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Fayat DYNAPAC F2500W, Operation & Maintenance Instructions Manual, Page: 274 / 340

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Fayat DYNAPAC F2500W Operation & Maintenance Instructions Manual Download Page 274

F 60 2

Danger due to hydraulic oil

Hydraulic oil under high pressure can cause severe 
to fatal injuries!
- Only competent staff should work on the hydraulic 

system!

- Any hydraulic hoses that are cracked or soaked through 

must be replaced immediately.

- Depressurise the hydraulic system.
- Lower screed and open hopper.
- Stop the engine and remove the ignition key before any 

maintenance work.

- Secure the vehicle to prevent it being switched on again.
- Consult a doctor immediately if injured.
- Comply with all further information in these instructions 

and in the safety manual.

Hot surfaces!

Surfaces including those behind covering parts, together 
with combustion gases from the engine or screed heater 
can be very hot and cause injuries!
- Wear your personal safety gear.
- Do not touch hot parts of the vehicle.
- Only perform maintenance and repair work after the 

vehicle has cooled down.

- Comply with all further information in these instructions 

and in the safety manual.

WARNING

CAUTION

Summary of Contents for DYNAPAC F2500W

Page 1: ...OPERATION MAINTENANCE Paver Finisher F2500W F2500WS Type 896 05 0423 4812311885 ...

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

Page 3: ...tion 1 B Vehicle description 1 1 Application 1 2 Description of assemblies and functions 2 2 1 Vehicle 3 Construction 3 3 Danger zones 7 4 Safety devices 8 5 Technical data standard configuration 10 5 1 Dimensions all dimensions in mm 10 5 2 Allowed angle of rise and slope 11 5 3 Permissible approach angle 11 5 4 Turning circle 11 5 5 Weights F2500WS all weights in t 12 5 6 Performance data F2500W...

Page 4: ...2 2 1 Preparations 2 3 Securing the load 4 3 1 Prepare the low bed trailer 4 3 2 Driving onto the low bed trailer 5 3 3 Lashing equipment 6 3 4 Loading 7 3 5 Preparing the vehicle 8 4 Securing the load 9 4 1 Securing at the front and at the sides 9 Step 1 fasten lashing chains at the front 9 Step 2 fasten lashing chains at the side 9 4 2 Securing at the rear screed with side board 10 4 3 Securing ...

Page 5: ... indicator 19 Auger lighting o 20 Engine compartment lighting o 20 LED working light o 21 500 watt spotlight o 22 Camera o 22 Auger height adjustment ratchet o 23 Auger height displays 23 Sensor rod sensor rod extension 24 Manual separator fluid spray o 26 Separator fluid spraying system o 27 Conveyor limit switches PLC version 28 Conveyor limit switches conventional version 29 Ultrasonic auger li...

Page 6: ...13 Oil pressure indicator lamp for the diesel engine 3 13 1 2 Preparation for transportation 15 Driving and stopping the paver finisher 17 1 3 Preparations for paving 18 Separator fluid 18 Screed heater system 18 Direction marks 19 Loading conveying material 21 1 4 Starting for paving 23 1 5 Checks during paving 24 Paver function 24 Quality of the layer 24 1 6 Paving with screed control at paver f...

Page 7: ...er upgrading working width 3 14 m 10 Auger upgrading working width 3 78 m 10 Auger upgrading working width 4 42 m 10 Auger upgrading working width 5 06 m 11 Auger upgrading working width 5 70 m 11 3 3 Material shaft hinged 12 3 4 Hopper scraper 13 4 Offsetting the screed 14 5 Levelling 15 5 1 Slope controller 15 5 2 Fitting the height sensing device 16 5 3 Mounting the grade control system 16 5 4 ...

Page 8: ...1 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 tightening 6 10 Mounting screws Outer auger bearing Check tightening 7 11 Auger blade 8 12 F51 Maintenance engine assembly Tier 3 o 1 1 Maintenance engine assembly 1 1 1 Maintenance intervals 3 1 2 Po...

Page 9: ... 1 1 Maintenance intervals 3 1 2 Points of maintenance 5 Planetary gear 1 5 Drive wheels 2 6 Replacing dismantling and installing the wheels 7 Air pressure table 9 Pressures for equipment Bandag on Michelin XHA 9 Pressures for equipment Michelin XGC Techking ETGC 9 Lubrication points 3 11 Steering 11 F82 Maintenance electrical system 1 1 Maintenance electrical system 1 1 1 Maintenance intervals 3 ...

Page 10: ...paver finisher 7 6 1 Shutdowns for up to 6 months 7 6 2 Shutdowns lasting from 6 months to 1 year 7 6 3 Recommissioning the machine 7 7 Environmental protection disposal 8 7 1 Environmental protection 8 7 2 Disposal 8 8 Bolts torques 9 8 1 Standard metric threads strength class 8 8 10 9 12 9 9 8 2 Fine metric threads strength class 8 8 10 9 12 9 10 F111 Lubricants and operating substances 1 1 Lubr...

Page 11: ...ample 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 vehicle option is used In the interest of continued development the manufacturer reserves the right to make changes to the vehicle which will not however change the essential features of the type of vehicl...

Page 12: ...nsible for compliance with the resulting regulations and measures A The following warnings prohibitive symbols and instructive symbols indicate dangers for persons the vehicle and the environment due to residual risks when operating the vehicle A Failure to observe this information prohibitions and instructions can result in life threatening injuries A The Guidelines for the Correct Use and Applic...

Page 13: ...result in fatal or se vere injuries unless the corresponding actions are taken Caution Indication of a possible danger that result in moderate or mi nor injuries unless the corresponding actions are taken Note Indication of a possible drawback unless the corresponding actions are taken e g unwanted conditions or consequences can occur 1 3 Other supplementary information Other information and impor...

Page 14: ...itched off Warning on dangerous electrical voltage m All maintenance and repair work on the screed s electrical system must always be carried out by an electrician Warning on suspended loads m Never stand under suspended loads Warning on danger of crushing m There is a danger of crushing when certain components are operat ed or certain functions or vehicle movements are carried out Always make sur...

Page 15: ...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 16: ...start engine drive Maintenance and repair work may only be carried out with the diesel engine shut down Spraying with water is prohibited Extinguishing with water is prohibited Unauthorised maintenance is prohibited Only qualified experts may conduct maintenance A Consult the Dynapac Service Department Fire naked flames and smoking are prohibited Do not switch ...

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

Page 18: ... Hydraulic oil Diesel fuel Coolant Cleaning liquids must not get into the soil or sewer system during cleaning maintenance and repair work Substances must be caught stored transported and brought to pro fessional disposal sites in suitable containers Environmentally hazardous substance 1 8 Fire prevention A Locally applicable regulations may require suitable extinguishing agents to be carried on t...

Page 19: ...oc umentation A For example the maintenance instructions of the engine manufac turer m Description depiction applicable when equipped with gas heater m Description depiction applicable when equipped with electric heat er t Used to indicate standard equipment o Used to indicate optional equipment ...

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

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

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

Page 23: ...he 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 user is considered to be the person who in accordance with existing contractual agreements between the owner and the user of the paver finisher is charged with the observance of the operating duties...

Page 24: ...A 2 ...

Page 25: ...pplication The Dynapac paver finisher 6 is a wheeled paver finisher which is used for paving bituminous mixed material roll down or lean mixed concrete track laying ballast and unbound mineral aggregates for foundations for paving ...

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

Page 27: ...able hydrostatic travel drive allows the speed of the paver fin isher to be matched toall work conditions The operation of 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 extra equipment option is available o Automatic levelling slope control system o ...

Page 28: ...ver finisher drives via the attached distribution gear and its auxiliary drive shafts Travel drive The continuously adjustable travel drive pumps are connected to the travel drive engines by means of high pressure hydraulic hoses These oil engines drive the drive wheels via planetary gears The multi stage planetary gear covers the various driving ranges and the braking function Steering system ope...

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

Page 30: ...de control system Crossbeams screed lifting device The screed lifting device is used to lift the screed during transportation The screed s approach angle can be changed using the eccentric adjustment facility on the crossbeam Depending on the paving condition requirements the crossbeam can be moved backwards or forwards This adjustment enlarges the material space between the au ger and screed Auto...

Page 31: ...le 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 in the danger zone before switching the vehicle on or starting it moving The vehicle operator must ensure that no one is in the danger zone Sound the horn before driving away Comply with all further...

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

Page 33: ... intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation d r a u g e f a s t r o p s n a r t r e p p o H 1 2 Crossbeam lock mechanical 3 Main switch 4 Emergency stop button 5 Horn 6 Ignition key s t h g i L 7 8 Protective roof latch o 9 Fire extinguisher o 10 Screed warning light o s g n i r e v o c s p a l f l a r e t a l s ...

Page 34: ...l data standard configuration 5 1 Dimensions all dimensions in mm A For screed technical data refer to the screed operating instructions R65 6380 2240 6100 1850 2845 3100 3900 3250 3140 2550 2055 302 495 2125 500 425 ...

Page 35: ...n gradient slope lateral inclina tion which is above the specified limit value please consult the customer service de partment for your vehicle 5 3 Permissible approach angle 5 4 Turning circle Internal turning circle 2 47 m External turning circle 6 06 m max 15 max 15 max 15 max 15 max 17 max 16 ...

Page 36: ...d the screed attachments see the operating instruc tions for the screed Paver finisher without screed approx 13 2 14 2 Paver finisher with screed 9 approx 16 5 17 5 With extension parts for max working width additionally max With filled hopper Additionally max approx 13 0 ...

Page 37: ...idth with cut off shoe Fully variable hydr adjustment up to Maximum paving width with extension parts V5100TV 2 55 2 00 5 10 6 60 m Transport speed 0 15 km h Transport speed reversing 0 15 km h Operating speed 3 30 m min Paving height 100 300 mm Max grain size 40 mm Theoretical paving performance 650 t h ...

Page 38: ...g wheels 4 x 560 300 390 elastic solid rubber tyres e k a r b e v i r d l e v a r T s e k a r B hydraulic parking brake 3 7 1 C 7 6 B S Q s n i m m u C e p y t e k a M l e s e i d r e d n i l y c 6 n o i s r e V engine water cooled Performance 129 kW 175 hp at 2200 rpm Pollutant emissions in accordance with EU 3A Tier 3 Fuel consumption full load Fuel consumption 2 3 load 19 9 l h 29 8 l h Fuel ta...

Page 39: ...et height centre 575 mm Minimum inlet height outside 585 mm Hopper width outside open 3 460 mm Type Dual conveyor belt Width 2 x 580mm Conveyors Left and right auger separately controllable Drive Hydrostatic 0 1 Conveying volume controller Fully automatic via configurable switching points Auger diameter 380 mm Drive Hydrostatic external drive fully variable regardless of conveyor Auger halves can ...

Page 40: ...standstill Screed stop Screed stop with pretensioning max pressure 40 bar During paving Screed charging Screed relieving max pressure 40 bar Levelling system Mechanical grade control Optional systems with and without slope control On board voltage 24 V Batteries 2 x 12 V 88 Ah Operation 5 C 45 C Storage 5 C 45 C ...

Page 41: ...er of injuries Never remove any warnings or information signs from the vehicle Damaged or lost warning or information signs must be replaced immediately Make yourself familiar with the meaning and position of the warning and information signs Comply with all further information in these instructions and in the safety manual CAUTION ...

Page 42: ...B 18 22 21 22 21 22 21 11 4 5 72 6 52 51 50 2 1 26 27 28 29 25 3 32 31 30 3 54 20 24 60 8 22 22 53 14 6 52 23 15 ...

Page 43: ...B 19 71 70 41 42 xxxxxxxxxxxxxxxxx 9 73 9 ...

Page 44: ...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 se vere or fatal injuries Switch the engine off and remove the ignition key 3 Warning Danger of crushing Crushing points can cause severe or fatal injuries Maintain a safe distance from the danger area 4 Warning Hot surface Risk of ...

Page 45: ...er from incorrect towing Vehicle movements can cause severe or fatal injuries The traction system brake must be released before towing Always observe the operating instructions 9 Caution Possible collision of parts The ratchet lever must always be swivelled in Always observe the operating instructions 11 Warning Danger from running engine If the drive engine is left running this can cause severe o...

Page 46: ...ed 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 be carried out to the starter batteries Comply with the maintenance instructions 15 Warning Possible damage to the engine electronics After turning the engine off the on board voltage may not be swi...

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

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

Page 49: ...B 25 No Pictogram Meaning 33 Tamper speed adjuster Position of the speed adjuster 34 Vibration speed adjuster Position of the speed adjuster ...

Page 50: ...e 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 batteries 54 First aid kit ...

Page 51: ...mmation Avoid contact with the human body also avoid inhaling the vapours and seek med ical advice if feeling unwell N Environmentally hazardous sub stance May cause immediate or delayed danger to the eco system when released into the environment Do not release into the sewage system ground or environment depending on hazard potential Comply with special disposal regulations Diesel fuel complies w...

Page 52: ...t enter or work under screed only secured with crossbeam lock for transportation 71 Attention danger of high voltage in vehicle electrical system Disconnect batteries and electronics dur ing welding work or when charging the batteries or use a service watchdog D978000024 in accordance with the cor responding instruction manual 72 Attention Only use approved radiator anti freeze Never mix different...

Page 53: ...B 29 No Pictogram Meaning 73 Overview Tyre pressure working width speed preselection 73 Overview Tyre pressure working width speed preselection ...

Page 54: ...iption 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 total weight in kg 7 Maximum permitted axle load kg axle 1 8 Maximum permitted axle load kg axle 2 9 Maximum permitted axle load kg axle 3 10 Rated performance in kW 1 2 4 5 7 9 3 6 10 8 ...

Page 55: ...B 31 6 8 Explanation of 17 digit PIN serial number A Manufacturer B Family Model C Code letter F Serial number 10002014JHC002076 A B C F ...

Page 56: ...gine type plate 1 is affixed on top of the engine The type plate states the engine type serial number and engine data Please state the engine number of the engine when ordering spare parts See also operating instructions for the engine ...

Page 57: ...ission level of the paver finisher was measured under free field condi tions according to EN 500 6 2006 and ISO 4872 Sound pressure level at the operator s position at the height of the head LAF dB A Sound capacity level LWA dB A 7 2 Operating conditions during measurement The diesel engine was running at maximum speed The screed was lowered into working position The tamper and the vibrator were r...

Page 58: ...ents of the EMC Directive 2004 108 EC Interference emission according to DIN EN 13309 35 dB µV m for frequencies of 30 MHz 1GHz measured at a distance of 10 m 45 db µV m for frequencies of 30 MHz 1 GHz measured at a distance of 10 m Interference immunity against electrostatic discharge ESD according to DIN EN 13309 The paver finisher did not show any discernible reactions to contact discharges of ...

Page 59: ...B 35 ...

Page 60: ...B 36 ...

Page 61: ...any 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 When loading via ramps there is a risk that the machine will slip tilt or overturn Drive carefully Keep people away from the danger area Additional stipulations for transportation on public roads m Co...

Page 62: ...aken into consideration when selecting the attachment and loading equipment 2 1 Preparations Prepare the paver finisher for transportation see chapter D Remove all overlaying or loose parts from finisher and screed see also operating instructions for the screed Store these parts in a safe place m Move the auger to the uppermost position to avoid collisions f When screed is operated with the option...

Page 63: ...the hopper lids Engage both hopper transport safeguards Lift the screed Insert the transportation safeguards of the screed Fully extend the levelling cylinder Retract the screed parts until the screed matches the basic width of the paver finisher ...

Page 64: ...ble 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 lashing strength of LC 4 000 daN m The total height and total width must not exceed the maximum permissible dimensions m The ends of lashing chains and straps must be secured to prevent them working loos...

Page 65: ...C 12 5 3 2 Driving onto the low bed trailer f Make sure that there are no persons in the danger area during loading Use the work gear and low engine speeds to drive onto the low bed trailer ...

Page 66: ...force and load rating m Always tighten the lashing chains and straps hand tight 100 150 daN m Lashing equipment must be checked by the user for any signs of damage before use On detecting any signs of damage that affect safety the lashing equipment must be withdrawn from further use Lashing chain permissible lashing force LC 4 000 daN Lashing straps permissible lashing force LC 2 500 daN Shackles ...

Page 67: ...e of gravity of the paver finisher Comply with the following if the paver finisher has to be placed in the front section of the low bed trailer B for load distribution reasons or on account of the length of the paver finisher The paver finisher must stand freely if the push rollers would only touch the goose neck half way up C There must be a positive fit between the paver finisher push rollers an...

Page 68: ...n both sides Position the non slip mats under the screed across the whole width of the vehicle 3 and lower the screed Switch off the paver finisher Attach and secure the protective hood 4 to the operating panel Lower the roof and set the retainers 5 properly on both sides see section entitled Protective roof Fold up the walkway plates of the screed and fasten on both sides using lashing straps 6 a...

Page 69: ...ashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown m The lashing angles should be ß between 6 55 and a between 20 65 Step 2 fasten lashing chains at the side m Diagonal lashing secures the wheeled paver at the front and sides using the lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown ...

Page 70: ...using the lashing points on the paver finisher eyebolts and on the low load trailer Fasten the lashing straps as shown Screw the supplied eyebolts 7 first of all in the holes provided in the arms A Alternatively additional lashing points 8 are provided on the chassis at the rear These should be used preferably for transports without screed without arms 7 8 ...

Page 71: ...finisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing straps as shown Step 2 fasten lashing chains m Diagonal lashing secures the paver finisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown ...

Page 72: ... 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 switch off the engine Remove the key and or cover the operating panel with the protective hood and secure it ...

Page 73: ... the roof Operating panel locked in central position Steering wheel knob 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 Engine hood and lateral flaps closed Rotary beacon swivelled inwards and in lowest setting ...

Page 74: ...ring is compressed or stretched together with roof is raised or lowered Release the pin 1 on both sides of the roof Compress or stretch the spring 2 until the roof has reached the upper or lower limit position Insert the pin 1 in the respective position on both sides of the roof 1 2 ...

Page 75: ... parts from finisher and screed see also operating instructions for the screed Store these parts in a safe place f When screed is operated with the optional gas heating system Remove the gas bottles for the screed heating system Close main shut off valves and bottle valves Turn off the valves on the bottles and remove the gas bottles from the screed Transport the gas bottles on a second vehicle he...

Page 76: ...the hopper lids Engage both hopper transport safeguards Lift the screed Insert the transportation safeguards of the screed Fully extend the levelling cylinder Retract the screed parts until the screed matches the basic width of the paver finisher ...

Page 77: ...Set the fast slow switch to Hare if necessary Turn the preselector to zero Swivel the drive lever to maximum f The vehicle already advances slightly on deflecting the drive lever Adjust required vehicle speed with the preselector To stop the vehicle swivel the drive lever to the middle setting and set the preselector to zero ...

Page 78: ...ty 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 Heed the operating weight of the vehicle Do not enter the danger zone Use only lifting gear that can bear the load Do not leave any load or loose parts on the vehicle Comply with all further informa...

Page 79: ...mounted is located in the area of the front edge 3 of the rear wheel Secure vehicle wherever it is parked up Engage the transport safeguards Remove any attachments and extension parts from the paver finisher and the screed until the basic width has been attained Take off all protruding or loose parts and the gas bottles of the screed heater see chapters E and D Lower the protective roof 1 2 3 ...

Page 80: ...ear 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 finisher remains in a horizontal position during transportation ...

Page 81: ... finisher and the screed until the basic width has been attained A Two high pressure cartridges 2 are lo cated on both of the travel drive pumps 1 The following activities must be carried out to activate the towing function Loosen lock nut 3 half a turn Screw in the bolt 4 until increased re sistance occurs Then screw the bolt a further half turn into the high pressure cartridge Tighten the lock n...

Page 82: ...ve body While pumping next step check that the knob remains in the pressed position Actuate lever 7 of hand pump until sufficient pressure has been built up and traction system brakes have been released m On completion of the towing process re store the initial status m Only release the traction system brakes when the machine is sufficiently secured against accidental rolling or is already properl...

Page 83: ...isher out of the construction area m Only ever tow the shortest distance to the means of transport or the next park ing possibility m The max permissible towing speed is 10 m min In hazardous situations a towing speed of 15 m min is only permitted tem porarily m The max permissible towing eye 9 load is 200 kN 9 ...

Page 84: ...ition 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 place Caution Possible damage to the engine electronics After the drive engine is switched off the on board voltage may not be switched off until after a period 100 seconds main switch Always observe...

Page 85: ...em from tilling over and rolling or sliding away f Roller type jacks must not be moved when under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequately dimensioned and be able to take the corresponding weight f There must not be anyone on the vehicle while it is being lifted f All raising and lowering work must be carried out uniformly with all hy...

Page 86: ...C 12 26 ...

Page 87: ...Always make sure during work that no one is endangered by the vehicle Ensure that all protective covers and hoods are fitted and secured accordingly Immediately rectify damage which as been ascertained Operation must not be continued when the vehicle is defective Do not let any persons ride on the paver finisher or the screed Remove obstacles from the road and the work area Always try to choose a ...

Page 88: ... 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 clothing Comply with the warning and information signs on the vehicle Stop the engine and remove the ignition key for any maintenance work Comply with all further information in these instructions and i...

Page 89: ...ns that can pose a hazard when the diesel engine starts up turning to the side conveying function of auger and conveyor prevent the engine from starting start inhibit when switched on or when set to MANUAL or AUTO These functions must be Straight ahead travel or OFF ...

Page 90: ...D 12 4 10 15 16 19 18 20 17 14 11 12 13 10 21 22 ...

Page 91: ...alve and the valves on the bottles by hand To restart the engine the button must be pulled out again 12 Engine speed adjuster Continuously variable engine speed setting if drive lever is extended Min setting Idling speed Max position Nominal speed A For paving select the rated speed reduce the speed for transportation A The automatic speed control keeps the set speed con stant even under a load 13...

Page 92: ...D 12 6 10 15 16 19 18 20 17 14 11 12 13 10 21 22 ...

Page 93: ...the drive lever the following functions can be activated 1 position Conveyor and auger on 2 position Screed motion tamper vibration on travel drive on increase speed until the stop is reached A Use the preselector to set the maximum speed f The vehicle speed cannot be reduced to 0 with the preselector The vehicle advances slightly with deflect ed drive lever even if the travel drive preselector is...

Page 94: ...D 12 8 10 15 16 19 18 20 17 14 11 12 13 10 21 22 ...

Page 95: ...cle advances slightly with deflect ed drive lever even if the travel drive preselector is set to zero 19 Steering wheel The steering wheel movement is transferred hydraulically to the front wheels f Take the special steering ratio into consideration when transporting the machine through tight curves approx 3 turns for a full steering lock Danger of accidents A For precise adjustments position 0 st...

Page 96: ...D 12 10 24 23 ...

Page 97: ...ft hopper lid Lower switch position Open left hopper lid f On actuation heed danger zones of moving parts of the vehicle 24 Open close right hopper Pushbutton function Upper switch position Close right hopper lid Lower switch position Open right hopper lid f On actuation heed danger zones of moving parts of the vehicle ...

Page 98: ...D 12 12 28 26 27 25 ...

Page 99: ...apacity with out material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 26 Right auger Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The conveying func tion of the right half of the auger is switched on when the drive lever is swivelled out and is con tinuously controlled via the material limit switches Operating mode OFF...

Page 100: ...D 12 14 28 26 27 25 ...

Page 101: ...tic function is overrid den with reduced delivery capacity f On actuation heed danger zones of moving parts of the vehicle 28 Right auger MANUAL conveying direction outwards inwards Pushbutton function Left switch position Manual start of the conveying function Conveying direction inwards Right switch position Manual start of the conveying function Conveying direction outwards A For manual trigger...

Page 102: ...D 12 16 30 29 ...

Page 103: ...screed Right switch position Retract left half of screed f On actuation heed danger zones of moving parts of the vehicle 30 Retract extend right screed Pushbutton function Left switch position Retract right half of screed Right switch position Extend right half of screed f On actuation heed danger zones of moving parts of the vehicle ...

Page 104: ...D 12 18 32 31 ...

Page 105: ...ry rate without material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 32 Right conveyor Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The conveying func tion of the right conveyor is switched on when the drive lever is swivelled out and is continu ously controlled via the material limit switches Operating mode OFF The co...

Page 106: ...D 12 20 34 35 33 ...

Page 107: ...s inserted f On actuation heed danger zones of moving parts of the vehicle 34 Raise lower screed Pushbutton function Upper switch position Lift the screed m Switch 33 must be deactivated for this function as the screed otherwise lowers again Lower switch position Lower screed m Check whether the screed transport safeguard is inserted f On actuation heed danger zones of moving parts of the vehicle ...

Page 108: ...D 12 22 37 36 ...

Page 109: ...d out Operating mode OFF Screed vibration is switched off Operating mode MANUAL Screed vibration is switched on constantly 37 Tamper Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The screed tamper is switched on when the drive lever is swivelled out Operating mode OFF The screed tamper is switched off Operating mode MANUAL The screed tamper is switched on constantly ...

Page 110: ...D 12 24 39 38 ...

Page 111: ...der Lower switch position Extend left levelling cylinder f On actuation heed danger zones of moving parts of the vehicle 39 Retract extend right levelling cylinder Pushbutton function Upper switch position Retract right levelling cylinder Lower switch position Extend right levelling cylinder f On actuation heed danger zones of moving parts of the vehicle ...

Page 112: ...D 12 26 40 41 42 43 ...

Page 113: ...lights ON OFF Detent switch function Upper switch position Front working lights ON Lower switch position Front working lights OFF f Avoid dazzling other road users 42 Rear working lights ON OFF o Detent switch function Upper switch position Rear working lights ON Lower switch position Rear working lights OFF f Avoid dazzling other road users 43 Rotary beacon ON OFF o Detent switch function Upper s...

Page 114: ...D 12 28 44 46 47 45 ...

Page 115: ...function Upper switch position Call the fault code A Press the switch until the three digit code has been out put by the warning lamp A Refer to the Malfunctions section for calling up error codes 45 Not used 46 Travel drive fast slow Pushbutton function Upper switch position Preselection of the speed level transportation speed fast Lower switch position Preselection of the speed level operating s...

Page 116: ...D 12 30 77 78 79 80 81 82 83 70 71 72 73 74 75 76 ...

Page 117: ... been switched on for checking purposes 73 Not used 74 Indicator lamp hydraulic filter Lights up when the hydraulic filter needs replacing A Replace filter element acc to Maintenance Instructions 75 Travel drive error message Lights up if there is a fault in the travel drive or if an actuated emergency stop button prevents the machine from starting A Warning lamp goes off as soon as the error has ...

Page 118: ...D 12 32 77 78 79 80 81 82 83 70 71 72 73 74 75 76 ...

Page 119: ...should be rectified as soon as possible A The error code can be retrieved using the Call up er ror malfunction switch A Lights up for a few seconds once the ignition has been switched on for checking purposes 80 Not used 81 Start inhibit Indicates that an enabled function stops the machine from starting 82 Indicator lamp Hydraulic oil temperature m Lights up if the hydraulic oil temperature is too...

Page 120: ...t right the function switches only control the corresponding function on the particular side of the machine m Important Do not disconnect remote controls with emergency stop button during op eration This causes the paver finisher to be shut down 90 91 92 94 93 95 96 96 ...

Page 121: ...d to indicate when the ve hicle starts to move A The horn can also be used to communicate acoustical ly with the truck driver for material loading 92 Auger left right Operating mode AUTO OFF MANUAL Detent switch function Operating mode AUTO The conveying func tion of the left right half of the auger is switched on when the drive lever is swivelled out and is continuously controlled via the materia...

Page 122: ...D 12 42 90 91 92 94 93 95 96 96 ...

Page 123: ...witch position Operating mode MANUAL height adjustment is carried out using the corresponding function switches on the remote control or operating panel Lower switch position Operating mode AUTO height adjustment is car ried out automatically via the connected grade con trol system 95 Retract extend left right screed Pushbutton function Switch position in the corresponding direction extend or retr...

Page 124: ...D 12 44 ...

Page 125: ...falling from the vehicle which can cause severe to fatal injuries During operation the operator must be at the intended driver s seat and be seated properly Never jump onto or off a moving vehicle Keep accessible surfaces free of any soiling e g operat ing substances to avoid the risk of slipping Use the steps provided and hold onto the handrail with both hands Comply with all further information ...

Page 126: ... the roof Operating panel locked in central position Steering wheel knob 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 Engine hood and lateral flaps closed Rotary beacon swivelled inwards and in lowest setting ...

Page 127: ...ing is compressed or stretched together with roof is raised or lowered Release the pin 1 on both sides of the roof Compress or stretch the spring 2 until the roof has reached the upper or lower limit position Insert the pin 1 in the respective position on both sides of the roof 1 2 ...

Page 128: ...he control platform Storage space There are two removable containers 2 under the lockable bottom flap For storing the on board tool kit remote controls and other accessories The fuse and terminal box is beneath the metal containers D 31 4 ...

Page 129: ...D 30 5 Control platform 4 2 3 ...

Page 130: ...ons left right m Make sure it is latched properly f Only adjust the operating position whilst the vehicle is stationary Pushing the operating panel Release panel latch 2 and slide panel console to the desired position using the handle 3 Insert panel latch 2 into one of the detent positions 4 ...

Page 131: ...lled for operation beyond the outer edge of the vehicle Press latch 1 swivel seat console to the desired position and allow latch to engage again m Make sure it is latched properly f Only adjust the oper ating position whilst the vehicle is stationary 1 ...

Page 132: ...l box which contains all fus es and relays etc is located beneath the central control platform floor panel A An assignment plan for fuses and relays can be found in chapter F8 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 ...

Page 133: ... instructions see section Starting the paver finisher external starting starting aid Main battery switch The main battery switch separates the current circuit from the battery to the main fuse A For the assignment of all fuses see chapter F To interrupt the battery s current cir cuit turn the key pin 3 to the left and pull it out A Do not lose the key pin as in this case the paver finisher can no ...

Page 134: ...er during transportation Screed lock mechanical o A The screed locks must additionally be engaged on both sides of the vehicle pri or to transportation with the screed lifted f Transportation with an unsecured screed leads to a risk of accidents Lift the screed On both sides of the paver finisher slide the screed lock beneath the crossbeams using the lever 1 place the lever in the detent position ...

Page 135: ...tation with an unsecured screed leads to a risk of accidents Lift the screed Activate the function on the operating panel A The two screed locks 1 extend hydraulically m ATTENTION Insert screed lock only at crown adjustment zero Screed lock only for transportation Do not enter or work under screed only secured with screed lock for transportation Danger of accident 1 ...

Page 136: ...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 swivelled and fixed again in one of the adjacent locating bores 3 The pointer 4 can be swivelled to dif ferent positions using the locking knob 5 m The scale 2 and pointer 4 must be swivelled in completely to transport the mac...

Page 137: ...swivelling headlights 1 are located on the auger box for illuminating the au ger compartment They are engaged together with the working lights A These are activated together with the other working lights on the operating panel o A 1 ...

Page 138: ...D 31 21 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 139: ...d height by alternatingly actuating the left and right ratchets A The current height can be read on both auger height indicators A Observe the notes on adjusting the auger height in the chapter Set up and modifica tion Auger height indicators A scale 1 on which the currently set auger height can be read off is located on back wall of the frame A Display in cm m When setting the auger height adjust...

Page 140: ...ases the basic width of the paver finisher f If the sensor rod or sensor rod extension are used ensure that there is no one in the vehicle s danger area A The sensor rod is adjusted when the vehicle is positioned with its set working width on the paving route and the reference marking running parallel to the paving route has been set up Adjusting the sensor rod The sensor rod 1 is located on the f...

Page 141: ...After releasing the wing nuts 5 the end section of the sensor rod extension 6 can be set to the desired length the angle can additionally be changed by swivel ling on the joint 7 A Either the adjustable indicator or the chain can be used as an aid to orientation m Tighten all assembly parts properly after setting up A The sensor rod extension s joint 7 can be mounted on both sides of the vehicle i...

Page 142: ...Remove the spray 1 from its bracket Build up pressure by actuating the pump lever 2 The pressure is indicated on the ma nometer 3 Actuate the manual valve 4 to spray On completion of work secure the manual spray in its bracket with a lock 5 f Do not spray into open flame or on hot surface Danger of explosion 5 2 1 2 2 3 4 ...

Page 143: ...ngages here The hose is automatically retracted into the guide after pulling and dis charging again Actuate button 3 toactivate and de activate the pump The indicator lamp 4 lights up when the emulsion pump is running Actuate the manual valve 5 to spray f Do not spray into open flame or on hot surface Danger of explosion A The spraying system is fed by a tank 6 at the vehicle step f Refill the can...

Page 144: ...e 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 deactivation point release the two mounting screws 2 and set the switch to the required height After adjusting retighten all mounting parts properly 1 2 ...

Page 145: ...sor s angle After adjusting retighten all mounting parts properly A The connection cables 4 are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed over the full working width A We recommend adjusting the limit switch positions during material distribu...

Page 146: ...set the sensor height the deacti vation point loosen the star handles 4 and adjust the linkage to the re quired length After adjusting retighten all mounting parts properly A The connection cables are connected to the relevant sockets on the remote con trol bracket A The sensors should be adjusted so that 2 3 of the augers are covered with the paving material A The paving material must be conveyed...

Page 147: ... Left seat console 24V socket A Voltage is present when the main switch is switched on Pressure setting front wheel drive o The traction force of the front wheels can be adjusted with a pressure setting of 0 200bar A The front wheel drive is active when at a standstill in working gear The pressure setting is adjusted at the regulator 1 Pressure is displayed at the manometer 2 1 2 1 ...

Page 148: ...ure control valve for paving stop with relieving Valve 2 is used to set the pressure for Screed control with paver finisher stop float ing stop with relieving Switching on see screed stop paving stop Chapters Operating panel Operation For pressure indication see manometer 3 Manometer for screed charging relieving The manometer 3 indicates the pressure for Screed charging relieving when the drive l...

Page 149: ...l screed to the desired position using the lever 3 and engage the locking knob again A If the levelling unit is connected to a height controller this has the function of balanc ing out any rapid rise in the screed position The levelling cylinders are extended until the correct height is reached The change in approach angle can only take place slowly and uniformly on both sides at once during pavin...

Page 150: ...e locking plate 3 on the lower side of the crossbar Remove insert plate 5 Move the push roller crossbar as far as it will go to the front rear position A Shift the push roller crossbar at the tow ing eye 6 or use a suitable assembly le ver in its guide left and right to push it into the corresponding position Turn the insert plate 5 180 and rein sert into the groove in the front or rear position P...

Page 151: ...D 30 38 Fire extinguisher A The paver finisher personnel must be fa miliarised with fire extinguisher 1 oper ation A Observe the inspection intervals for the fire extinguisher 1 ...

Page 152: ...function of the rotary beacon must be checked daily before starting work Loose the knob bolt 1 and swivel the bracket 90 degree Fasten the knob bolt 1 to fix the bracket Activate the function on the operating panel as necessary A o ...

Page 153: ...s 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 infeed area Parts that may become necessary for extending the auger Parts that may become necessary for extending the screed Percentage spirit level levelling rail 4 m long Levelling wire Protective...

Page 154: ...ighting 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 the driver s seat dur ing operation poses a risk of falling from the vehicle which can cause severe to fatal injuries The operator must be at the intended driver s seat during operation Never jump o...

Page 155: ...p immediately Steering The paver finisher must immediately fol low every steering wheel movement in a precise manner Check straight ahead travel Horn On the operating panel on both remote controls Briefly press the horn button Horn signal must sound Lights Switch on with the ignition key walk around the paver finisher to check and switch off again Screed hazard flasher with vario screeds With the ...

Page 156: ...urely seated Screed transport safeguard When the screed is raised before transport make sure that the cross beam lock is fixed correctly Hopper transport safeguard When the hopper is closed before transport the locks must be fixed correctly Protective roof Both locking bolts must be in the pro vided bore hole Other facilities Engine panels Lateral flaps Check that the hoods and flaps are securely ...

Page 157: ...D 42 5 1 3 10 2 8 9 6 7 4 5 ...

Page 158: ...osition and the speed adjuster 2 to minimum Insert the ignition key 3 in position 0 A Starting is not possible when the Start inhibit 4 or drive mode 5 indicator lamps indicate that an emergency stop button 6 7 on the remote control has been pressed or the auger function 8 or conveyor function 9 are switched to AUTO or MANUAL operating mode Press the starter button 10 to start the engine Run the s...

Page 159: ...D 42 7 1 3 10 2 8 9 6 7 4 5 ...

Page 160: ...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 discharged vehicle e g to the engine block or to a bolt 4 on the ve hicle frame f Do not connect the starting aid cable to the negative terminal of the discharged battery Danger of explosion m Lay the starting aid cable so that it can be disconnected once...

Page 161: ...rt the other vehicle Press the starter button 10 to start the engine Run the starter continuously for a maximum of 30 seconds then take a break for 2 minutes If the engine still has not started after two attempts ascertain the cause If the engine starts up disconnect the starting aid cable again in reverse order ...

Page 162: ...D 42 10 2 1 ...

Page 163: ...D 42 11 After starting m Let the paver finisher warm up for approx 5 minutes if the engine is cold ...

Page 164: ...D 42 12 2 3 1 ...

Page 165: ...tled down automatically Driving mode remains possible After cooling down to normal temperature the engine will run with full perform ance again Battery charge indicator 2 Must go out after starting when the engine revs up m If the lamp does not go out or lights up during operation Briefly rev up the engine Switch off the engine and determine the fault if the lamp does not go out For further possib...

Page 166: ...D 42 14 1 2 5 7 6 3 ...

Page 167: ...levelling cylinders with the switch 5 A To extend the levelling cylinders levelling operating mode 6 must be switched to MANUAL on the remote controls Use switch 7 to adjust the screed to the basic width of the paver finisher m Lift the auger if necessary A If the engine is started with the drive lever pivoted out the travel drive is inhibited To be able to start the travel drive the drive lever m...

Page 168: ...D 42 16 2 2 3 1 5 4 ...

Page 169: ...Turn the travel drive preselector 2 to medium speed For driving carefully tilt the drive lever 3 forward or backward according to the drive direction desired Adjust the speed with the preselector 2 Carry out steering movements with the steering wheel 4 f In emergency situations press the emergency stop button 5 To stop set the preselector 2 to 0 and move the drive lever 3 into its centre position ...

Page 170: ...d auger push roller with a separator fluid m Do not use diesel fuel as it dissolves the bitumen prohibited in Germany Screed heater system Switch on the screed heater approx 15 30 minutes depending on the ambient tem perature before paving begins Warming up prevents the material from sticking to the screed plates ...

Page 171: ...straight paving a direction mark must be present or established road edge chalk lines or similar Slide the operating panel to the de sired side and secure it Pull the direction indicator out of the bumper arrow and adjust it accordingly ...

Page 172: ...D 42 20 5 4 A 2 1 3 ...

Page 173: ...nd the conveyor on the remote controls if applica ble to auto Switch the conveyors on The conveyor limit switches A must switch off when the material has approximate ly reached the area beneath the auger crossbeam Check that the material is transferred properly Manually switch on or off the conveyor if the material is not conveyed properly until a sufficient amount of material lies in front of the...

Page 174: ...D 42 22 3 1 4 8 9 2 5 7 6 10 11 ...

Page 175: ...s or drive wheels as the screed tends to level an uneven ground The reference points for the layer thickness are the caterpillar chains or drive wheels The basic setting of the screed must be corrected when the actual layer thickness de viates significantly from the values indicated by the scales see the operating instruc tions for the screed A The basic setting is for asphalt material Item Travel...

Page 176: ... the way Uniform material transport and distribution or supply to the screed may require cor rections to settings of the material switches for conveyor and auger A See the section Malfunctions when paver functions fail Quality of the layer Paving height Slope Evenness in the driving direction and at right angles to it check with 4 m levelling rod Surface structure texture behind the screed A See s...

Page 177: ... with relief when the paver finisher is halting floating paving when the paver finisher is driving floating paving with screed charging or relieving when the paver finisher is driving A Relieving reduces the screed weight and increases the traction force Charging increases the screed weight reduces the traction force but increases the compaction ratio To be used with light weight screeds in except...

Page 178: ...D 42 26 1 2 B A C A C ...

Page 179: ...inisher stop in paving operation screed stop floating stop floating paving Switch 2 has the following positions A screed stop floating position OFF screed is hydraulically held in position A Function for setting up the paver finisher and for lifting lowering the screed C floating position The following functions are active depending on operating status Floating stop when the paver finisher is stat...

Page 180: ...D 42 28 1 2 B A C A C 3 4 ...

Page 181: ...neutralised thus preventing the screed from possibly sinking into the material A The pressure is set to approx 20 bar in the factory Adjusting the pressure Pressure adjustments can only be made while the diesel engine is running Therefore Start the diesel engine and set the traction controller 3 to zero Set switch 2 to Floating position Set pressure for screed charging or relieving Swivel the driv...

Page 182: ...D 42 30 1 2 B A C A C 3 4 ...

Page 183: ...ating stop with relief Set the drive lever 4 to the centre position Set switch 2 to position C Set the pressure using pressure regu lating valve 7 read the pressure off at the manometer 6 Basic setting 20 bar 0 80 20 100 1400 1200 1000 800 600 400 200 psi bar CN 837 20 6 7 ...

Page 184: ...D 42 32 1 2 ...

Page 185: ... create an edge like the end of a layer Set the drive lever 1 to the centre position During extended interruptions e g lunch break Set the drive lever 1 to the centre position and the speed adjuster 2 to minimum Switch the screed heater system off Switch off the ignition When screed is operated with the optional gas heating system close the valves of the bottles A The screed must be heated up to t...

Page 186: ...D 42 34 1 3 10 9 2 8 7 6 5 4 ...

Page 187: ...rs OFF Switch the screed heater system off Switch lighting OFF Switch off the ignition 9 Close the main shut off valves and the bottle valves for the screed gas heater system Remove the levelling units and stow them away in the boxes close all flaps Remove all parts that extend beyond the paver finisher contour or secure them if the paver finisher is to be transported over public roads on a low be...

Page 188: ...D 42 36 2 Malfunctions 2 1 Error code query for engine 3 1 2 ...

Page 189: ... the warning lamps 1 or 2 a code to which a defined fault is assigned can be displayed using the query switch 3 Output of the flash code is performed by the other warning lamp if a fault is displayed by warning lamp 1 output is carried out via warning lamp 2 and vice versa ...

Page 190: ...ch 3 into display position until the three digit code has been output via the warning lamp While the switch for error queries is being actuated the warning lamp which first signalled the fault which occurred goes out Example PAUSE 4x 2x 5x PAUSE ...

Page 191: ... the warning lamp which signalled the fault lights up again This continues until the corresponding error or malfunction has been rectified A If several errors occur at the same time the various flash codes are displayed next to one another by pressing the output switch m Notify customer service of the fault number displayed on your paver finisher staff in this department will then discuss with you...

Page 192: ...D 42 40 2 2 Error codes ...

Page 193: ...D 42 41 ...

Page 194: ...D 42 42 ...

Page 195: ...D 42 43 ...

Page 196: ...D 42 44 ...

Page 197: ...D 42 45 ...

Page 198: ...D 42 46 ...

Page 199: ... long waves change in the material temperature demixing roller has stopped on the hot material roller has turned or roller speed has been changed too fast incorrect operation of the roller incorrectly prepared foundation truck brake is applied too tight long standstill times between loads grade control reference line is not suitable incorrect installation of the grade control limit switch is not c...

Page 200: ...w screed extendable parts are incorrectly installed cold screed bottom plates are worn or warped screed is not operated in the floating position paver finisher speed is too high auger is overloaded changing material pressure against the screed Marks in the surface truck hits too much against the finisher while aligning to the finisher too much play in the mechanical screed link suspension truck br...

Page 201: ...the suction line of the pump Seal or replace the connections Tighten or replace the hose clamps Oil filter is soiled Clean the filter if necessary replace the filter Conveyor or augers run too slowly 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 pressure limit ing valves i...

Page 202: ... Hydraulic oil level is too low Top up oil Leak in the suction line Tighten the connections Flow rate regulator defective Replace Leaking seals of the hydraulic cylinder Replace Control valve is defective Replace Power supply interrupted Check fuse and cables replace if necessary ...

Page 203: ...upply interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote con trol is set to Auto Set the switch to Manual Power supply interrupted Check fuse and cables replace if necessary Switch on the operating panel defective Replace Excess pressure valve defective Replace Flow rate regulator defec tive Replace Seals defective Replace Crossbeams ...

Page 204: ...servo unit Insufficient supply pressure Check and adjust if necessary Check the suction filter replace the supply pump and the filter if necessary Drive shaft of hydraulic pumps or engines broken Replace pump or engine Irregular engine speed engine stop function does not work Fuel level too low Check the fuel level refill fuel if necessary Fuse engine speed con trol defective Replace fuse strip on...

Page 205: ...ydrau lic system hot hydraulic fluid may spurt out at high pressure Switch off the engine and depressurise the hydraulic system Protect your eyes Mount all protective devices before re commissioning the paver finisher The walkway must always reach over the entire working width of the screed The hinged walkway plate may only be folded up under the following conditions When paving next to a wall or ...

Page 206: ...ng thickness 10 cm Min height setting 18 cm from the ground A An incorrect height setting can result in the following problems during paving Auger too high Too much material in front of the screed material overflow When operating with larger working widths demixing and traction problems may occur Auger too low Not enough material that can be precompacted by the auger Irregularities resulting from ...

Page 207: ... height by alternatingly actuating the left and right ratchets A The current height can be read on both auger height indicators A Observe the notes on adjusting the auger height in the chapter Set up and modifica tion Auger height indicators A scale 1 on which the currently set auger height can be read off is located on back wall of the frame A Display in cm m When setting the auger height adjust ...

Page 208: ...g widths of more than 3 00 m the auger should be fitted with extension parts on both sides to improve material distribution and to reduce the wear f The diesel engine must be switched off whenever work is performed on the auger Danger of injuries A If the operating conditions on the construction site permit an auger extension to be fitted or render this necessary always additionally fit the outer ...

Page 209: ...arts 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 and simultaneously tighten the auger shaft bolts Insert the plug 3 at the end of the auger A Depending on the operating width the outer auger bearing and or auger end bearing must be installed 2 4 3...

Page 210: ...ring to the brace shaft with the relevant assembly parts 4 bolts washers pins A If necessary insert fitted plates 5 Reinstall the previously removed assembly parts 1 and simultaneously tighten the auger shaft and bearing shaft bolts Mount the auger half 5 on the outer side of the bearing with the relevant assembly parts 6 bolts washers nuts Insert the plug 2 at the end of the auger 4 1 6 7 2 3 5 ...

Page 211: ... 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 assembly parts 8 bolts washers nuts Reinstall the previously removed assembly parts 5 of the auger blade and simul taneously tighten the auger shaft and bearing shaft bolts Insert the plug 6 at the end ...

Page 212: ...640L Auger extension part 640 mm left 640R Auger extension part 640 mm right 960L Auger extension part 960 mm left 960R Auger extension part 960 mm right 320 Material shaft 320 mm 640 Material shaft 640 mm 960 Material shaft 960 mm 960BL Material shaft 960 mm with brace left 960BR Material shaft 960 mm with brace right 160L 160R 320L 320R 640L 640R 960L 960R 320 640 960 960BL 960BR ...

Page 213: ...E 12 9 Symbol Meaning Outer auger bearing Auger end bearing ...

Page 214: ...E 12 10 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 215: ...E 12 11 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 216: ...he hopper scrapers 1 must be adjusted on both hopper lids Loosen the mounting screws 2 Set a gap of 6 mm across the whole length of the scraper Retighten the mounting screws 2 properly f Risk of injury due to sharp edged parts Wear suitable safety gloves to protect your hands 1 2 ...

Page 217: ...e between the auger and screed Loosen the four mounting screws 1 Remove the screws and move the ve hicle forwards The crossbeam remains in its position on slide rails now tighten the screws 1 back down A When paving thin layers the material can settle in front of the screed if the screed is set to the rear position When paving thick layers the screed then climbs better 1 ...

Page 218: ...s are provided for mounting on the sensor s retaining plate A The digital slope controller must be mounted in such a way that the marking arrow on the housing points in the direction of travel A The analogue slope controller must be mounted in such a way that the displays for the operator visibly point backwards Connect the left or right connection cable to the intended handset or vehicle socket A...

Page 219: ...ush 4 and spring washers 5 Tighten the pin 3 so that the sensor arm is just still able to swivel A Mount the spring washers 5 in the op posite direction A The sensor arm can be secured on the side shield with the lock 6 5 3 Mounting the grade control system Insert the grade control system into the clamp bracket 1 and secure with the clamping bolt 2 to prevent rotation 1 2 5 4 3 6 F0258_A1 TIF 1 2 ...

Page 220: ...ossible 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 assembly parts and clamping points must be tightened properly to ensure safe and precise sensor arm operation Connect the left or right grade control system connection cable to the intended ha...

Page 221: ...extensions A The big ski enables the alignment of the individual sensors at the front and rear to be shifted over the reference The sonic ski can actually be positioned in front of and be hind the vehicle in order to guarantee safe reference sensing even on cornering A Before starting paving the big ski must be set with the grade control system mount ed to its reference cable kerb etc The big ski ...

Page 222: ... side next to the screed or also above the screed This is dependent on the paving width required in each case A The procedure for mounting the big ski is the same in both cases A So that the big ski can be operated as parallel to the ground as possible during pav ing it must be attached according to the subsequent paving conditions To do this the screed should be lowered to the desired course thic...

Page 223: ...ting bores A or to secure them to the crossbeam using clamping plates B A The front bracket is mounted directly behind the traction point the rear bracket is mounted at approximately the height of the auger Mount both holders 1 to the crossbeam with corresponding bolts 2 or Place both clamping plates 3 over the crossbeam at the corresponding point and mount with bolts 4 and sleeves 5 A For differe...

Page 224: ...ixing ring s 45 chamfer must point upwards Then slide the two swivel arms 3 onto the tube of the big ski bracket A The rear swivel arm is positioned rotat ed by 180 on the big ski bracket Slide a fixing ring 4 flat version onto the front swivel arm and secure with the relevant star handle bolt 1 3 4 2 ...

Page 225: ...e the centre element together with the rear swivel arm until the front sliding part 4 can be pushed onto the front swivel arm from above Then secure the rear sliding part with a fixing ring 5 and the relevant star handle bolt A Once the first part of the beam has been assembled it is initially aligned The centre element is now aligned horizontally using the fixing rings on the swivel arms and also...

Page 226: ...oth the 9 m and 13 m versions A Structure of the 9 m version Extension part at the front rear each Structure of the 13 m version Two extension parts at the front rear each Place the extension module 1 onto the centre element 2 and secure with a bolt 3 1 3 2 MBS1 bmp ...

Page 227: ...ance away from it A Extendable sensor brackets 1 are mounted in the two outer positions the normal sensor bracket 2 is mounted in the centre Place the sliding bracket 3 over the corresponding big ski element from the inner side Insert the sensor bracket 4 into the sliding bracket 5 from below and se cure with the relevant star handle bolts Place the clamping ring 6 onto the sensor bracket tube and...

Page 228: ...ables the two outer sensors to be swivelled during paving for diverse requirements e g cornering By loosening the star handle bolts 5 the length of the extension arm can be adjusted The sensor bracket with extension arm can be swivelled by loosening the star handle bolts 3 A If a sensor extension arm is swivelled to the side it must be ensured that the attached sensor is subsequently aligned in th...

Page 229: ...sed to initially mount the distributor box 1 on the mounting plate 2 A The input connector always points in the direction of travel Then mount the mounting plate on one of the two sliding brackets 4 on the centre element using a star handle bolt 3 m Mounting the big ski on the right hand side of the vehicle To meet the requirement that the input connector always points in the direction of travel t...

Page 230: ...n 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 interface 5 5 4 1 2 3 5 ...

Page 231: ...d set up Set 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 side board with the socket 4 of the screed A The cover of the extendable part must be removed to install the cables Install the cables to rule out the risk of any damage to the cables m If the...

Page 232: ...ade 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 seal unused sockets or plugs with the corresponding protective caps ...

Page 233: ...s 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 igni tion key and main switch Affix a sign Do not start to the vehicle Perform a visual inspection and check all functions every day Proceed with all maintenance tasks according to the maintenance sche...

Page 234: ...aces 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 parts of the vehicle Only perform maintenance and repair work after the vehicle has cooled down Comply with all further information in these instructions and in the safety manual Danger due to electric...

Page 235: ...F 23 1 F 23 Maintenance review 1 Maintenance review 72 40 51 82 90 100 32 60 ...

Page 236: ... the following service hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F32 q q q Auger F40 q q q q q q q Engine F51 q q q q q q Hydraulic system F60 q q q q q q Wheel chassis F72 q q q q q q Electrical system F82 q q q Lubrication points F90 q q q q Checking stopping F100 q q q Maintenance required q ...

Page 237: ...F 32 1 F 32 Maintenance conveyor 1 Maintenance conveyor ...

Page 238: ...transport 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 corresponding screed transport safeguards Ensure that opened hoods and covering parts are locked properly Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces...

Page 239: ...s If necessary 1 q Conveyor chain Check tightness q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Conveyor drive drive chains Check chain tightness q Conveyor drive drive chains Adjust chain tightness 3 q Replace conveyor deflectors conveyor plates Maintenance q Maintenanceduringtherunning inperiod g ...

Page 240: ...r to break when material falls into the space between the chain and the sprocket An excessively slack chain may catch on protruding objects and be destroyed Adjustment of chain tension A One adjusting screw is located on both halves of the conveyor for adjusting the chain tension A The adjusting screws A are located at the reversal behind the crossbeam Loosen the lock nut A on the rear of the reve...

Page 241: ...ng the chains would lead to the destruction of the drive wheels m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyor deflectors Conveyor plates Deflector plates Conveyor chain reversing rollers Conveyor drive chain sprockets A Your Dynapac customer service will be happy to provide support during maintenance repai...

Page 242: ...ion If the tension has been set properly the chain must be able to move freely ap prox 10 15 mm To re tension the chains Unfasten mounting screws B and lock nut C slightly Use the tensioning screw D to set the required chain tightness Retighten mounting screws B and lock nuts C correctly A The tensioning screws are accessed through the bottom plates of the operat ing platform B B C D 10mm A ...

Page 243: ...deflectors with new bolts A At the latest the conveyor plates B must be replaced when the wear limit of 5 mm in the rear area beneath the chain has been reached m If components have to be replaced as a result of wear the following components should always be replaced in sets Conveyor chain Conveyor deflectors Conveyor plates Deflector plates Conveyor chain reversing rollers Conveyor drive chain sp...

Page 244: ...F 32 8 ...

Page 245: ...F 40 1 F 40 Maintenance auger assembly 1 Maintenance auger assembly ...

Page 246: ...emove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion fuels from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the vehicle Only perform maintenance and repair wo...

Page 247: ...planetary gear Check oil level q Auger planetary gear Top up oil g q Auger planetary gear Change oil 3 q Auger drive chains Check tension q Auger drive chains Adjust tension 4 q Auger box Check oil level q Auger box Top up oil q Auger box Change oil 5 q Seals and sealing rings Check wear q Seals and sealing rings Replace seals Maintenance q Maintenance during the running in period g ...

Page 248: ...0 If necessary 6 g Gearbox bolts Check tightening q Gearbox bolts Tighten to correct torque 7 g g Outer bearing bolts Check tightening q Outer bearing bolts Tighten to correct torque 8 q Auger blade Check wear q Auger blade Replace auger blade Maintenance q Maintenance during the running in period g ...

Page 249: ... any bitumen res idues which may have entered and to supply the bearings with fresh grease when warm A If the auger is extended the outer rings should be loosened slightly when initially greasing the outer bearing points in or der to improve ventilation on greasing The outer rings must be properly se cured again after greasing A New bearings must be filled with 6 strokes of grease using a grease g...

Page 250: ... oil into the filler bore at B until the oil level has reached the lower edge of the inspec tion bore A Screw the filler B and inspection screws A back in To change oil A The oil should be changed when at oper ating temperature Unscrew the filler screw B and drain plug C Drain the oil Screw the drain plug C back in Unscrew the inspection screw A Fill the specified oil into the filler bore at B unt...

Page 251: ... augers outer circumference should be 10 mm f Risk of injury due to sharp edged parts To re tension the chains Release the mounting screws A Set the chain tension correctly using the threaded pins B Tighten the threaded pins to 20 Nm using a torque wrench Subsequently loosen the threaded pins again by one full revolution Retighten the bolts A C A A B ...

Page 252: ...Change oil A The oil should be changed when at oper ating temperature Place a suitable collecting container under the auger box Loosen bolts D from the circumfer ence of the worm shaft flange A The oil runs out between the flange and auger box Drain out all oil Correctly retighten flange bolts D di agonally Pour the specified oil in through the open top cover C of the auger box until the oil level...

Page 253: ...ling rings 5 A After reaching operating temperature check the gearbox for leaks m In case of visible leaks e g between the flange surfaces A of the gearbox re placement of the seals and sealing rings is necessary I II A A ...

Page 254: ...rbox 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 attained the full tightening torque and note the corre sponding tightening pattern whilst doing so A E B C D E B I II ...

Page 255: ...ing the running in period the tightening torques of the outer auger bearing mounting screws must be checked Tighten to the following torques if nec essary F 210 Nm m If the auger s working width is changed the tightening check must be repeated after the running in period C ...

Page 256: ...ced and the blades B have to be replaced Remove the bolts C washers D nuts E and auger blade B f Risk of injury due to sharp edged parts m Auger blades must be installed play free the contact surfaces must be dirt free Install the new auger blade B re place the bolts C washers D and nuts E if necessary A B C D E B ...

Page 257: ...tenance engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work and service intervals itemised here are binding in nature ...

Page 258: ...emove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion fuels from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the vehicle Only perform maintenance and repair wo...

Page 259: ...ean the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel system Fuel filter drain the water separa tor q Engine fuel system Replace fuel pre filter q Engine fuel system Replace fuel filter q Engine fuel system Bleed fuel system Maintenance q Maintenanceduring...

Page 260: ... filter Air filter cartridge Replace 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling system Top up coolant q Engine cooling system Check coolant concentration q Engine cooling system Coolant concentration Adjust q Engine cooling system Change coolant Maintenance q Maintenanceduringtherun...

Page 261: ...e 10 50 100 250 500 annually 1000 annually 2000 every 2 years If necessary 6 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q Engine drive belt Replace drive belt Maintenance q Maintenanceduringtherunning inperiod g ...

Page 262: ... run dry and time consuming venting bleeding can therefore be avoided For filling in the fuel Remove cap A Fill in fuel through the filling port until the required fill lever is achieved Replace the cap A Clean the tank and system Unscrew the drain plugs B in both tanks and drain about 1 l fuel into a collection pan When fastening the screw again after draining make sure to use a new seal A B B ...

Page 263: ... in overheating and engine destruction For filling in the oil Remove cap B Fill up oil to correct level Return cap B Use dipstick to check level again Oil change A The oil drain screw is accessed via the cover C in the vehicle s material tunnel Remove the bolts D from the frame and pull the cover C out in the direc tion of travel After completing the maintenance work reinstall the cover C properly...

Page 264: ... 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 allow the oil to drain completely Replace the screw cap and tighten properly Refill with oil as described above Changing the oil filter A All filters are accessed via the service flap F on the vehicle...

Page 265: ...nch or filter strap and unscrew it Clean the contact surface Apply light coating of oil to the gasket on the new filter and fill filter with oil before installing it Tighten filter by hand A After installing the oil filter attention must be paid to the oil pressure display and good sealing during the test run Check oil level again H ...

Page 266: ...pleting the maintenance work reinstall the service flap A properly A The fuel filter system consists of two fil ters Prefilter with water separator C Main filter D Prefilter draining of water A Drain the collecting vessel at regular in tervals or in response to an error mes sage from the engine control unit Drain off separated water at the cock E and collect then close the cock again B A D C A G E...

Page 267: ...plunger is now pressed out via the spring Pump until a very high resistance is perceptible and pumping can only be carried out very slowly Now continue pumping a few more times The return line must be filled Start the engine and operate for approx 5 minutes at idle speed or low load Check the prefilter for leaks whilst doing this Lock the manual fuel pump s G bayonet lock by pressing and simultane...

Page 268: ...ty dust collector Empty the dust removal valve A on the air filter housing by compressing the discharge slot Remove any dust deflectors by press ing together the upper valve section A Clean the dust removal valve from time to time A ...

Page 269: ...or Open the air filter housing B at the clips C Move filter element D to the side a lit tle and then pull it out of the housing Pull out the safety element E and check for signs of damage A Replace the safety element E after the filter has been serviced 3 times but after 2 years at the latest never clean it E C C B D D ...

Page 270: ...em is under pressure When it is opened there is danger of scalding m Use only approved coolants A Observe the instructions in the chapter entitled Operating substances Remove the drain screw B on the ra diator and let the coolant drain com pletely Reinstall the drain screw B and tight en properly Fill in coolant through the filling open ing A on the compensation tank up to approx 7 cm C from the t...

Page 271: ...ry remove leaves dust or sand from the radiator A Observe engine s operating instructions Checking coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentration if necessary A Observe engine s operating instructions ...

Page 272: ... transverse cracks in the belt are acceptable m In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces belt re placement is necessary A Observe engine s operating instructions Replace drive belt A Observe engine s operating instructions ...

Page 273: ...F 60 1 F 60 Maintenance hydraulic system 1 Maintenance hydraulic system ...

Page 274: ...Secure the vehicle to prevent it being switched on again Consult a doctor immediately if injured Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts together with combustion gases from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot parts of the ...

Page 275: ... 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 depressurising begin slowly and carefully when opening the threaded connections in the hy draulic lines Continue to loosen the threaded connections with caution in order to notice possible dangers resulting...

Page 276: ...nk 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 Hydraulic oil tank Change ventilation filter 3 q High pressure filter Check maintenance indicator q q High pressure filter Replace filter element Maintenance q Maintenanceduringtherunning inperiod g ...

Page 277: ...p 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 Hydraulic system Retighten screw connections q q Hydraulic hoses Replace hoses 6 q q Auxiliary flow filter Replace filter element o Maintenance q Maintenanceduringtherunning inperiod g ...

Page 278: ... 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 rises to the centre of the sight glass A 5 mm Screw cap B on again A Regularly remove dust and dirt from the oil tank vent C Clean the surfaces of the oil cooler m Use only the recommended hydraulic oi...

Page 279: ...to 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 and let the oil drain completely Unscrew the drainage hose and return the screw cap A The oil should be changed when at operating temperature m When changing the hydraulic oil also change the filter D ...

Page 280: ...er securing screws A and lift off cover Disassemble the removed unit into Cover B Separating plate C Filter D Dirt trap E Clean the filter housing cover sepa rating plate and dirt trap Check the O rings F replace if necessary Coat the sealing surfaces and O rings with clean operating fluid m The filter must be bled following filter re placement F E D C B A ...

Page 281: ...Place 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 therefore free of air bubbles A The process from assembling the filter cover to starting the drive engine should take place in less than 3 minutes as the oil level in the filter housing otherwise falls...

Page 282: ...r cartridge Clean the filter housing Insert the new filter cartridge Replace the seal ring of the filter housing Turn on the filter housing by hand and tighten it using a wrench Start trial operation and check the tightness of the filter A Replace the seal ring whenever the filter cartridge is replaced A After replacing the filter element the red mark in the maintenance indicator A automatically r...

Page 283: ...wait for a moment as the oil which has been poured in first has to flow off m Make sure to clean the screw and the vi cinity of the drain bore Oil change Place the end of the oil drain port hose C in the collection container Remove the screw cap with a wrench and allow the oil to drain completely Replace the screw cap and tighten properly Pour in the prescribed quality of oil through the dipstick ...

Page 284: ...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 285: ...ing pinched or buckled points leaks damage or deformation to the hose fittings affecting the sealing function replace ments are not necessary for minor damage to the surface hose coming away from the fitting corrosion of the fitting with a detrimental effect on function and strength failure to comply with the installation requirements period of use has exceeded 6 years Here it is the date of manuf...

Page 286: ...ening of the hoses prevents them from chafing on components or on each other components with sharp edges must be covered when installing hydraulic hoses bending radii are not smaller than the permitted values When hydraulic hoses are connected to moving parts the length of the hose must be dimensioned to ensure that the bending radii are not smaller than the permitted smallest values right across ...

Page 287: ...oth er and always ensure that they are at the correct pressure In individual cases the period of use can be stipulated according to experience and may differ from the following general indications When producing the hose pipe the hose purchased by the meter should not be more than four years old The period of use of a hose pipe should not exceed six years including any possi ble storage period The...

Page 288: ...n the filter then close the non return valve again Replace filter element B and sealing ring C Turn filter element clockwise with the help of carrier straps and at the same time raise it slightly Wait for a moment until the oil has escaped downwards then remove the filter element Check inlet and outlet in filter housing D As required top up hydraulic oil level in filter housing then screw down the...

Page 289: ...F 72 1 F 72 Maintenance travel drive steering 1 Maintenance travel drive steering ...

Page 290: ...transport 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 corresponding screed transport safeguards Ensure that opened hoods and covering parts are locked properly Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces...

Page 291: ... point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality Maintenance q Maintenance during the running in period g ...

Page 292: ...tyres q Drive wheels Check air pressure q Drive wheels Adjust air pressure g Drive wheels Check wheel nuts q Drive wheels Tighten wheel nuts 3 q Lubrication points Lubricate king pins q Lubrication points Lubricate steering q Lubrication points Lubricate floating axle q Lubrication points Lubricate o wheel bearings Maintenance q Maintenance during the running in period g ...

Page 293: ...nto the filler bore at A until the oil level has rea ched the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at ope rating temperature m Ensure that no dirt or foreign bodies are able to enter the gear Turn the rear wheel so that the drain plug B is located at the bottom Unscrew and remove the drain plug B and filler screw A and drain off...

Page 294: ...eels 2 Check tyres replace tyres Check the tyres on a daily basis for signs of damage cracks or blister for mation Regularly check compliance with the minimum profile depth m Replace damaged or worn tyres immediately ...

Page 295: ...n under load f Chocks or supporting beams positioned so that they cannot be shifted or tilted must be adequately dimensioned and be able to take the corresponding weight f There must not be anyone on the machine while it is being lifted Dismantle the arm Lift the machine with the jack at the intended position 1 under the machine frame Place the wooden block 2 under the wheel as a safeguard Place a...

Page 296: ...heck the tyre pressure in cold conditi on A slight increase in tyre pressure du ring operation is normal and there is no need to relieve pressure f Only ever set the tyre pressure using a self regulating filler connection Never stand directly in front of the tyres when filling them with air f Please comply with the safety instructions for checking and adjusting the air pressure A Bear in mind that...

Page 297: ... operating speed C Max min air pressure at transportation speed D Screed type E Max air pressure for screed without extension parts F Max air pressure for screed with extension parts G Max air pressure A Ascertain the tyre type before adjusting the pressure Pressures for equipment Bandag on Michelin XHA Pressures for equipment Michelin XGC Techking ETGC B C D F E D E A G G ...

Page 298: ...wheel nuts tighten wheel nuts A Following wheel replacement check the wheel nuts after the running in time Check tighten all wheel nuts using a torque wrench as shown A Adjust the torque to 510Nm 8 4 9 5 1 7 3 10 6 2 ...

Page 299: ...ng nipples B are on the rear axle of the main frame and supply the steering linkage with grease via a lu brication line Floating axle A The lubricating nipples C are located on the left and right of the floating axle s centre bearing Wheel bearings o A Each of the wheels is equipped with a lubricating nipple D on the wheel hub In the case of front wheel drive the drive wheels have no lubricating n...

Page 300: ...F 72 12 ...

Page 301: ...F 82 1 F 82 Maintenance electrical system 1 Maintenance electrical system ...

Page 302: ... 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 with electric screed heater check the insulation monitoring every day according to the instructions Comply with all further information in these instructions and in the safety manual Danger from bat...

Page 303: ...attery 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 damage Check the cooling air openings for pollution or clogging clean if necessary o 3 q Electrical fuses Maintenance q Maintenance during the running in period g ...

Page 304: ...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 circuited A Keep the battery surfaces clean and dry use only a damp or antistatic cloth for cleaning m Do not open batteries without plugs A If the starting capacity is insufficient check and possible recharg...

Page 305: ...every cell if this needs to be topped up only use distilled water m When recharging batteries every cell must be opened i e plugs and or covers must be removed m Only use commercially available automatic battery chargers according to the manu facturer s instructions A Preferably use the slow recharging procedure and adjust the charge current accord ing to the following rule of thumb Battery capaci...

Page 306: ...ulated 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 lamp OFF at first no switch off is necessary and operation can be continued However the cause of the fault must be determined and rectified immediately by a specialist electrician f Danger due to elec...

Page 307: ...ernator 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 cleaner is not permissible 2 1 ...

Page 308: ...A The fuses installed may differ depending on equipment F Function A F1 1 Main fuse 1 50 F1 2 Main fuse 2 50 F1 3 Raise lower roof 23 F1 Screed 10 F2 Screed 10 F3 Hopper 10 F4 Motor start 5 F5 Tamper vibration 7 5 F6 Extend retract screed 10 ...

Page 309: ...F11 Screed heater system 10 F12 Conveyor 7 5 F13 Connector 12V 10 F14 Levelling 10 F15 Not used F16 Connector 24V 10 F17 Indicator displays 5 F18 Auger 10 F19 Screed 10 F20 Rotary beacon o 7 5 F21 Travel drive computer voltage supply 25 F22 Not used F23 Horn 15 F24 Engine start 10 F25 Not used F26 Engine control unit power supply 30 F27 GPS module 2 F28 Not used F29 Ignition 3 F30 Reverse buzzer o...

Page 310: ...t for access F32 Travel drive computer 20 F33 Not used F34 Not used F35 Rear working lights 10 F36 Front working lights 10 F37 Diagnostic interface engine 2 F38 Diagnostic interface control unit 2 F51 Control voltage raise lower roof 5 F52 Raise roof 15 F53 Lower roof 15 F Function A ...

Page 311: ...F 82 11 Relays in the engine compartment K Function 0 Engine start ...

Page 312: ...vel drive computer voltage supply 3 Not used 4 Engine start 5 Travel drive computer outputs 6 Release operating functions 7 Front working lights 8 Rear working lights 9 Horn 10 Start inhibit emergency stop 15 10 15 25 15 10 15 25 15 10 10 15 25 15 15 10 25 10 ...

Page 313: ...3 Not used 14 Not used 15 Not used 16 Reverse buzzer o 17 Not used 18 Not used 19 Not used 20 Not used 21 Not used 22 Not used 23 Not used 24 Auto conveyor left 25 Auto conveyor right 26 Auto auger left 27 Auto auger right 28 Levelling K Function ...

Page 314: ...n 1 Floating position 2 Screed start auto 3 Screed hazard warning flashers left hand 4 Screed hazard warning flashers right hand 30 Latch for extending retracting screed left 31 Latch for extending retracting screed right 32 Operating hour meter ...

Page 315: ...F 82 15 Relay in connection box under the operating platform K Function 40 Raise roof 41 Lower roof ...

Page 316: ...F 82 16 ...

Page 317: ...0 Maintenance lubricating points 1 Maintenance lubricating points A The information on the lubricating points for the various assemblies is assigned to the specific maintenance descriptions and must be read there ...

Page 318: ...em Interval Maintenance point Note 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Check lubricant tank fill level o q Top up lubricant tank o q Bleed central lubrication system o q Check pressure limiting valve o q Check flow of lubricant at the consumer o 2 q Bearing points Maintenance q Maintenance during the running in period g ...

Page 319: ...k of injury due to escaping lubricant as the system operates at high pressures f Ensure that the diesel engine cannot be started when working on the system f Observe safety regulations for handling hydraulic systems m Ensure maximum cleanliness when working on the central lubrication system The following assemblies lubricating points can be automatically supplied with grease by the central lubrica...

Page 320: ...in a fill level above the MIN mark a on the tank Top up lubricant tank A lubricating nipple b is located on the lubricant tank a for filling purposes Connect the grease gun c enclosed on delivery to the filling nipple b and fill the lubricant tank a up to the MAX mark Alternatively unscrew cover d and fill tank from above A When the lubricant tank is completely empty the pump may have to run for u...

Page 321: ...bricant has emerged Check all connections and lines for leaks Check pressure limiting valve m If lubricant emerges at the pressure lim iting valve a this indicates a malfunc tion in the system The consumers are no longer adequate ly supplied with lubricant Release all distribution lines b leading from the distributor c to the consumers in succession If lubricant emerges from one of the released di...

Page 322: ...e Remove the lubrication line a and install a normal lubricating nipple b Connect the grease gun c en closed on delivery to the lubricating nipple b Operate the grease gun until the lu bricant visibly emerges Rectify any faults in the flow of lubri cant Reinstall the lubrication lines Check all connections and lines for leaks c a b ...

Page 323: ...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 324: ...F 90 8 ...

Page 325: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping ...

Page 326: ...500 1000 annually 2000 every 2 years If necessary 1 q General visual inspection 2 regularly Check that the bolts and nuts fit firmly 3 q q Inspection by an expert 4 q Cleaning 4 q Cleaning sensors 5 q Preserving the paver finisher Maintenance q Maintenance during the running in period g ...

Page 327: ... actions to correct any detected malfunction to avoid damages dan gers or environmental hazards 3 Check that the bolts and nuts fit firmly Bolts and nuts must be checked regularly to ensure that they 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 torques ...

Page 328: ...l lube points acc to specification Clean the vehicle with water after laying mineral aggregates lean mixed concrete etc m Do not spray bearing points electrical or electronic components with water Remove residual paving material m After cleaning work with the high pres sure cleaner grease all lube points acc to specification f Danger of slipping Ensure that all steps and ladders are free of grease...

Page 329: ...arts 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 vehicle Stop the engine and remove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including thos...

Page 330: ...F 100 6 5 3 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions m Daily cleaning with a dry lint free cloth ...

Page 331: ...oved batteries every 2 months Protect all bare metal components e g piston rods on hydraulic cylinders with a suitable corrosion inhibitor If it is not possible to park the vehicle is an enclosed building or under cover it must be covered with a suitable size of tarpaulin In all cases seal all air intake and ex haust apertures with plastic film and adhesive tape 6 2 Shutdowns lasting from 6 months...

Page 332: ...isposal must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oily or greasy parts hydraulic hoses lube pipes etc must be treated separately A Electric devices accessories and packaging should be recycled in an env...

Page 333: ... 1 6 4 1 6 7 7 1 9 M6 8 2 1 12 3 14 3 7 8 1 9 11 2 7 13 3 3 M8 20 5 28 7 1 34 8 19 4 7 26 6 6 31 7 9 M10 41 10 57 14 70 17 37 9 52 13 62 16 M12 73 18 97 24 120 30 63 16 89 22 107 27 M14 115 29 154 39 195 45 100 25 141 35 169 42 M16 185 46 243 61 315 75 156 39 219 55 263 66 M18 238 60 335 84 402 100 215 54 302 76 363 91 M20 335 84 474 119 600 150 304 76 427 107 513 128 M22 462 116 650 162 759 190 4...

Page 334: ... 5 M8x1 21 7 5 4 30 6 7 6 36 7 9 2 19 5 4 9 27 4 6 8 32 8 8 2 M10x1 25 42 1 10 5 59 2 15 71 17 8 37 7 9 4 53 13 63 6 15 9 M12x1 25 75 7 18 9 106 2 26 127 31 9 67 2 16 8 94 5 24 113 28 3 M14x1 5 119 29 7 167 42 200 50 1 106 26 149 37 178 44 6 M16x1 5 183 45 6 257 64 308 77 162 40 227 57 273 68 2 M18x1 5 267 66 8 376 94 451 112 7 236 59 331 83 398 99 4 M20x1 5 373 93 2 524 131 629 157 3 328 82 461 1...

Page 335: ...ts listed below or comparable qualities of well known brands m Only use containers which are clean on inside and outside for filling oil or fuel A Note capacities see section Capacities m Incorrect oil or lubricant levels promote rapid wear and paver finisher failure m Never mix synthetic oils with mineral oils ...

Page 336: ...F 111 2 2 1 6 5 7 4 3 6 ...

Page 337: ...el 315 litres 4 Hydraulic oil reservoir Hydraulic oil 240 litres 5 Pump distribution gear Gearbox oil 7 0 litres 6 Planetary gear Travel drive Gearbox oil 2 5 litres 7 Planetary gear augers on each side Gearbox oil 1 5 litres 7 Auger box Gearbox oil 4 0 litres 7 Outer auger bearing per bearing Hot bearing grease 115 grams Separator fluid tank Separator emulsion 25 litres Central lubrication system...

Page 338: ... not approved separator emulsion Considerable damage can be caused to the vehicle by using separator emulsions and other cleaning agents not approved by the factory without prior consultation The use of separator emulsions and cleaning agents that are not approved makes the vehicle guarantee null and void Only use approved separator emulsions cleaning agents and operating substances NOTE ...

Page 339: ...F 111 8 ...

Page 340: ...www dynapac com ...

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