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Fayat Dynapac Redline DRF25-70C, Instruction Manual

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Fayat Dynapac Redline DRF25-70C Instruction Manual Download Page 22

V 10

3

Guarantee conditions

A

The guarantee conditions are included in the

  

 scope of supply of the machine. 

This contains a complete specif

 

ication of the va

 

lid conditions.

The guarantee becomes null and void if

- damage occurrs through malfunctions caused by improper use and incorrect oper-

ation.

- repairs or manipulations are carried out by persons who are neither trained nor au-

thorised accordingly.

- accessories or spare parts are used t hat cause damage and which are not ap-

proved by Dynapac.

Summary of Contents for Dynapac Redline DRF25-70C

Page 1: ...INSTRUCTION MANUAL DRF25 70C Asphalt Finisher SERIAL NUMBER 10002181VMC100224 ENGINE Cummins QSB 6 7 C173 129KW 2200 4812209453_B EN Mar 2022 DRF25 70C Asphalt Finisher 01 ...

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

Page 3: ...ble incorrect usage 12 A Correct use and application 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 5 Weights DRF25 70C all weights in t 12...

Page 4: ...ms 36 7 7 Electromagnetic compatibility EMC 36 C10 Transportation 1 1 Safety regulations for transportation 1 2 Transportation on low bed trailers 4 2 1 Preparations 4 3 Securing the load 6 3 1 Prepare the low bed trailer 6 3 2 Driving onto the low bed trailer 7 3 3 Lashing equipment 8 3 4 Loading 9 3 5 Preparing the vehicle 10 4 Securing the load 11 4 1 Securing at the sides 11 4 2 Securing at th...

Page 5: ... 8 Seat console 11 Fuse box 14 Batteries 15 Main battery switch 15 Hopper transport safeguard 16 Screed lock mechanical 16 Paving thickness indicator 18 Auger lighting o 19 LED working light o 20 Auger height adjustment ratchet o 22 Auger height displays 22 Sensor rod sensor rod extension 23 Manual separator fluid spray o 25 Separator fluid spraying system o 26 Conveyor limit switches conventional...

Page 6: ... the morning or when starting paving 3 Check list for the machine operator 3 1 1 Starting the paver finisher 6 Before starting the paver finisher 6 Normal starting 6 External starting starting aid 8 After starting 11 Observe indicator lamps 13 Engine coolant temperature check 1 13 Battery charge indicator 2 13 Oil pressure indicator lamp for the diesel engine 3 13 1 2 Preparation for transportatio...

Page 7: ... code query for engine 36 Output of numerical code 38 2 2 Error codes 40 2 3 Problems during paving 47 2 4 Malfunctions on the paver finisher or screed 49 E10 Set up and modification 1 1 Special notes on safety 1 2 Distribution auger 2 2 1 Height adjustment 2 Grain sizes up to 16 mm 2 Grain sizes 16 mm 2 2 2 Mechanical adjustment with ratchet o 3 2 3 Hydraulic adjustment o 3 2 4 Height adjustment ...

Page 8: ... the sensor arm 28 5 5 Big ski 9 m 29 Mounting the big ski bracket on the crossbeam 31 Mounting the swivel arms 32 Mounting the center element 33 Extending the big ski 34 Mounting the sensor bracket 35 Mounting and aligning the sensors 36 Mounting the distributor box 37 Connection diagram 38 5 6 Levelling shoe 6m 9m 39 10 Limit switch 49 10 2 Auger limit switches left and right mounting the conven...

Page 9: ...ntenance intervals 3 1 2 Points of maintenance 4 Chain tension conveyor 1 4 Conveyor drive drive chains 2 6 Conveyor deflectors conveyor plates 3 7 F40 Maintenance auger assembly 1 1 Maintenance auger assembly 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 bo...

Page 10: ...tem 1 1 1 Maintenance intervals 3 1 2 Points of maintenance 5 Hydraulic oil tank 1 5 Suction return flow hydraulic filter 2 7 Bleeding the filter 8 Ventilation filter 8 High pressure filter 3 9 Pump distribution gear 4 10 Bleeder 11 Hydraulic hoses 5 12 Marking hydraulic hoses storage period period of use 14 Auxiliary flow filter 6 15 F73 Maintenance drive units 1 1 Maintenance drive units 1 1 1 M...

Page 11: ...ral lubrication system 1 3 Bearing points 2 7 F100 Tests stopping 1 1 Tests checks cleaning stopping 1 1 1 Maintenance intervals 2 2 General visual inspection 3 3 Check that the bolts and nuts fit firmly 3 4 Inspection by an expert 4 5 Cleaning 5 5 1 Cleaning the hopper 6 5 2 Cleaning the conveyor and auger 6 5 3 Cleaning optical or acoustic sensors 7 6 Preserving the paver finisher 8 6 1 Shutdown...

Page 12: ...ances 1 1 1 Capacities 3 2 Lubricant specifications 4 2 1 Engine 4 2 2 Cooling system 4 2 3 Hydraulic system 4 2 4 Pump distribution gear 4 2 5 Drive unit planetary gear 5 2 6 Auger drive planetary gear 5 2 7 Auger box 5 2 8 Grease 5 2 9 Separator emulsion 6 2 10 Hydraulic oil 7 ...

Page 13: ...Example 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 vehi...

Page 14: ...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 15: ...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 16: ...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 17: ...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 18: ...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 19: ...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 20: ... 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 21: ...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 22: ...n of the valid conditions The guarantee becomes null and void if damage occurrs through malfunctions caused by improper use and incorrect oper ation repairs or manipulations arecarried out by persons whoare neither trained nor au thorised accordingly accessories or spare parts are used t hat cause damage and which are not ap proved by Dynapac ...

Page 23: ...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 24: ...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 25: ...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 26: ...A 2 ...

Page 27: ...he Dynapac DRF25 70C paver finisher is a paver finisher with a caterpillar drive 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 28: ... Levelling cylinder for paving thickness 6 t Traction roller 7 t Crossbeam pull bar 8 t Paving thickness indicator 9 t Crossbeam 10 t Travel drive of the caterpillar drive 11 t Auger 12 t Screed 13 t Operator s platform 14 t Operating panel can be moved to left or right side 15 t Protective roof 16 o Working lights 17 t Lane cleaner t Standard equipment o Optional equipment 12 1 2 7 6 5 8 9 10 13 ...

Page 29: ...ravel drive allows the speed of the paver fin isher to be matched to all 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 Additional cut of...

Page 30: ...avel drive The continuously adjustable travel drive pumps are connected to the travel drive engines by means of high pressure hydraulic hoses These hydraulic motors drive the caterpillar chains via planetary gears that are mounted directly inside the drive wheels of the caterpillar chains Steering system operator s platform The independent hydrostatic travel drives al low the paver finisher to be ...

Page 31: ...en 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 conti...

Page 32: ...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 33: ...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 34: ...B 8 4 Safety devices 1 3 5 10 7 9 11 4 5 6 7 12 2 8 ...

Page 35: ...se devices at regular intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation 1 Hopper transport safeguard 2 Crossbeam lock mechanical hydraulic o 3 Main switch 4 Emergency stop button 5 Horn 6 Ignition key 7 Lights 8 Protective roof latch o 9 Fire extinguisher o 10 Screed warning light o 11 Covers lateral flaps coverings 12 ...

Page 36: ...cal data standard configuration 5 1 Dimensions all dimensions in mm A For screed technical data refer to the screed operating instructions R65 6400 2900 6145 950 1850 2845 3100 3900 3400 3290 2550 1990 320 430 2125 ...

Page 37: ...ting your vehicle in an inclined position gradient slope lateral inclina tion which is above the specified limit value please consult the customer service de partment for your vehicle 5 3 Permissible approach angle max 15 max 15 max 15 max 15 max 15 max 15 ...

Page 38: ...inisher with screed approx 18 2 DRV51TVE approx 18 5 DRV60TVE With extension parts for max working width additionally max approx xxx With filled hopper Additionally max approx 15 0 For the weights of the screed and the screed attachments see the operating instruc tions for the screed B 12 ...

Page 39: ... with cut off shoe Fully variable hydr adjustment up to Maximum paving width with extension parts DRV51TV 2 55 2 00 5 10 8 2 m DRV60TV 3 00 2 00 6 00 9 0 m Transport speed 0 4 km h Operating speed 0 30 m min Paving height 150 310 mm Max grain size 30 mm Theoretical paving performance 750 t h B 14 m ...

Page 40: ...t e k a M s e i d r e d n i l y c 6 n o i s r e V el 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 35 1 l h 23 4 l h Fuel tank capacity See chapter F Pressure generation Hydraulic pumps viadistribution gear directly flanged to the engine Pressure distribution Hydraulic circuits for ...

Page 41: ...ight 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 be switched to opposite directions Reversible direction of rotation Conveying volume controller Fully automatic via configurable switching points Auger hei...

Page 42: ...reed 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 Alternator o 25 kVA 400 V Operation 5 C 45 C Storage 5 C 45 C ...

Page 43: ...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 44: ...B 19 22 21 22 21 22 21 52 11 8 53 22 6 52 51 50 2 1 26 28 29 25 3 22 32 31 30 6 3 54 20 24 60 14 4 5 27 1 23 15 ...

Page 45: ...B 20 71 70 40 41 42 xxxxxxxxxxxxxxxxx 9 9 7 7 ...

Page 46: ...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 ig nition 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 47: ... injuries Always observe the maintenance instructions 8 Caution Danger from incorrect towing Vehicle movements can cause severe or fatal injuries The traction system brake must be released before 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 runnin...

Page 48: ...d with water Handling tyres filled with water incorrect ly can cause severe to fatal injuries Always observe the operating instructions 14 Maintenance for the starter batteries Maintenance work has to 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 swit...

Page 49: ...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 50: ...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 51: ... 6 3 Noise marking No Pictogram Meaning 33 Tamper speed adjuster Position of t he speed adjuster 34 Vibration speed adjuster Position of t he speed adjuster No Pictogram Meaning 40 sound output level Noise ...

Page 52: ...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 53: ...mmation Avoid contact with the human body also avoid inhaling the vapours and seek med ical advice if feeling unwell N Environmentally hazardous sub stance May cause immediate or delayed danger to the eco system when released into the environment Do not release into the sewage system ground or environment depending on hazard potential Comply with special dis posal regulations Diesel fuel complies ...

Page 54: ...ly at crown adjustment zero Cross beam lock only for transportation Do not 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 manua...

Page 55: ...No Pictogram Meaning 75 Engine start All switches in neutral The engine cannot be started when functions are switched on Always observe the operating instructions B 30 ...

Page 56: ...r 9 Item Designation 1 Paver finisher type 2 Year of construction 3 Operating weight incl al l extension parts in kg 4 Maximum permitted total weight in kg 5 Max permissible load onthe front axle in kg 6 Max permissible load onthe rear axle in kg 7 Max permissible load onthe trailer axle in kg 8 Rated performance in kW 9 Product identification number PIN 1 3 5 7 9 2 8 4 6 ...

Page 57: ...B 32 6 8 Explanation of 17 di git PIN serial number A Manufacturer B Family Model C Code letter F Serial number 10002014JHC002076 A B C F ...

Page 58: ...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 59: ...red The sound emission 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 90 0 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 running at...

Page 60: ...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 61: ...rmany 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 ...

Page 62: ...ies The transportation vehicle must always meet the requirements for transportation and be designed for this Ensure that the transportation vehicle is secured correctly during loading and unloading Do not enter the danger zone Always work with a banksman during loading and unloading Do not leave any load or loose parts on the vehicle Comply with all further information in these instructions and in...

Page 63: ...y the company and who can be expected to reliably perform the tasks assigned to them High visibility clothing must be worn The banksman and vehicle driver must have made themselves familiar with the dimensions of the vehicle and the transportation vehicle Directions are given by radio or with hand signals The banksman and vehicle driver must have agreed together beyond any doubt on the meaning of ...

Page 64: ...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 65: ...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 66: ...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 67: ...e sure that there are no persons in the danger area during loading Use the work gear and low engine speeds to drive onto the low bed trailer Caution Possible collision of parts When driving up inclines lock the lane clearer in the upper position NOTE ...

Page 68: ...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 69: ...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 70: ... 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 latches 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 and any possibly existing ho...

Page 71: ...the paver finisher and on the low load trailer Fasten the lashing chains as shown 4 2 Securing at the front m Diagonal lashing secures the paver finisher at the front using the lashing points on the 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 ...

Page 72: ...secures the paver finisher at the rear at right angles to the direction of travel using the lashing points on the paver finisher eyebolts and on the low load trailer Fasten the lashing straps as shown Screw the supplied eyebolts first of all in the holes provided in the arms 7 ...

Page 73: ...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 74: ...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 se cure it ...

Page 75: ...he 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 NOTE ...

Page 76: ...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 77: ... 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 78: ...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 79: ...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 80: ...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 81: ...the screed mounted is located in area 3 of the vehicle 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 o 1 2 3 ...

Page 82: ...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 83: ... finisher and the screed until the basic width has been attained A Two high pressure cartridges 2 are located 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 nu...

Page 84: ...etion 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 properly connected to the towing vehicle Attach the tow bar to the coupling 9 located in the bumper A Now carefully and slowly tow the paver finisher out of the construction area m Only ever tow the shortest distance to ...

Page 85: ...nition key and the main switch 1 and take it with you do not hide them somewhere on the ma chine Protect the operating panel with the dust cover 2 and lock it Store loose parts and accessories in a safe place 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 obser...

Page 86: ...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 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 main tenance work Comply with all further information in these instructions and ...

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 10 4 10 15 16 19 18 20 17 14 11 12 13 10 21 22 ...

Page 91: ...t 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 Straight ahead travel synchronisa tion Using this p...

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

Page 93: ...ver the following functions can be activated 1st position Conveyor and auger on 2nd 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 set to ...

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

Page 95: ...peed cannot be reduced to 0 with the preselector The vehicle advances slightly with deflect ed drive lever even if the travel drive preselector is set to zero 19 Steering potentiometer The steering wheel movement is transferred electrohydraulically A For precise adjustments position 0 straight ahead see the straight ahead travel synchronisation For turning on the spot see switch Turning on the spo...

Page 96: ...D 10 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 10 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 10 14 28 26 27 25 ...

Page 101: ...ic 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 triggeri...

Page 102: ...D 10 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 10 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 10 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 10 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 10 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 10 26 40 41 42 43 ...

Page 113: ...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 switch position Rotary beacon ON Lower switch position Rotary beacon OFF A Switch on for safety on roads and in the construction site...

Page 114: ...D 10 28 44 46 47 45 ...

Page 115: ... level operating speed slow 47 Turning on the spot Detent switch function Upper switch position Straight ahead travel standard operation Lower switch position Turning on the spot The paver finisher turns on the spot the caterpillar chains run in opposite directions when the steering is turned to 10 Steering turned to the left vehicle turns to the left Steering turned to the right vehicle turns to ...

Page 116: ...D 10 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 10 32 77 78 79 80 81 82 83 70 71 72 73 74 75 76 ...

Page 119: ...r damage from occurring Each fault should be rectified as soon as possible A The error code can be called up using the switch Call up error malfunction 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 th...

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 10 42 90 91 92 94 93 95 96 96 ...

Page 123: ...switch 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 carried out automatically via the connected grade control system 95 Retract extend left right screed Pushbutton function Switch position in the corresponding direction extend or retra...

Page 124: ...D 10 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: ...ower limit position Insert the pin 1 in the respective position on both sides of the roof 1 2 Danger of crushing due to moving vehicle parts Vehicle parts performing movements can cause severe or fatal injuries Remaining in the vehicle s danger zone during operation is prohibited Do not reach into the danger zone Comply with the warning and information signs on the vehicle Comply with all further ...

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 30 4 ...

Page 129: ...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 operating position whilst the vehicle is stationary 1 ...

Page 130: ...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 131: ... 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 132: ...en dan ger during transportation Screed lock mechanical o A The screed locks must additionally be engaged on both sides of the vehicle pri or to transportation with the screed lifted f Transportation 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 p...

Page 133: ...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 134: ...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 135: ...D 30 20 LED working light o There are two LED spotlights 1 at the front and rear of the vehicle f Always align the working lights to avoid dazzling the operating personnel or oth er road users 1 ...

Page 136: ...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 137: ...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 138: ...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 139: ...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 140: ...lly engages here The hose is automatically retracted into the guide after pulling and dis charging again Actuate button 3 to activate 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 t...

Page 141: ...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 142: ...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 143: ... set the sensor height the deacti vation point loosen the star handles 4 and adjust the linkage to the required length After adjusting retighten all mounting parts properly A The connection cables are 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 144: ...A socket 1 is located behind the left right seat consoles Additional working lights can be connected here for example Right seat console 12V socket Left seat console 24V socket A Voltage is present when the main switch is switched on 1 ...

Page 145: ...sure 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 ...

Page 146: ... up and se cure in the uppermost position with a shackle 2 To lower the lane clearer it must be lifted a little and the shackle 2 must be swivelled back A The blade s level above the ground is adjusted with a bolt 4 Caution Possible collision of parts The lane clearer must be adjusted in the lower setting with a few mm between the ground and the blade 3 When driving up inclines swivel the lane cle...

Page 147: ...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 148: ...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 149: ...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 150: ...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 151: ...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 152: ...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 153: ...op immediately Steering The paver finisher must immediately follow 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 154: ... side shields the side plates and the covers are securely seated Screed transport safeguard When the screed is raised before transport make sure that the cross beam lock is fixed correctly Hopper transport safeguard When the hopper is closed 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 Latera...

Page 155: ...D 40 5 1 3 10 2 8 9 6 7 4 5 ...

Page 156: ...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 157: ...D 40 7 1 3 10 2 8 9 6 7 4 5 ...

Page 158: ...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 vehicle 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 159: ...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 160: ...D 40 10 2 1 ...

Page 161: ...D 40 11 After starting m Let the paver finisher warm up for approx 5 minutes if the engine is cold ...

Page 162: ...D 40 12 2 3 1 ...

Page 163: ...tled down automatically Driving mode remains possible After cooling down to normal temperature the engine will run with full per formance 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 164: ...D 40 14 1 2 5 7 6 3 ...

Page 165: ... the 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 start the travel drive first the drive lever m...

Page 166: ...D 40 16 2 2 3 1 5 4 ...

Page 167: ... 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 by actuating the steering potentiometer 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 p...

Page 168: ...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 169: ...traight paving a direction mark must be present or established road edge chalk lines or similar Slide the operating panel to the de sired side and secure it Pull the direction indicator out of the bumper arrow and adjust it ac cordingly ...

Page 170: ...D 40 20 5 4 A 2 1 3 ...

Page 171: ...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 172: ...D 40 22 3 1 4 8 9 2 5 7 6 10 11 ...

Page 173: ...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 174: ... 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 175: ... 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 176: ...D 40 26 1 2 B A C A C ...

Page 177: ...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 178: ...D 40 28 1 2 B A C A C 3 4 ...

Page 179: ... 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 dri...

Page 180: ...D 40 30 1 2 B A C A C 3 4 ...

Page 181: ...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 set ting 20 bar 0 80 20 100 1400 1200 1000 800 600 400 200 psi bar CN 837 20 6 7 ...

Page 182: ...D 40 32 1 2 ...

Page 183: ... 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 184: ...D 40 34 1 3 10 9 2 8 7 6 5 4 ...

Page 185: ...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 186: ...D 40 36 2 Malfunctions 2 1 Error code query for engine 3 1 2 ...

Page 187: ... 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 188: ...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 189: ... 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 190: ...D 40 40 2 2 Error codes ...

Page 191: ...D 40 41 ...

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Page 193: ...D 40 43 ...

Page 194: ...D 40 44 ...

Page 195: ...D 40 45 ...

Page 196: ...D 40 46 ...

Page 197: ... 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 198: ...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 199: ...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 200: ... 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 201: ...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 defective Replace Seals defective Replace Crossbeams l...

Page 202: ...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 203: ...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 204: ...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 205: ...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 2 3 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 ad...

Page 206: ... braces from the attaching point on the material shaft Carry out height adjustment Push the slewing brackets with braces onto the attaching point on the material shaft Install the split pin 1 and retaining pin 2 again A If the retaining pins 2 cannot be set in the new position extend or shorten the braces by turning the adjustment rods until a through hole is available to set the retaining pin 2 L...

Page 207: ...ng the adjustment rods 5 until the retaining pins can be inserted Retighten the lock nuts 4 Install the split pin 1 and retaining pin 2 m Each time the height is adjusted the auger must be realigned via the braces A See section Aligning the auger ...

Page 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 4 at the end of the auger A Depending on the operating width the outer auger bearing and or auger end bearing must be installed 2 4 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 640mm left 640R Auger extension part 640 mm right 960L Auger extension part 960 mm left 960R Auger extension part 960 mm right 320 Material shaft 320 mm 640 Material shaft 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 10 11 Symbol Meaning Outer auger bearing Auger end bearing ...

Page 214: ...E 10 12 Auger upgrading working width 3 14 m Auger upgrading working width 3 78 m Auger upgrading working width 4 42 m 320 R 320 L 320 320 640 640 640 R 640 L 640 640 640 R 640 L 320 R 320 L 320 320 ...

Page 215: ...E 10 13 Auger upgrading working width 5 06 m Auger upgrading working width 5 70 m 320 L 320 320 R 320 960 R 960 L 960 960 960 R 960 L 960 960 640 640 640 R 640 L ...

Page 216: ...E 10 14 Auger upgrading working width 6 34 m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960 ...

Page 217: ...E 10 15 Auger upgrading working width 6 98 m m m 960 BR 640 R 160 L 640 L 960 BL 960 L 960 160R 960 R 960 320 L 320 320 R 320 ...

Page 218: ...E 10 16 Auger upgrading working width 7 62 m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960 ...

Page 219: ...E 10 17 Auger upgrading working width 8 26 m m m 960 BR 640 R 160 L 640 L 960 BL 640 640 L 640 640 R 960 L 960 160R 960 R 960 320 L 320 320 R 320 ...

Page 220: ...E 10 19 3 3 Mounting the auger brace 11 8 12 20 19 15 14 26 16 18 26 21 1 10 13 17 27 23 1 2 3 4 5 6 7 18 22 23 24 25 ...

Page 221: ...race bracket 8 and secure with the retain ing pin 11 Secure the retaining pins 11 with a split pin 12 A The first brace set must be set in the rear bore If the operating width necessitates a second brace the front bore must be used Mount the slewing bracket 14 at the brace shaft 13 with retaining pins 15 Secure the retaining pins 15 with a split pin 16 Mount the braces 17 on the fulcrum bracket 10...

Page 222: ...just the length of the adjustment rod here The rotational direc tion for extending or shortening the adjustment rod is determined by the left hand thread L or right hand thread R A A cord which aligns with the screed or the rear wall of the vehicle can be tensioned e g to provide assistance during alignment Extend the upper and lower adjustment rods until the material shafts are aligned vertically...

Page 223: ...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 224: ...st be adjusted to the prevailing paving conditions e g positive or negative crowning etc Loosen screw 2 and remove screws 3 Adjust guide plate to the required size basic setting 25mm Retighten the mounting screws 2 3 properly f Risk of injury due to sharp edged parts Wear suitable safety gloves to protect your hands 1 2 3 3 ...

Page 225: ...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 226: ...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 227: ...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 228: ...ssible 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 han...

Page 229: ...nd 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 essentially consists of the following components Centre element 1 Extension modules 2 C...

Page 230: ... 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 231: ...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 232: ...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 233: ...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 234: ...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 secure with the relevant star handle bolts Place the clamping ring 6 onto the sensor bracket tube and ...

Page 235: ...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 236: ...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 237: ...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 238: ...tending the screed Push the levelling piece 1 in the extension pipe 2 Tighten the clamping bolts at the extension pipe Push the extension 3 into the levelling piece 1 Secure properly with wing nuts 4 Insert the holding tube 5 in the clamp bracket 6 on the side board Tighten the bolts of the clamp bracket correctly Fix the front pull rod 7 in the holding tube with a spring cotter pin so that the sh...

Page 239: ...e height sensing unit so that the sensing arm 13 lies on the refer ence wire 14 in the middle A Tighten the reference wire with the rope tensioner if too loose Connect the corresponding cable lead with the provided socket in the remote control bracket and with the sensor m Route the connection cable so that it cannot be damaged during operation m Use of the levelling shoe increases the basic width...

Page 240: ...erent types of pavers have different steps For DRF25 the steps as follows 1 Start the engine 2 Warming up the engine and hydraulic system 3 Set the pointer on levelling cylinder to the middle position of scale plate at both side 4 Set the toggle switch of levelling mode on remote control to auto mode 5 Put the Drive speed potentiometer at 0 speed to avoid machine move forward during setting E 10 4...

Page 241: ...6 Set the engine speed at working rpm 1600 2200rpm 7 Move drive lever forward 8 Perform minimum pulse setting as per instructions from TF as below E 10 42 ...

Page 242: ... the star handles 4 and adjust the linkage to the required 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 over the full working width A We recommend adjusting...

Page 243: ...nd 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 th...

Page 244: ...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 245: ...rew 1a Connect the plug of the lead 2 with the socket 2a on the remote control m If the remote control is not mounted the plug has to be set on the bridge socket 3 Connect the connection lead 4 of the side board with the socket 5 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 2 6 7 8 4 3 1 1...

Page 246: ...nection possibilities Auger limit switches 6 Grade control system 7 External levelling system 8 24 volt consumers e g additional lighting 9 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 247: ...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 248: ...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 249: ...F 20 1 F 20 Maintenance review 1 Maintenance review 73 40 50 80 90 100 30 60 ...

Page 250: ... after the following service hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F30 q q q Auger F40 q q q q q q q Engine F50 q q q q q q Hydraulics F60 q q q q q q Drive units F73 q q q q q q q Electronics F80 q q q Lubrication points F90 q q q q Checking stopping F100 q q q Maintenance required q ...

Page 251: ...F 30 1 F 30 Maintenance conveyor 1 Maintenance conveyor ...

Page 252: ...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 253: ...If necessary 1 q Conveyor chain Check tightness q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Conveyor drive drive chains Check chain tightness q Conveyor drive drive chains Adjust chain tightness 3 q Replace conveyor deflectors conveyor plates Maintenance q Maintenance during the running in period g ...

Page 254: ...be stopped or to break when material falls into the space between the chain and the sprocket An excessively slack chain may catch on protruding objects and be destroyed Adjustment of chain tension A 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...

Page 255: ...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 256: ...n has been set properly the chain must be able to move freely approx 10 15 mm To re tension the chains Unfasten mounting screws A and lock nut B slightly Use the tensioning screw C to set the required chain tightness Retighten mounting screws A and lock nuts B correctly A A B D ...

Page 257: ...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 258: ...F 30 8 ...

Page 259: ...F 40 1 F 40 Maintenance auger assembly 1 Maintenance auger assembly ...

Page 260: ...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 261: ...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 262: ...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 263: ... 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 264: ... 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 265: ... 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 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 271: ...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 272: ...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 273: ...n the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel system Fuel filter drain the water 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 Maintenance during ...

Page 274: ...ilter 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 Maintenance during the ru...

Page 275: ...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 Maintenance during the running in period g ...

Page 276: ...nnot run dry and time consuming venting bleeding can therefore be avoided For filling in the fuel Unscrew cap A Fill in fuel through the filling port until the required fill lever is achieved Replace the cap A Clean the tank and system Unscrew the drain plug B at the bot tom of the tank and drain into a collec tion pan about 1 l fuel When returning the screw make sure to use a new seal A B ...

Page 277: ... 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 278: ... 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 279: ...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 280: ...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 281: ...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 282: ...pty dust collector Empty the dust removal valve A on the air filter housing by compressing the discharge slot Remove any baked on dust by press ing together the upper valve section A Clean the dust removal valve from time to time A ...

Page 283: ...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 284: ...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 285: ...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 286: ... 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 287: ...F 60 1 F 60 Maintenance hydraulic system 1 Maintenance hydraulic system ...

Page 288: ...ecure the vehicle to prevent it being switched on again Consult a doctor immediately if injured Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces 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 v...

Page 289: ...oil tank 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 Intake return hydraulic filter change vent 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 Maintenance during the running in period g ...

Page 290: ...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 Maintenance during the running in period g ...

Page 291: ...d on the side of the tank For filling in the oil Remove cap B Fill in oil through the filling opening un til the oil level rises to the centre of the sight glass A 5mm Screw cap B on again A Regularly remove dust and dirt from the oil tank vent C Clean the surfaces of the oil cooler m Use only the recommended hydraulic oils see section Recommended hy draulic oils A When filling for the first time ...

Page 292: ...ew 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 collecting 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 E F ...

Page 293: ...r mounting screws A and lift off cover Disassemble the removed unit into Cover B Separating plate C Filter D Dirt trap E Clean the filter housing cover sepa rating plate and dirt trap Check the O rings F replace if nec essary Coat the sealing surfaces and O rings with clean operating fluid m The filter must be bled following filter re placement F E D C B A ...

Page 294: ...lace a transparent hose H onto the bleed screw ending in a suitable con tainer Start the up drive engine at idle speed Close the bleed screw G as soon as the oil forced through the hose is clear and therefore free of air bubbles A The process from assembling the filter cover to starting the drive engine should take place in less than 3 minutes as the oil level in the filter housing otherwise falls...

Page 295: ... cartridge Clean the filter housing Insert the new filter cartridge Replace the seal ring of the filter hous ing Turn on the filter housing by hand and tighten it using a wrench Start trial operation and check the tightness of the filter A Replace the seal ring whenever the filter cartridge is replaced A After replacing the filter element the red mark in the maintenance indicator A automatically r...

Page 296: ...or 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 openin...

Page 297: ...F 60 11 Bleeder A The bleeder A can be found on the rear of the pump distribution gear housing The functioning of the bleeder must be ensured If soiling has occurred the bleeder should be cleaned A ...

Page 298: ...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 299: ...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 300: ...noth er and always ensure that they are at the correct pressure In individual cases the period of use can be stipulated according to experience and may differ from the following general indications When producing the hose pipe the hose purchased by the meter should not be more than four years old The period of use of a hose pipe should not exceed six years including any possi ble storage period Th...

Page 301: ...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 302: ...F 60 16 ...

Page 303: ...F 73 1 F 73 Maintenance drive units 1 Maintenance drive units ...

Page 304: ...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 305: ...0 1000 annually 2000 every 2 years If necessary 1 q Chain tension Check q Chain tension Adjust q Chains Relieve 2 q Bottom plates Check wear q Bottom plates Replace 3 q Rollers Check for leaks q Rollers Check wear q Rollers Replace Maintenance q Maintenance during the running in period g ...

Page 306: ...2 years If necessary 4 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality q Planetary gear Screw connections Check q Planetary gear Screw connections Tighten Maintenance q Maintenance during the running in period g ...

Page 307: ...ant safety measures and should only be carried out by a specialist workshop A Your Dynapac customer service will be happy to provide support during maintenance repair and the replacement of wearing parts Danger from pretensioned springs Incorrectly performed maintenance and repair work can cause severe or fatal injuries Always observe the maintenance instructions Do not perform any unauthorised ma...

Page 308: ...dler wheel thereby increasing wear levels m If the chains are tensioned too tightly this increases wear on the idler wheel and drive unit mounting and also increases wear on track bolts and bushes Checking adjusting chain tension The chain tension is adjusted with grease tensioners The filling ports A are located on the RH and LH sides of the drive unit frame x A ...

Page 309: ...tension ensure that the position of the chain to the idler wheel is as shown in diagram A A Correct if necessary by moving the vehicle a little The correct setting has been adjusted when the pressure gauge C shows a value between 65 85 bar A B C ...

Page 310: ...e tension is too high see section Relieving the chain A Repeat this procedure on both drive units Relieving the chain f The grease in the tensioning element is under pressure Carefully and slowly un screw the filling valve but not too far Unscrew the filling connection A us ing a tool until the grease is able to emerge from the lateral hole A The idler wheel moves back independ ently or must be re...

Page 311: ...te with the front edge A over the chain links bolt eye B Lubricate the threads and the contact surfaces beneath the bolt heads with a thin film of oil or grease Insert the bolts C into the holes and screw them into the nuts D a few turns Tighten the bolts without applying significant torque Tighten the bolts diagonally to the required torque 155 8 Nm E m Check that each bolt has attained the full ...

Page 312: ... measures when rais ing and securing loads Remove the defective roller Install the new roller using new as sembly parts Tighten the bolts without applying sig nificant torque Tighten the bolts diagonally to the re quired torque Tighten to the following torques Small rollers A 220 Nm Large rollers B 87 Nm m Check that each bolt has attained the full tightening torque Lower the track chassis and ten...

Page 313: ...r bore at A until the oil level has reached the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at oper ating temperature m Ensure that no dirt or foreign bodies are able to enter the gear Turn the conveyor chain sprocket so that the drain plug B is located at the bottom Unscrew and remove the drain plug B and filler screw A and drain off ...

Page 314: ...are located at the rear of the gearbox Oil inlet B Oil level check C Oil drain D A Carry out the oil level check and oil change as per the description above m When draining using the drain D a small residual quantity of oil remains in the gearbox Max oil level up to lower edge of oil check C Reinstall the protective cover A prop erly B C D A ...

Page 315: ...re firmly seated m Improperly tightened screws may lead to increased wear and to the destruction of components The correct tightening torque for the connecting screws for the gearbox drive unit frame B is 500Nm 50Nm The correct tightening torque for the connecting screws for the hydraulic motor gearbox C is 210 Nm B C ...

Page 316: ...F 73 14 ...

Page 317: ...1 F 80 Maintenance electrical system 1 Maintenance electrical system ...

Page 318: ...ot 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 batte...

Page 319: ...tery 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 320: ...t 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 recharge t...

Page 321: ...ery 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 capacity...

Page 322: ...ated 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 electr...

Page 323: ...ator 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 324: ...he 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 325: ...1 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 5...

Page 326: ...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 327: ...11 Relays in the engine compartment K Function 0 Engine start ...

Page 328: ...l 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 329: ...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 330: ... 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 331: ...15 Relay in connection box under the operating platform K Function 40 Raise roof 41 Lower roof ...

Page 332: ...16 ...

Page 333: ...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 334: ...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 335: ...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 336: ...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 337: ...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 338: ...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 339: ...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 340: ...F 90 8 ...

Page 341: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping ...

Page 342: ...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 343: ... 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 Caution Possible damage to or destruction of parts Self locking nuts must always be replaced after removal Special torques not mentioned in this manual are stated at the corresponding place in t...

Page 344: ...isher screed and optional gas or electric system checked by a trained spe cialist when required according to the operating conditions and the nature of application however at least once a year check that they are all in good operational condition ...

Page 345: ...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 346: ...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 347: ...F 100 7 5 3 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions m Daily cleaning with a dry lint free cloth ...

Page 348: ...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 349: ...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 350: ... 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 351: ... 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 352: ...F 100 12 ...

Page 353: ...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 354: ...F 110 2 2 4 7 5 6 6 3 1 ...

Page 355: ...50 litres 4 Hydraulic oil reservoir Hydraulic oil 200 litres 5 Pump distribution gear Gearbox oil 7 0 litres 6 Planetary gear drive unit Gearbox oil 1 8 itres 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 option...

Page 356: ...Esso Exxon Fuchs Mobil Shell Engine Oil 200 Dynapac AGIP Chevron Caltex Delo Petronas Finke Coolant 200 Antifreeze Special Extended Life Coolant Antifreeze G12 Aviaticon Finkofreeze P12 Dynapac AGIP Chevron Caltex Fuchs Mobil Shell Hydraulic 100 Rando HDZ 46 Rando HDZ 46 Tellus Oil S2 V46 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 400 Titan ATF 6000 SL Spirax S4 ATF HDX Spirax S6 ATF VM...

Page 357: ...Grease A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 100 Omala S2 GX 220 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Gear Oil 100 Omala S2 GX 220 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Omala S4WE460 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Chevron Paver Grease Gadus S5 T460 1 5 High Temp Premium2 ...

Page 358: ... 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 359: ...recommended m When changing from mineral oil pressure fluids to biodegradable pressure fluids please contact our factory advisory service Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 Shell Natural HF E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 ...

Page 360: ...F 110 8 ...

Page 361: ...www dynapac com Dynapac China Compaction Paving Equipment Co Ltd Tianjin China ...

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