258: ...stop with relieving This is used to set the pressure for Screed control with paver finisher stop floating stop with relieving Switching on see screed stop paving stop Chapters Operating panel Operati...

Page 259: ...pacting elements of the screed are engaged m The pumping interval adjusted in the facto rymustbemodifiedto thepavingsituation A Changing the duration of lubrication and breaks may be necessary when la...

Page 260: ...clearer 1 up and se cure in the uppermost position with a shackle 2 To lower the lane clearer it must be lifted a little and the shackle 2 must be swivelled back A The blade s level above the ground i...

Page 261: ...screed to the desired position using the lever 3 and engage the locking knob again A If the levelling unit is connected to a height controller this has the function of balanc ing out any rapid rise i...

Page 262: ...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 e...

Page 263: ...90 mm Activate the function on the operating panel as necessary m Extending the push roller increases the transportation length of the paver finisher f On actuation ensure that nobody is in the dange...

Page 264: ...el must be fa miliarised with operation of the fire extin guisher 2 A Observe the inspection interval for the fire extinguisher First aid kit o f Any dressings that have been used must be replaced imm...

Page 265: ...ecure with a wing bolt 1 Raise the bracket 2 swivel to the out er position and allow to engage there Slide the rotary beacon with the tube 3 out to the desired height and secure with the clamping bolt...

Page 266: ...2 into the container which is to be emptied A To enable the container to be emptied completely the suction hose must reach down to the floor of the container Activate the function on the operating pan...

Page 267: ...D 30 41 Illuminated balloon o 3 4 5 1 2 10 6 9 8 7...

Page 268: ...lammable materials e g petrol and gas a safety distance of at least 1 metre must be maintained from combustible materials f Make sure that the area above the balloon is clear and open and no power lin...

Page 269: ...uide rod Once the illuminated balloon is completely mounted aligned and secured connect the plug 9 of the illuminated balloon in the corresponding switch cabinet sockets 10 m Never adjust the holding...

Page 270: ...ermoon and stow dry in the related transport cover Clean m The Powermoon covers may be wiped off with a damp cloth for cleaning We recom mend washing up liquid as a cleaning agent for the upper and lo...

Page 271: ...of the paver and the driver of the material truck The corresponding signal system shows the truck driver which action to perform reversing stop tip material depart The system consists of Two LED ligh...

Page 272: ...D 30 46...

Page 273: ...Diesel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector Two filled propane gas bottles Shovel and broom Scraper spatula for cleaning the auger and the hopper...

Page 274: ...ghting must be provided when working at night Comply with all further information in these instructions and in the safety manual Danger of falling from the vehicle Entering and leaving the vehicle and...

Page 275: ...ediately 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...

Page 276: ...are securely seated Screed transport safeguard When the screed is raised before transport make sure that the cross beam lock is fixed correctly Hopper transport safeguard When the hopper is closed bef...

Page 277: ...D 41 5 13 11 12 10 15 120...

Page 278: ...ting 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 A It is impossible to start the vehicle if an emergency stop...

Page 279: ...D 41 7 13 11 12 10 15 120...

Page 280: ...connect the positive terminal 1 of the starting aid battery to the posi tive terminal 2 of the vehicle battery Then connect the negative terminal 3 of the starting aid battery to the ground of the di...

Page 281: ...t the other vehicle Press the starter button 12 to start the engine Run the starter continuously for a maximum of 30 seconds then take a break for 2 minutes If the engine still has not started after t...

Page 282: ...D 41 10 13 68...

Page 283: ...ter starting To increase the engine speed Press button 68 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 engi...

Page 284: ...D 41 12 A B C...

Page 285: ...led down automatically Driving mode remains possible After cooling down to normal temperature the engine will run with full perform ance again Battery charge indicator lamp B Must go out after startin...

Page 286: ...D 41 14 D 68 50 56 55 49...

Page 287: ...be damaged When the hydraulic oil is cold Activate set up mode function 68 Set the conveyor function 49 50 to manual and the auger function 55 56 to manual Conveyor and auger start to operate Let the...

Page 288: ...D 41 16 35 34 15 13 16 69 63 61 64 46 45 68 126 130 75...

Page 289: ...extend the levelling cylinders with switch 61 63 64 A To extend the levelling cylinders levelling operating mode 126 130 must be switched to MANUAL on the remote controls Use switch 45 46 to adjust t...

Page 290: ...D 41 18 33 15 13 16 10...

Page 291: ...the drive lever 13 forward or backward according to the drive direction desired Adjust the speed with the preselector 15 Carry out steering movements by actuating the steering potentiometer 16 f In c...

Page 292: ...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 am...

Page 293: ...raight paving a direction mark must be present or established road edge chalk lines or similar Slide the operating panel to the de sired side and secure it Pull the direction indicator out of the bump...

Page 294: ...D 41 22 59 67 37 36 54 48 53 47 A B...

Page 295: ...uto Activate function 67 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 beneat...

Page 296: ...D 41 24 70 54 48 53 47 71 72 15 13 33 123 127 126 130 126 130...

Page 297: ...drive wheels as the screed tends to level an uneven ground The reference points for the layer thickness are the caterpillar chains or drive wheels The basic setting of the screed must be corrected whe...

Page 298: ...the way Uniform material transport and distribution or supply to the screed may require cor rections to settings of the material switches for conveyor and auger A See the section Malfunctions when pav...

Page 299: ...lief 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...

Page 300: ...D 41 28 13 15 74 73 70 69...

Page 301: ...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 s...

Page 302: ...oves 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...

Page 303: ...D 41 31...

Page 304: ...D 41 32 13 15 74 73 70 69...

Page 305: ...ng function 74 LED ON Set the pressure 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 a...

Page 306: ...D 41 34 13 15 11 12...

Page 307: ...edge like the end of a layer Set the drive lever 13 to the centre position During longer breaks e g lunch break Set the drive lever 13 to the centre position and the speed adjuster 15 to minimum Pres...

Page 308: ...D 41 36 13 11 15 69 75 12...

Page 309: ...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 p...

Page 310: ...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 inco...

Page 311: ...screed extendable parts are incorrectly installed cold screed bottom plates are worn or warped screed is not operated in the floating position paver finisher speed is too high auger is overloaded cha...

Page 312: ...r augers run too slowly Hydraulic oil level in the tank is too low Top up oil Power supply interrupted Check fuses and cables replace if necessary Switch is defective Replace the switch One of the pre...

Page 313: ...pply interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote con trol is set to Auto Set the switch to Manual Power supply interrupted Check...

Page 314: ...ervo unit Insufficient supply pressure Check and adjust if necessary Check the suction filter replace the supply pump and the filter if necessary Drive shaft of hydraulic pumps or engines broken Repla...

Page 315: ...drau lic system hot hydraulic fluid may spurt out at high pressure Switch off the engine and depressurise the hydraulic system Protect your eyes Mount all protective devices before re commissioning th...

Page 316: ...g thickness 10 cm Min height setting 18 cm from the ground A An incorrect height setting can result in the following problems during paving Auger too high Too much material in front of the screed mate...

Page 317: ...by alternately adjusting the right hand and the left hand side The current height can be read at the scale 2 2 3 Hydraulic adjustment o Determine the currently set height of the auger crossbeam left a...

Page 318: ...braces 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 retai...

Page 319: ...ted 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 m In the case o...

Page 320: ...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...

Page 321: ...rts 2 bolts washers nuts Dismantle the assembly parts 3 of the adjacent auger blade remove plug 4 Guide the auger shaft extension into the auger shaft Reinstall the previously removed assembly parts 3...

Page 322: ...ing to the brace shaft with the relevant assembly parts 4 bolts washers pins A If necessary insert fitted plates 5 Reinstall the previously removed assembly parts 1 and simultaneously tighten the auge...

Page 323: ...Dismantle the assembly parts 5 of the adjacent auger blade remove plug 6 Guide the auger end bearing 7 into the auger extension Secure the auger end bearing to the material shaft with the relevant ass...

Page 324: ...640L Auger extension part 640mm left 640R Auger extension part 640 mm right 960L Auger extension part 960 mm left 960R Auger extension part 960 mm right 320 Material shaft 320 mm 640 Material shaft 6...

Page 325: ...E 11 11 Symbol Meaning Outer auger bearing Auger end bearing...

Page 326: ...E 11 12 Auger upgrading working width 3 14 m Auger upgrading working width 3 78 m Auger upgrading working width 4 42 m 320 R 320 L 320 320 640 640 640 R 640 L 640 640 640 R 640 L 320 R 320 L 320 320...

Page 327: ...E 11 13 Auger upgrading working width 5 06 m Auger upgrading working width 5 70 m 320 L 320 320 R 320 960 R 960 L 960 960 960 R 960 L 960 960 640 640 640 R 640 L...

Page 328: ...E 11 14 Auger upgrading working width 6 34 m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960...

Page 329: ...E 11 15 Auger upgrading working width 6 98 m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960 320 L 320 320 R 320...

Page 330: ...E 11 16 Auger upgrading working width 7 62 m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960...

Page 331: ...E 11 17 Auger upgrading working width 8 26 m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960 320 L 320 320 R 320...

Page 332: ...E 11 18 Auger upgrading working width 8 90 m 960 BR 640 R 160 L 640 L 960 BL 640 640 640 R 640 L 640 640 L 640 640 R 960 L 960 160R 960 R 960 m m...

Page 333: ...E 11 19 Auger upgrading working width 9 54 m m m 960 BR 640 R 160R 960 R 960 960 L 960 160 L 640 L 960 BL 960 L 960 960 R 960 640 640 L 640 640 R...

Page 334: ...E 11 20 Auger upgrading working width 10 18 m 160 L 640 L 960 BL 960 L 960 160 L 640 L 960 BL 960 L 960 960 BR 640 R 160R 960 R 960 960 BR 640 R 160R 960 R 960 m m...

Page 335: ...E 11 21 Auger upgrading working width 10 82 m m m 960 BR 640 R 160R 960 R 960 160 L 640 L 960 BL 960 L 960 160 L 640 L 960 BL 960 L 960 320 L 320 960 BR 640 R 160R 960 R 960 320 R 320...

Page 336: ...E 11 22 Auger upgrading working width 11 46 m m m 960 BR 640 R 160R 960 R 960 160 L 640 L 960 BL 960 L 960 160 L 640 L 960 BL 960 L 960 960 BR 640 R 160R 960 R 960 640 640 L 640 640 R...

Page 337: ...11 23 Auger upgrading working width 12 10 m m m 960 BR 640 R 160R 960 R 960 160 L 640 L 960 BL 960 L 960 160 L 640 L 960 BL 960 L 960 320 L 320 960 BR 640 R 160R 960 R 960 320 R 320 640 640 L 640 640...

Page 338: ...11 24 Auger upgrading working width 12 74 m 960 BR 640 R 160R 960 R 960 m m 160 L 640 L 960 BL 960 L 960 960 L 960 160 L 640 L 960 BL 960 L 960 320 L 320 960 BR 640 R 160R 960 R 960 960 R 960 320 R 32...

Page 339: ...E 11 25 3 3 Mounting the auger brace 11 8 12 20 19 15 14 26 16 18 26 21 1 10 13 17 27 23 1 2 3 4 5 6 7 18 22 23 24 25...

Page 340: ...ace bracket 8 and secure with the retain ing pin 11 Secure the retaining pins 11 with a split pin 12 A The first brace set must be set in the rear bore If the operating width necessitates a second bra...

Page 341: ...ust the length of the adjustment rod here The rotational direc tion for extending or shortening the adjustment rod is determined by the left hand thread L or right hand thread R A A cord which aligns...

Page 342: ...E 11 28 m In the case of large working widths with double braces the procedure must be carried out on both lower pairs of braces 30 31 and both upper pairs of braces 32 33 30 31 33 32...

Page 343: ...creed retraction Mount the left right material shafts on the auger box with the relevant as sembly parts 1 A If a terminal bearing is mounted for the ex isting auger width the adapter plate 2 also has...

Page 344: ...e hopper scrapers 1 must be adjusted on both hopper lids Loosen the mounting screws 2 Set a gap of 6 mm across the whole length of the scraper Retighten the mounting screws 2 properly f Risk of injury...

Page 345: ...t be adjusted to the prevailing paving conditions e g positive or negative crowning etc Loosen screw 2 and remove screws 3 Adjust guide plate to the required size basic setting 25mm Retighten the moun...

Page 346: ...between the auger and screed Loosen the four mounting screws 1 Remove the screws and move the ve hicle forwards The crossbeam remains in its position on slide rails now tighten the screws 1 back down...

Page 347: ...are provided for mounting on the sensor s retaining plate A The digital slope controller must be mounted in such a way that the marking arrow on the housing points in the direction of travel A The an...

Page 348: ...d Tighten the pin 2 so that the sensor arm is just still able to swivel A The sensor arm can be secured on the side board with the lock 3 5 3 Mounting the grade control system Insert the grade control...

Page 349: ...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 fol lowing the adjustment work A All...

Page 350: ...with the sensor arm 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 o...

Page 351: ...can be mounted at the 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...

Page 352: ...et directly at the existing bores or as described in the following to secure it to the crossbeam using clamp ing plates A The front bracket is mounted directly be hind the traction point the rear brac...

Page 353: ...s 45 chamfer must point upwards Then slide the two swivel arms 3 onto the tube of the big ski bracket A The rear swivel arm is positioned rotat ed by 180 on the big ski bracket Slide a fixing ring 4 f...

Page 354: ...centre element together with the rear swivel arm until the front sliding part 4 can be pushed onto the front swivel arm from above Then secure the rear sliding part with a fixing ring 5 and the releva...

Page 355: ...th the 9 m and 13 m versions A Structure of the 9 m version Extension part at the front rear each Structure of the 13 m version Two extension parts at the front rear each Place the extension module 1...

Page 356: ...nce away from it A Extendable sensor brackets 1 are mounted in the two outer positions the normal sensor bracket 2 is mounted in the centre Place the sliding bracket 3 over the corresponding big ski e...

Page 357: ...bles the two outer sensors to be swivelled during paving for diverse requirements e g cornering By loosening the star handle bolts 5 the length of the extension arm can be adjusted The sensor bracket...

Page 358: ...ed to initially mount the distributor box 1 on the mounting plate 2 A The input connector always points in the direction of travel Then mount the mounting plate on one of the two sliding brackets 4 on...

Page 359: ...diagram A The three sensors are connected to the distributor box and the distributor to the ma chine according to the following scheme Sensors Front 1 Centre 2 Rear 3 Distributor box 4 Machine interf...

Page 360: ...ending the screed Push the levelling piece 1 in the extension pipe 2 Tighten the clamping bolts at the extension pipe Push the extension 3 into the levelling piece 1 Secure properly with wing nuts 4 I...

Page 361: ...height sensing unit so that the sensing arm 13 lies on the refer ence wire 14 in the middle A Tighten the reference wire with the rope tensioner if too loose Connect the corresponding cable lead with...

Page 362: ...E 11 48 6 Automatic steering unit 20 2 1 3 6 7 8 4 12 9 10 5 11 17 18 15 16 14 21 13 19...

Page 363: ...xtension 5 onto the connection tube and fix in the same way Fix support wheel 6 in a suitable position using the corresponding assembly parts Heed vertical alignment Insert tube 7 to the required leng...

Page 364: ...A The distance between the sensor and reference cable should be 350 mm A All assembly parts must be mounted and tightened properly to ensure safe and pre cise operation of the automatic steering unit...

Page 365: ...e operating panel as necessary The automatic steering unit can be overridden by actuating the steering potentiometer The switch 1 is used to set the sens ing side Right Automatic steering unit on the...

Page 366: ...E 11 52 7 Emergency stop during feeder operation A If the function is not in use the bridge connector must be fitted to the corre sponding socket as otherwise the travel drive is blocked 1...

Page 367: ...sor to the centre socket TEMP of the signal converter 4 A The signal converter 4 should be positioned above the centre hose guide of the screed with the related magnetic holders Install the connection...

Page 368: ...e 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 re...

Page 369: ...ket is placed in the open hopper and secured in position It is used to take larger volumes of material provided by a feeder m The material bucket may only be used in the following combinations MH2500...

Page 370: ...ap 2 t Swivelling side flaps 3 t Maintenance door 4 t Reflector plate for feeder clearance sensor 5 t Reflector plate extension pipe for operation on the side 6 t Fixture for paver option extraction s...

Page 371: ...E 11 57 Technical data Dimensions bucket MH2500 short version 3700 2185 1395 1645 3700 2550 1425 2185 1895...

Page 372: ...E 11 58 Dimensions bucket MH2550 long version 3690 2070 1320 1470 3690 3020 2070 1930 3000...

Page 373: ...ts Volume Bucket MH2500 short version approx 1 2t Bucket MH2550 long version approx 1 7t Bucket MH2500 short version approx 10 9 m3 24 0t approx 10 0m3 22 0t OFFSET Bucket MH2550 long version approx 1...

Page 374: ...ger of injuries Never remove any warnings or information signs from the vehicle Damaged or lost warning or information signs must be replaced immediately Make yourself familiar with the meaning and po...

Page 375: ...itted at these points No Pictogram Meaning C Warning hot surface risk of burning Hot surfaces can cause severe injuries Keep your hands at a safe distance from the danger area Use protective clothing...

Page 376: ...E 11 62 11 4 Instructive symbols prohibitive symbols warning symbols No Pictogram Meaning E Do not open hazard...

Page 377: ...oads positive fit force connection diagonal lashing etc in accordance with the specific transport vehicle m The low loader must have the necessary number of lashing points with a lashing strength of L...

Page 378: ...th the stated values for permitted lashing force and load rating m Always tighten the lashing chains as stated by the manufacturer m Tighten the lashing straps as tight as possible m Lashing equipment...

Page 379: ...E 11 65 Lashing 1 2...

Page 380: ...the bucket and on the low load trailer Fasten the lashing straps as shown A Fasten the lashing straps diagonally to the bucket and to the lashing points on the low load trailer A Use non slip mats at...

Page 381: ...E 11 67 Loading with the crane MH2500 A 1 2 3...

Page 382: ...E 11 68 Loading with the crane MH2550 1 2 3 B...

Page 383: ...s 1 2 A A Loading example bucket MH2500 short version m The max permissible attachment point load at the attachment points is 44kN A B Loading example bucket MH2550 long version m The max permissible...

Page 384: ...E 11 70 Lash the bucket in the paver 1 4 3 2...

Page 385: ...and straps must be secured to prevent them working loose and falling down unintentionally m Clean bucket and paver hopper before inserting the bucket remove material resi dues Removing adhering mater...

Page 386: ...E 11 72 Mode of operation 2 1 1 7 A B 5 4 6 3 6 8 9 10...

Page 387: ...pe extension with the corresponding clamping levers 7 m When the reflector plate is fitted to the side this increases the basic width of the ve hicle Note the danger area A The magnetic foil included...

Page 388: ...If the bucket is inserted in a paver during cleaning the paver must be switched off and secured to prevent it being switched on again Spray all surfaces coming into contact with asphalt material with...

Page 389: ...et remote control to holder 1 Connect plug 2 with the remote control m If the remote control is not implemented the plug 2 has to be set to the bridge socket 2a Connect the connection lead 3 of the si...

Page 390: ...de control system 6 External levelling system 7 24 volt consumers e g additional lighting 8 A When using an external levelling system this must be logged in using the remote con trol menu A Always sea...

Page 391: ...Ensure that maintenance and repair work is always only carried out by trained specialist staff All maintenance repair and cleaning work should only be carried out with the engine turned off Remove ig...

Page 392: ...ces Surfaces including those behind covering parts together with combustion fuels from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot pa...

Page 393: ...F 28 1 F 28 Maintenance review 1 Maintenance review 74 40 81 90 100 31 60 F52 F50 T i e r 3 S t a g e I I I a T i e r 4 i S t a g e I I I b F54 T i e r 4 F S t a g e I V...

Page 394: ...lly 2000 every 2 years 4000 every 3 years 5000 20000 If necessary Conveyor F31 q q q Auger F40 q q q q q q q Engine Tier3 Stage IIIa F50 q q q q q q Engine Tier4i Stage IIIb F52 q q q q q q q Engine T...

Page 395: ...F 31 1 F 31 Maintenance conveyor 1 Maintenance conveyor...

Page 396: ...ransport close both halves of the hopper and fit the cor responding hopper transport safeguards When the vehicle is parked and during maintenance and transport raise the screen and fit the correspondi...

Page 397: ...f necessary 1 q Conveyor chain Check tightness q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Conveyor drive drive chains Check chain tightness q Conveyor drive drive chains Adjust...

Page 398: ...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...

Page 399: ...g the chains would lead to the destruction of the drive wheels m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyo...

Page 400: ...has been set properly the chain must be able to move freely approx 10 15 mm To re tension the chains Unfasten mounting screws A and lock nut B slightly Use the tensioning screw C to set the required...

Page 401: ...eflectors with new bolts A At the latest the conveyor plates B must be replaced when the wear limit of 5 mm in the rear area beneath the chain has been reached m If components have to be replaced as a...

Page 402: ...F 31 8...

Page 403: ...F 40 1 F 40 Maintenance auger assembly 1 Maintenance auger assembly...

Page 404: ...move the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts togethe...

Page 405: ...lanetary gear Check oil level q Auger planetary gear Top up oil g q Auger planetary gear Change oil 3 q Auger drive chains Check tension q Auger drive chains Adjust tension 4 q Auger box Check oil lev...

Page 406: ...If necessary 6 g Gearbox bolts Check tightening q Gearbox bolts Tighten to correct torque 7 g g Outer bearing bolts Check tightening q Outer bearing bolts Tighten to correct torque 8 q Auger blade Ch...

Page 407: ...any bitumen res idues which may have entered and to supply the bearings with fresh grease when warm A If the auger is extended the outer rings should be loosened slightly when initially greasing the o...

Page 408: ...oil into the filler bore at B until the oil level has reached the lower edge of the inspec tion bore A Screw the filler B and inspection screws A back in To change oil A The oil should be changed when...

Page 409: ...augers outer circumference should be 10 mm f Risk of injury due to sharp edged parts To re tension the chains Release the mounting screws A Set the chain tension correctly using the threaded pins B Ti...

Page 410: ...hange oil A The oil should be changed when at oper ating temperature Place a suitable collecting container under the auger box Loosen bolts D from the circumfer ence of the worm shaft flange A The oil...

Page 411: ...ing rings 5 A After reaching operating temperature check the gearbox for leaks m In case of visible leaks e g between the flange surfaces A of the gearbox re placement of the seals and sealing rings i...

Page 412: ...box bolts must be checked A Please check which gear version is used in your vehicle Tighten to the following torques if nec essary A 86 Nm B 83 Nm C 49 Nm D 49 Nm E 86 Nm m Check that each bolt has at...

Page 413: ...ng the running in period the tightening torques of the outer auger bearing mounting screws must be checked Tighten to the following torques if nec essary F 210 Nm m If the auger s working width is cha...

Page 414: ...ed and the blades B have to be replaced Remove the bolts C washers D nuts E and auger blade B f Risk of injury due to sharp edged parts m Auger blades must be installed play free the contact surfaces...

Page 415: ...enance engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work a...

Page 416: ...move the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts togethe...

Page 417: ...the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel syste...

Page 418: ...lter Air filter cartridge Replace 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system...

Page 419: ...0 50 100 250 500 annually 1000 annually 2000 every 2 years If necessary 6 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt Maintenance...

Page 420: ...not run dry and time consuming venting bleeding can therefore be avoided For filling in the fuel Unscrew cap A Fill in fuel through the filling port until the required fill lever is achieved Replace t...

Page 421: ...in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use dipstick to check level again Oil change A The oil drain screw is accessed via t...

Page 422: ...optional asphalt fume control system there is a drainage hose behind the left side flap Place the end of the oil drain port hose E1 in the collection container Remove the screw cap with a wrench and a...

Page 423: ...ch or filter strap and unscrew it Clean the contact surface Apply light coating of oil to the gasket on the new filter and fill filter with oil before installing it Tighten filter by hand A After inst...

Page 424: ...leting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two fil ters Prefilter with water separator C Main filter D Prefilter draining of water A Drain t...

Page 425: ...lunger is now pressed out via the spring Pump until a very high resistance is perceptible and pumping can only be carried out very slowly Now continue pumping a few more times The return line must be...

Page 426: ...ty dust collector Empty the dust removal valve A on the air filter housing by compressing the discharge slot Remove any baked on dust by press ing together the upper valve section A Clean the dust rem...

Page 427: ...r Open the air filter housing B at the clips C Move filter element D to the side a lit tle and then pull it out of the housing Pull out the safety element E and check for signs of damage A Replace the...

Page 428: ...m is under pressure When it is opened there is danger of scalding m Use only approved coolants A Observe the instructions in the chapter entitled Operating substances Remove the drain screw B on the r...

Page 429: ...y remove leaves dust or sand from the radiator A Observe engine s operating instructions Checking coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentrat...

Page 430: ...transverse cracks in the belt are acceptable m In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces belt re placement is necessary A Observe engine...

Page 431: ...enance engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work a...

Page 432: ...move the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts togethe...

Page 433: ...n the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel syst...

Page 434: ...er Air filter cartridge Clean 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 sy...

Page 435: ...If necessary 6 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt 7 q Crankshaft ventilation filter Replace filter element 8 q Exhaust...

Page 436: ...avoided m Observe the instructions for fuel recom mendations and the specification in the chapter on Lubricants and operating sub stances For filling in the fuel Unscrew cap A Fill in fuel through the...

Page 437: ...in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use dipstick to check level again Oil change A The oil drain screw is accessed via t...

Page 438: ...optional asphalt fume control system there is a drainage hose behind the left side flap Place the end of the oil drain port hose E1 in the collection container Remove the screw cap with a wrench and a...

Page 439: ...ch or filter strap and unscrew it Clean the contact surface Apply light coating of oil to the gasket on the new filter and fill filter with oil before installing it Tighten filter by hand A After inst...

Page 440: ...leting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two fil ters Prefilter with water separator C Main filter D Prefilter draining of water A Drain t...

Page 441: ...lunger is now pressed out via the spring Pump until a very high resistance is perceptible and pumping can only be carried out very slowly Now continue pumping a few more times The return line must be...

Page 442: ...by compressing the discharge slot Remove any baked on dust by press ing together the upper valve section Open the collector housing B at the clips C and remove dust accumula tions Properly reposition...

Page 443: ...A Clean the filter element F and replace after one year at the latest Blow out with dry pressure air max 5 bar from inside outor tap it in case of emergency only A Do not damage cartridge when doing s...

Page 444: ...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...

Page 445: ...y remove leaves dust or sand from the radiator A Observe engine s operating instructions Checking coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentrat...

Page 446: ...transverse cracks in the belt are acceptable m In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces belt re placement is necessary A Observe engine...

Page 447: ...the filter cover with warm soapy water E and dry it with compressed air f Wear protective goggles when using working with compressed air Never blow compressed air towards other peo ple f Use personal...

Page 448: ...filter must be dismantled for full inspection A detailed description can be found in the operating manual for the engine m All safety instructions can be found in the operating manual for the engine...

Page 449: ...enance engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work a...

Page 450: ...move the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts togethe...

Page 451: ...Clean the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel...

Page 452: ...filter Air filter cartridge Clean 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 coolin...

Page 453: ...filling level q AdBlue DEF tank Top up AdBlue DEF q q AdBlue DEF tank Replace suction filter q AdBlue DEF tank Check tank cover q AdBlue DEF tank Clean tank cover q AdBlue DEF dosing unit Inspection...

Page 454: ...wenn erforderlich 7 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt 8 q Crankshaft ventilation filter Replace filter element 9 q Exha...

Page 455: ...k of combustion from static electricity than earlier grades of die sel that contained more sulphur An explosion or combus tion can cause severe to fatal injuries When refuelling vehicles always ensure...

Page 456: ...gh the filling port until the required fill lever is achieved Replace the cap A Clean the tank and system Unscrew the drain plug B at the bot tom of the tank and drain into a collec tion pan about 1 l...

Page 457: ...in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use dipstick to check level again Oil change A The oil drain screw is accessed via t...

Page 458: ...optional asphalt fume control system there is a drainage hose behind the left side flap Place the end of the oil drain port hose E1 in the collection container Remove the screw cap with a wrench and a...

Page 459: ...t coating of oil to the gasket on the new filter and fill filter with oil before installing it Lightly oil the filter cartridge gasket and screw under the bracket Once the gasket has contact with the...

Page 460: ...leting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two fil ters Prefilter with water separator C Main filter D Prefilter draining of water A Drain t...

Page 461: ...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...

Page 462: ...o be disman tled first in order to reach the filters Open engine hood remove screws B underneath the shaft Loosen clips C on inside of frame and remove air outlet shaft A After completing the maintena...

Page 463: ...by compressing the discharge slot Remove any baked on dust by press ing together the upper valve section Open the collector housing B at the clips C and remove dust accumula tions Properly reposition...

Page 464: ...ne electronics service display or according to the maintenance interval Open the collector housing B at the clips C Open the collector housing D at the clips E Pull out the filter element F and safe t...

Page 465: ...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...

Page 466: ...y remove leaves dust or sand from the radiator A Observe engine s operating instructions Checking coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentrat...

Page 467: ...70070 The storage temperature for AdBlue DEF is between 5 C and 25 C 23 F and 77 F Store in sealed containers to avoid impurities No direct sunlight It is not advisable to store in a vehicle for longe...

Page 468: ...et AdBlue DEF in your eyes rinse your eyes immediately and thoroughly for at least 15 minutes with clear water Seek medical advice immediately Wash AdBlue DEF off your skin immediately with soap and w...

Page 469: ...fill the AdBlue DEF tank in well ventilated areas Always be careful when opening the AdBlue DEF as this can cause pressure to be released AdBlue DEF may leak as a result Do not inhale the ammonia vap...

Page 470: ...o change the filter the supply lines B at the AdBlue DEF multi head A must be dismantled and the elec trical connection plug C discon nected A Use a suitable container or cloth to take up any leaked r...

Page 471: ...e Pull the head at the same time m Do not pull the connection cable or con nection port Carefully pull the multi head up until the lower part is beneath the tank opening Carefully tilt the lower part...

Page 472: ...24 Filter change s n 003055 Loosen the fastening screw F of the filter Pull the used filter G from the suction pipe Fit the new filter onto the suction pipe and fasten with a new fastening screw F F...

Page 473: ...bout 45 Place the filter side and the tip of the lower part in the tank opening as shown Gradually insert the lower part in the tank opening proceeding carefully m Do not push the parts with force dir...

Page 474: ...the retaining ring E over the fil ter head Tighten the screws D properly Then mount the supply lines B and connect up to the power supply plug C m After installation check correct sealing during a tri...

Page 475: ...g screw F of the filter Pull the used filter G from the suction pipe Fit the new filter onto the suction pipe and fasten with a new fastening screw F A Ensure correct alignment of filter and holders L...

Page 476: ...ush the parts with force directly into the tank opening This will cause damage Position the head in the required align ment Ensure that the two noses I at the flange of the filter head fit in the corr...

Page 477: ...F 54 29 Tighten the screws D properly Then mount the supply lines B and connect up to the power supply plug C m After installation check correct sealing during a trial run B C D...

Page 478: ...cleaned as follows Loosen the retaining tab A and un screw the tank cover B from the tank Put the cover in a vessel filled with wa ter so that the water comes up to half the height of the blue edge la...

Page 479: ...F 54 31 Wipe the gasket with a damp cloth to remove any remaining DEF crystals or dirt Then connect the tank cover with the previously loosened retaining tab and screw onto the tank...

Page 480: ...filter with a click A Use the side of the service tool with the same colour markings as the filter m Depending on their condition the com pensation element and filter must be re placed after they hav...

Page 481: ...transverse cracks in the belt are acceptable m In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces belt re placement is necessary A Observe engine...

Page 482: ...the filter cover with warm soapy water E and dry it with compressed air f Wear protective goggles when using working with compressed air Never blow compressed air towards other peo ple f Use personal...

Page 483: ...hot surfaces During system cleaning the exhaust temperature and the surface temperature of the exhaust system is very hot and can cause severe injuries The exhaust and exhaust com ponents remain hot a...

Page 484: ...F 54 36...

Page 485: ...F 60 1 F 60 Maintenance hydraulic system 1 Maintenance hydraulic system...

Page 486: ...ecure the vehicle to prevent it being switched on again Consult a doctor immediately if injured Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces...

Page 487: ...to lower limit position Stop the engine and remove the ignition key before any maintenance work Secure the vehicle to prevent it being switched on again Let the hydraulic oil cool down A After depress...

Page 488: ...k Top up with oil q Hydraulic oil tank Change oil and clean 2 q Hydraulic oil tank Check maintenance indicator q q Hydraulic oil tank Change and vent the suction re turn flow hydraulic filter q Hydrau...

Page 489: ...up oil q Pump distribution gear Change oil q Pump distribution gear Check bleeder q Pump distribution gear Clean bleeder 5 g q Hydraulic hoses Visual inspection g q Hydraulic system Leak test q Hydra...

Page 490: ...extended the level can fall below the sight glass A The sight glass is located on the side of the tank For filling in the oil Remove cap B Fill in oil through the filler opening until the oil level ri...

Page 491: ...o use a new seal A When using the drainage hose o Unscrew seal cap E Screwing on the oil drainage hose F opens the valve to let the oil drain out Place the end of the hose in the col lecting vessel an...

Page 492: ...r securing screws A and lift off cover Disassemble the removed unit into Cover B Separating plate C Filter D Dirt trap E Clean the filter housing cover sepa rating plate and dirt trap Check the O ring...

Page 493: ...lace a transparent hose H onto the bleed screw ending in a suitable container Start the up drive engine at idle speed Close the bleed screw G as soon as the oil forced through the hose is clear and th...

Page 494: ...cartridge Clean the filter housing Insert the new filter cartridge Replace the seal ring of the filter housing Turn on the filter housing by hand and tighten it using a wrench Start trial operation a...

Page 495: ...ait 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 t...

Page 496: ...F 60 12 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 497: ...ng pinched or buckled points leaks damage or deformation to the hose fittings affecting the sealing function replace ments are not necessary for minor damage to the surface hose coming away from the f...

Page 498: ...ning of the hoses prevents them from chafing on components or on each other components with sharp edges must be covered when installing hydraulic hoses bending radii are not smaller than the permitted...

Page 499: ...th 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...

Page 500: ...the filter then close the non return valve again Replace filter element B and sealing ring C Turn filter element clockwise with the help of carrier straps and at the same time raise it slightly Wait...

Page 501: ...F 74 1 F 74 Maintenance drive units 1 Maintenance drive units...

Page 502: ...ransport close both halves of the hopper and fit the cor responding hopper transport safeguards When the vehicle is parked and during maintenance and transport raise the screen and fit the correspondi...

Page 503: ...1000 annually 2000 every 2 years If necessary 1 q Chain tension Check q Chain tension Adjust q Chains Relieve 2 q Bottom plates Check wear q Bottom plates Replace 3 q Rollers Check for leaks q Roller...

Page 504: ...years If necessary 4 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality q Planetary gear Screw connections Check q Planetary...

Page 505: ...nt safety measures and should only be carried out by a specialist workshop A Your Dynapac customer service will be happy to provide support during maintenance repair and the replacement of wearing par...

Page 506: ...ler wheel thereby increasing wear levels m If the chains are tensioned too tightly this increases wear on the idler wheel and drive unit mounting and also increases wear on track bolts and bushes Chec...

Page 507: ...ain to the idler wheel is as shown in diagram A A Correct if necessary by moving the vehicle a little Insert a measuring rule between the sliding piece C and D of the track to determine the maximum sl...

Page 508: ...nce again as described above A If the tension is too high see section Relieving the chain A Repeat this procedure on both drive units Relieving the chain f The grease in the tensioning element is unde...

Page 509: ...e with the front edge A over the chain links bolt eye B Lubricate the threads and the contact surfaces beneath the bolt heads with a thin film of oil or grease Insert the bolts C into the holes and sc...

Page 510: ...measures when rais ing and securing loads Remove the defective roller Install the new roller using new as sembly parts Tighten the bolts without applying sig nificant torque Tighten the bolts diagonal...

Page 511: ...bore at A until the oil level has reached the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at oper ating temperature m Ensure that no dir...

Page 512: ...re located at the rear of the gearbox Oil inlet B Oil level check C Oil drain D A Carry out the oil level check and oil change as per the description above m When draining using the drain D a small re...

Page 513: ...e firmly seated m Improperly tightened screws may lead to increased wear and to the destruction of components The correct tightening torque for the connecting screws for the gearbox drive unit frame B...

Page 514: ...F 74 14...

Page 515: ...F 81 1 F 81 Maintenance electrical system 1 Maintenance electrical system...

Page 516: ...not remove any protective safeguards Never spray water on electric or electronic components Maintenance work to the electric system should only be carried out by trained specialist staff When equipped...

Page 517: ...ttery acid q Top up with distilled water q Apply grease to battery terminals 2 q Alternator Insulation monitoring check elec tric system is functioning o q Alternator Visual check for pollution or dam...

Page 518: ...must be free of oxide and protected with a special terminal grease m When removing the batteries always first remove the negative terminal en suring that the battery terminals cannot be short circuite...

Page 519: ...very cell if this needs to be topped up only use distilled water m When recharging batteries every cell must be opened i e plugs and or covers must be removed m Only use commercially available automat...

Page 520: ...lated fault The indicator lamp goes out f If the insulation fault indicator lamp already indicates a fault before pressing the test button or if no fault is indicated during the simulation indicator l...

Page 521: ...rnator m The alternator 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 cleane...

Page 522: ...iffer depending on equipment F Function A F1 2 Main fuse 1 50 F1 2 Main fuse 2 50 F1 3 Diesel engine preheating ignition system 125 F1 4 Engine T4F 30 F1 Levelling 10 F2 Brake light 5 F3 Operating pan...

Page 523: ...0 F17 Hazard flashers 10 F18 Operating panel 3 F19 Diagnostic interface control unit display 2 F20 Diagnostic interface engine 2 F21 Power supply slave A11 25 F22 Power supply slave A1 5 F23 Connector...

Page 524: ...ights 10 F36 Windscreen wiper 10 F37 Central lubrication 7 5 F38 Main fuse lighting 25 F39 Left hand parking lights 5 F40 Parking lights right 5 F41 Operating panel illumination 5 F42 Low beam headlig...

Page 525: ...F 81 11 Relays in the engine compartment K Function 0 Engine start...

Page 526: ...nding on equipment K Function 1 Ignition 2 Drive engine start stop 3 Master slave screed controller 4 Engine start 5 Front lighting 6 Rear lighting 7 Auger lighting front 8 Horn 9 Parking light 10 T4F...

Page 527: ...lashers 16 Rotary beacon 17 Seat heating 18 Windscreen wiper 19 Windscreen washer system 20 Reverse buzzer 21 Central lubrication 22 Light in accordance with German Road Traffic Regulations 23 High be...

Page 528: ...F 81 14...

Page 529: ...Maintenance lubricating points 1 Maintenance lubricating points A The information on the lubricating points for the various assemblies is assigned to the specific maintenance descriptions and must be...

Page 530: ...m Interval Maintenance point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Check lubricant tank fill level o q Top up lubricant tank o q Bleed central lubrication system o q...

Page 531: ...of injury due to escaping lubricant as the system operates at high pressures f Ensure that the diesel engine cannot be started when working on the system f Observe safety regulations for handling hyd...

Page 532: ...n a fill level above the MIN mark a on the tank Top up lubricant tank A lubricating nipple b is located on the lubricant tank a for filling purposes Connect the grease gun c enclosed on delivery to th...

Page 533: ...ricant has emerged Check all connections and lines for leaks Check pressure limiting valve m If lubricant emerges at the pressure lim iting valve a this indicates a malfunc tion in the system The cons...

Page 534: ...Remove the lubrication line a and install a normal lubricating nipple b Connect the grease gun c en closed on delivery to the lubricating nipple b Operate the grease gun until the lu bricant visibly...

Page 535: ...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 536: ...F 90 8...

Page 537: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping...

Page 538: ...00 1000 annually 2000 every 2 years If necessary 1 q General visual inspection 2 regularly Check that the bolts and nuts fit firmly 3 q q Inspection by an expert 4 q Cleaning 4 q Cleaning sensors 5 q...

Page 539: ...they fit firmly retighten them if necessary A The spare parts catalogue states the special torques at the corresponding parts A For the necessary standard torques please refer to the section Bolts tor...

Page 540: ...sher screed and optional gas or electric system checked by a trained spe cialist when required according to the operating conditions and the nature of application however at least once a year check th...

Page 541: ...lube points acc to specification Clean the vehicle with water after laying mineral aggregates lean mixed concrete etc m Do not spray bearing points electrical or electronic components with water Remo...

Page 542: ...rts can cause severe or fatal injuries Do not enter the danger zone Do not reach into rotating or conveying parts Only wear close fitting clothing Comply with the warning and information signs on the...

Page 543: ...F 100 7 5 3 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions m Daily cleaning with a dry lint free cloth...

Page 544: ...ved batteries every 2 months Protect all bare metal components e g piston rods on hydraulic cylinders with a suitable corrosion inhibitor If it is not possible to park the vehicle is an enclosed build...

Page 545: ...impaired Corresponding preventive treatment must be applied to the machine This should be repeated at appropriate intervals when necessary All possible harmful influences must be taken into considera...

Page 546: ...sposal must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electro...

Page 547: ...1 6 4 1 6 7 7 1 9 M6 8 2 1 12 3 14 3 7 8 1 9 11 2 7 13 3 3 M8 20 5 28 7 1 34 8 19 4 7 26 6 6 31 7 9 M10 41 10 57 14 70 17 37 9 52 13 62 16 M12 73 18 97 24 120 30 63 16 89 22 107 27 M14 115 29 154 39 1...

Page 548: ...5 M8x1 21 7 5 4 30 6 7 6 36 7 9 2 19 5 4 9 27 4 6 8 32 8 8 2 M10x1 25 42 1 10 5 59 2 15 71 17 8 37 7 9 4 53 13 63 6 15 9 M12x1 25 75 7 18 9 106 2 26 127 31 9 67 2 16 8 94 5 24 113 28 3 M14x1 5 119 29...

Page 549: ...s listed below or comparable qualities of well known brands m Only use containers which are clean on inside and outside for filling oil or fuel A Note capacities see section Capacities m Incorrect oil...

Page 550: ...F 114 2 2 4 7 5 6 6 3 1 8...

Page 551: ...tres Tier 4F 4 Hydraulic oil reservoir Hydraulic oil 200 litres 5 Pump distribution gear Gearbox oil 7 0 litres 6 Planetary gear drive unit Gearbox oil 3 8 litres SD2500C CS 5 0 litres SD2550C CS 7 Pl...

Page 552: ...cohol m Diesel fuel contaminated with water or dirt can cause serious damage to the fuel sys tem Keep fuel and fuel system free of water and impurities m Observe the instructions for fuel recommendati...

Page 553: ...AGIP Chevron Caltex Fuchs Mobil Shell Finke Hydraulic 100 Rando HDZ 46 Rando HDZ 46 Tellus Oil S2 V46 Tellus S2 VX46 Aviaticon HV 46 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 400 Titan AT...

Page 554: ...Auger box A recommended 2 9 Grease A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Omala S4WE460 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Chevron Paver Grease Gadus S5 T460 1 5 High Te...

Page 555: ...id is prescribed pursuant to ISO 22241 1 respectively DIN 70070 For vehicles operating in North America the use of a DEF fluid with API approval is urgently recommended m Observe the instructions for...

Page 556: ...hen changing from mineral oil pressure fluids to biodegradable pressure fluids please contact our factory advisory service Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 Shell Naturelle...

Page 557: ......

Page 558: ...www dynapac com...

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