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Svedala-Demag DF 115 C Operating Instructions Manual

Road finisher
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Operating instructions
02-01.03
Road Finisher
DF 115 C
DF 135 C
900 98 06 40

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Summary of Contents for Svedala-Demag DF 115 C

  • Page 1 Road Finisher DF 115 C Operating instructions DF 135 C 02-01.03 900 98 06 40...
  • Page 3 Foreword For safe operation of the machine, a specific knowledge is necessary, which is pro- vided in these operating instructions. The information is provided in a concise, clear form. The chapters are arranged according to letters. Each chapter begins with page 1.

  • Page 5: Table Of Contents

    Table of contents Use for the intended purpose ..........1 Vehicle description ..............1 Description of application ................1 Assembly and functional description ............2 Vehicle ....................... 3 Design ....................3 Additional equipment ................3 Safety devices .................... 6 Emergency button ..................6 Steering ......................
  • Page 6 Transportation ................. 1 Safety regulations for transportation ............1 Transportation on low-bed trailers ............. 2 Preparations ....................2 Driving onto the low-bed trailer ..............3 After transportation ..................3 Transportation on public roads ..............4 Preparations ....................4 Driving on public roads ................5 Loading by crane ..................
  • Page 7 Operation ....................58 Preparing for operation ................58 Required devices and aids ..............58 Before starting work (in the morning or when starting paving) .... 58 Checklist for the machine operator ............59 Starting the paver finisher ................ 61 Before starting the paver finisher ............61 „Normal”...
  • Page 8 Setting-up and field replacement .......... 1 Special safety information ................1 Distribution spreader .................. 2 Height adjustment ..................2 For mechanical adjustment with ratchet ............ 2 For hydraulic adjustment (Optional) ............3 Spreader enlargement ................3 Mounting extensions .................. 4 Screed ......................
  • Page 9 Hydraulic cylinder (2.5) ................ 23 Track group (3.1) ................. 24 Conveyor drive transmission (3.2) ............25 Idler wheel (3.3) ................... 25 Conveyor chain (4.1) ................26 Center conveyor bearing (4.2) ............. 26 Conveyor drive transmission (4.3) ............27 Auger planetary gear (4.4) ..............28 Conveyor auger drive chains (4.5) ............

  • Page 11: A Use For The Intended Purpose

    A Use for the intended purpose The ”Guide to the intended and proper use of road finishers” is included in the scope of supply of this machine. It is an integral part of these operating instructions and must be observed in any event. National requirements apply without restriction. The road construction machine described in these operating instructions is a road fin- isher that is suitable for laying material, rolled or lean-mixes concrete, track ballast and uncombined mineral compounds for paving surfaces.

  • Page 13: B Vehicle Description

    B Vehicle description Description of application The SVEDALA DEMAG road finisher is equipped with a crawler for laying bituminous material, rolled or lean-mixes concrete, track ballast and uncombined mineral com- pounds for paving surfaces. Df_115_c.tif...

  • Page 14: Assembly And Functional Description

    Assembly and functional description Df_115_c.tif Item Designation Hopper (trough) Push rollers for truck docking Pipe for visual gauge (direction indicator) and trailing ski mount Crawler Levelling cylinder for laying thickness Traction roller Levelling arm draw bar Laying thickness indicator Levelling arm Track drive Spreader Screed...

  • Page 15: Vehicle

    Vehicle Design The road finisher has a frame in a steel welded construction on which the individual assemblies are mounted. The track groups (4) level out surface unevenness and ensure high laying accuracy due to the suspension of the screed (12). With the infinitely variable speed hydrostatic drive (10), the speed of the road finisher can be adapted to suit the respective working conditions.
  • Page 16 Engine: The road finisher is driven by a water-cooled, six-cylinder Deutz diesel en- gine. For further information, refer to the engine manual. Track group: The two track groups are independently driven. They operate directly without drive chains requiring care and maintenance. The tension of the track groups can be adjusted via grease tensioners.
  • Page 17 Screed lift and enlargement: By means of the spreader lift and enlargement, opti- mal adaptation to diverse laying thicknesses and widths is ensured. During adjustment with ratchets, the height is adjusted with turnbuckle spindles at the guide supports in the back panel. In a further version with hydraulic cylinders (optional), the height can be adjusted from the operation panel.

  • Page 18: Safety Devices

    Safety devices Safe working is only possible with perfectly functioning control and safety devices as well as properly fitted protective devices. The functions of the devices must be tested at regular intervals (see Chapter D, Sec- tion 2.1). Emergency button - on operation panel - on both remotes (optional) 11.eps...

  • Page 19: Horn

    Horn - on operation panel - on both remotes Horn.tif Horn_k.cdr Power switch The power switch is located on the right- hand side of the paver finisher between the central panel and hopper. F0077_a1.eps Trough safety lock F0076A_A1.eps Screed safety lock The screed safety locks are provided on both sides on the operation panel behind the seats.

  • Page 20: Other Safety Devices

    Other safety devices Df_115_c.tif Item Designation 23 Engine covers 24 Side flaps 25 Catwalks 26 Screed covers 27 Material duct 28 Screed hazard lights Other equipment: - Wedges - Warning triangle - First-aid box...

  • Page 21: Technical Data Standard Type

    Track group Two individually driven crawlers with rubber pad track groups Turning radius Turning on the spot Speed see above Engine DF 115 C Make/Type Deutz BF6M 2012 Design 6-cylinder diesel engine (water-cooled) Power 118 KW/160 BHP (at 2100 1/min)

  • Page 22: Hydraulic System

    Hydraulic system Hydraulic pumps via distribution gear Pressure generation (directly flanged on to engine) Hydraulic circuits for: -Final drive -Material feed and distribution - Tamper/vibration (optional) Pressure distribution - Cylinder actuating elements for trough, levelling, screed lift, screed extend/retract, Spreader lift (optional) - Downstream compressor (optional) Hydraulic oil tank capacity (see Chapter F)

  • Page 23: Material Feed

    Material feed Flight bar conveyor For left and right operation - Drive Hydrostatic, infinitely variable speed - Flow control Fully automatic via adjustable switching points Material distribution For left and right operation Distribution spreader Hydrostatic central drive, infinitely variable speed Independent of flight bar conveyor spreader halves - Drive switchable for operation in opposite directions...

  • Page 24: Dimensions (All Dimensions In Mm)

    4.11 Dimensions (all dimensions in mm) Abmass2.tif Designation Overall height with roof 3460 Transport height with roof folded down 3000 Min. transport height without roof and tail pipe 2610 Trough height (trough fully closed) 1600 Operation panel height 1600 Hopper length 2100 Dumping 1950...

  • Page 25: Standards

    EN standards Continuous sound pressure level The use of hearing protection is prescribed for this finisher. The sound emission value can vary significantly due to the various laying materials and exceed 85 dB(A). Dam- age to hearing can be caused if the machine is used without hearing protection. The sound emission values of the finisher were measured according to the draft standard ENV 500-6 of March 1997 and ISO 4872 under free field conditions.

  • Page 26: Whole Body Vibrations

    Whole body vibrations In normal use, the weighted effective acceleration values in the operator’s cab of a = 0,5 m/s² according to the draft standard prEN 1032-1995 are not exceeded. Hand-arm vibrations n normal use, the weighted effective acceleration values in the operator’s cab of = 2,5 m/s²...

  • Page 27: Identification Points For Signs

    Identification points for signs Safety information on gas system 1. Fix the gas cylinders in the holders provided and se- cure to prevent them falling and twisting. 2. Do not extract gas without using hose protection and gas regulator. 3. Gas cylinders, valves and fittings must be inspected for leaks every two years by an expert.
  • Page 28 Item Designation Serial plate Sign “Liquefied petroleum gas system” Sign “Filler neck for diesel fuel” Sign “Filler neck for hydraulic oil” Sign “Close safety valve immediately” Sign “Attention: Standing in the operating area..” Sign “Check hydraulic oil level” Sign “Hearing protection” Sign “Safety information on gas system”...

  • Page 29: Serial Plate Finisher (1)

    Serial plate finisher (1) Item Designation Finisher type Year of manufacture Serial number of finisher series Maximum permissible operating weight including all extension sections in kg Maximum possible load on front axle in kg Maximum permissible load on rear axle in kg Rated power in kW Product identification number (PIN) B 17...

  • Page 30: Serial Plate Liquefied Petroleum Gas System (2)

    Serial plate liquefied petroleum gas system (2) Liquefied petroleum gas system Year of manufacture: Propane Propane Inlet pressure 1,5 bar Connected load per burner 1,5 Kg/h Item Designation Year of manufacture Type of gas to be used Inlet pressure in bar Average gas consumption of mounted screed in kg/h B 18...

  • Page 31: C Transportation

    C Transportation Safety regulations for transportation Accidents can happen when the paver finisher and the screed are not properly pre- pared for transportation or when transportation is carried out improperly! Reduce both the paver finisher and the screed to their basic widths. Remove all pro- truding parts (such as the levelling device, auger limit switches, aprons, etc.).

  • Page 32: Transportation On Low-Bed Trailers

    Transportation on low-bed trailers Reduce the paver finisher and the screed to their basic widths; also remove any attached side plates. To prevent damages to the screed, the inclination of the ramp to be used must not exceed 11° (19%). Preparations - Prepare the paver finisher for opera- tion (see chapter D, section 3).

  • Page 33: Driving Onto The Low-Bed Trailer

    Driving onto the low-bed trailer Make sure that there are no persons in the danger area during loading. - Use the work gear and low engine speeds to drive onto the low-bed trailer. - Lower the screed onto wooden blocks on the low-bed trailer. - Switch off the paver finisher.

  • Page 34: Transportation On Public Roads

    Transportation on public roads Reduce the paver finisher and the screed to their basic widths; also remove any attached side plates. Preparations - Prepare the paver finisher for opera- tion (see chapter D, section 3). - Use switch (1) to close the hopper lids. Engage both hopper transport safe- guards (6).

  • Page 35: Driving On Public Roads

    Driving on public roads - Set the Fast/Slow switch (12) to “Hare”. - Turn the preselector (8) to maximum. - Use the drive lever (9) to regulate the speed. - Press the emergency stop button when a dangerous situation arises! Element1_SPSC.cdr,Element2_SPSC.cdr...

  • Page 36: Loading By Crane

    Loading by crane Use only lifting gear that can bear the load. (For the weights and dimensions, see chapter B, sections 3) Four lifting eyes (1,2) are provided for loading the vehicle with a crane. - Park the paver finisher and render it safe.

  • Page 37: Towing

    Towing Description of disconnect mechanism DF115C.Tif gear.bmp The disconnect mechanism allows the machine to be towed. The gear drive and hy- draulic motor are disconnected when the mechanism is activated. The integral parking brake in the gear drive is non functional when the gear drive is in the disengaged position! Ensure that the disconnect mechanism is only operated with the machine at a stand- still!

  • Page 38: Removing Lateral Flaps With Screed Raised

    Removing lateral flaps with screed raised. Should it be necessary to open the later- al flaps with the screed raised, i.e. when the crossbeams are in front of the lateral flaps, these can be pushed to the side and removed. - Open both locks (1).

  • Page 39: Safely Parking The Vehicle

    Safely parking the vehicle When the paver finisher is parked at a lo- cation accessible to the public, it must be secured in such a way that unauthorized persons or playing children cannot dam- age the vehicle. - Pull off the ignition key and the main switch (19) and take it with you –...

  • Page 41: D Operation

    D Operation Safety regulations Starting the engine, the traction drive, the conveyor, the auger, the screed or the lifting devices can cause injuries or even the death of persons. Make sure before starting any of these devices that no-one is working at, in or be- neath the paver finisher or within its danger area! - Do not start the engine or do not actuate any controls when this is expressly forbidden! Unless otherwise specified, the controls may only be actuated when the engine is...

  • Page 42: Operating Elements

    Operating elements Operating panel Bed_SPS_C2.tif, Element1_SPSC.cdr, Element2_SPSC.cdr, Element3_SPSC.cdr...
  • Page 43 General notes on the observation of CE regulations All functions of self-engaging buttons which might provoke a risk during start-up of the diesel engine (conveying function of auger and conveyor) are set to STOP in case of an emergency stop or a control restart. Changes of settings which are performed when the diesel engine is at a standstill („AUTO”...
  • Page 44 Element2_KC.cdr...
  • Page 45 Item Designation Brief description Key positions: 1 Ignition on 2 Parking/tail lights, fittings lighting, Ignition lock and if necessary working lights illumination switch 3 Headlights (dipped beam lighting) 4 Main beam lighting Release lock between 2 and 3 by pressing in. Turning key to left = parking light Not used In the case of an emergency (danger to persons, possible col-...
  • Page 46 Element2_KC.cdr...
  • Page 47 Item Designation Brief description For switching on the paver finisher functions and for continu- ously regulating the traction speed – forward or reverse. Zero position: starting is possible; engine at idling speed; no traction drive Drive lever Depending on the position of the drive lever, the following (forward - reverse) functions can be activated: - Position 1: Conveyor and auger on.
  • Page 48 Element1_SPSC.cdr...
  • Page 49 Item Designation Brief description Push-button: Left: open left hopper halve Right: open right hopper halve Open hopper If both hoppers are hydraulically actuated at the same time (1 valve), either the left button or the right button can be used for operation.
  • Page 50 Element1_SPSC.cdr D 10...
  • Page 51 Item Designation Brief description Self-engaging buttons with LED indication Hare: transport speed When button 16 is set to OFF (stands for paving), button 17 has to be set to „tortoise”. Traction drive Tortoise: operating speed for paving fast/slow - Only change the speed when the paver finisher is at a standstill! When restarting, the buttons are set to working speed (tortoise).
  • Page 52 Element1_SPSC.cdr D 12...
  • Page 53 Item Designation Brief description Not used Vibration Operation and application: see button (20). Self-engaging buttons with LED indication Toggling between two switching conditions. Auger Stop: Operational readiness left/right Auto Reset to STOP in case of an emergency stop or a restart. Button 16 locks the conveying function.
  • Page 54 Element1_SPSC.cdr D 14...
  • Page 55 Item Designation Brief description Self-engaging button with LED indication Switched off by pressing the button again or by pressing but- ton 25 or 31. 1. „MANUAL” auger operation - Requirements: button 24 must be set to „AUTO” „MANUAL” auger - Using the buttons in the pad (left) for the directions of operation and movement (29), the conveying speed of the automatic lifting/lowering the...
  • Page 56 Element1_SPSC.cdr D 16...
  • Page 57 Item Designation Brief description Push-button function Lift screed Self-engaging button with LED indication Lower screed/screed in floating position Screed floating position: Pressing the button turns the LED ON and prepares the screed for „floating position”, which is activated by the actuated drive lever (9). Pressing the button again or pressing the button Lift screed turns the LED off.
  • Page 58 Element3_SPSC.cdr, Kontrollleucht_SPSC.cdr D 18...
  • Page 59 Item Designation Brief description Display keyboard Button „Enter” starts the menu operation Buttons „Left/right” Control, input and display terminal Buttons „Scroll up/down” Button „Escape” closes the menu Normal display up to 120 °C = 248 °F. Stop the paver finisher when higher temperatures are Temperature indi- encountered (drive lever (9) to the center position), let cator for hydraulic oil...
  • Page 60 Element3_SPSC.cdr, Kontrollleucht_SPSC.cdr D 20...
  • Page 61 Item Designation Brief description Lights up if too high a volume of water has been detected in the fuel system water separator. Drain off the separated water immediately as described in the Maintenance Instructions to avoid damaging the "Water in fuel" engine.
  • Page 62 Element3_SPSC.cdr, Kontrollleucht_SPSC.cdr D 22...
  • Page 63 Item Designation Brief description Not assigned Lights up if the engine temperature is too high. The engine performance will be throttled down automat- ically. (still possible to process the paver finisher). Stop Engine tempera- paver finisher (drive lever in central position), leave en- ture check (red) gine to cool at idling speed.

  • Page 64: Operating The Input And Display Terminal

    Operating the input and display terminal TDM.cdr Display keyboard Button „Escape“ closes the menu (B)/(C) Buttons „Left/right“ (D)/(F) Buttons „Scroll up/down“ Button „Enter“ starts the menu operation D 24...

  • Page 65: Working In The Menu

    Working in the menu Once the ignition has been switched on and after a brief charging process, the main menu appears on the display: Various actual values are displayed here and operators can select from 6 sub-menus. 001.bmp - Capacity of flow/paving depth (1) - Operating hour meter (2) - Heating control for electrical screed heater ( ) (3) - Emergency function / screed stop and tamper start (4)
  • Page 66 Transport volume/layer thickness (1) Transport volume of conveyor As with the two remote controls, the transport speed of the two conveyors can be set separately. qsb_205.bmp - Reduce speed of left-hand conveyor - button (B) - Increase speed of left-hand conveyor - button (C) - Reduce speed of right-hand conveyor - button (D) - Increase speed of right-hand conveyor - button (E) The speed can be set to 8 different stages.
  • Page 67 Operating hour meter (2) Two different operating hours values are displayed: qsb_096.bmp - Total operating hours (1) with engine running - Real operating hours (2) during installation In order to observe maintenance intervals (chapter F), call up every day and note the total operating hours! D 27...
  • Page 68 Heating control for electrical screed heater (3) ( ) In this menu sub-item, the heating tem- perature for the following screed ele- qsb_151.bmp ments can be read off and can be jointly set for all screed elements: - Actual temperature value, main screed, on left (1) - Actual temperature value, main screed, on right (2) - Actual temperature value, extendable part, on left (3) - Actual temperature value, extendable part, on right (4)
  • Page 69 Emergency function / screed stop and tamper start (4) If a nominal value specification or actual value measurement fails (e.g. sensor qsb_147.bmp defective, remote control failed), the per- formance of various functions can be set for automatic operations. - auger (1) - slat bar conveyor (2) - tamper (3) - vibration (4)
  • Page 70 Automatic steering unit No functions are saved in the wheeled paver program in this sub-menu item! 011.bmp In this menu sub-item, the operator can use the selection (1) to set whether the automatic steering unit is to be activated or deactivated: - Selection 0: automatic steering unit deactivated - Selection 1: automatic steering unit activated.
  • Page 71 Error memory No functions are saved in the wheeled paver program in this menu sub-item! 009.bmp Errors which have arisen and are saved in the system can be called up in this menu sub-item: The number of error messages saved is shown in display (1). Selection (2) can be used to set whether the errors are to be shown one another in the display or whether this is initially not to be the case.
  • Page 72 Display showing various actual en- gine statuses (5) Several actual engine statuses can be monitored in this sub-item: 007.bmp - Engine temperature (1) - Oil pressure (2) - Fuel consumption in L/h (3) - Battery voltage (4) Select the „Sub-menu“ symbol (6) and confirm by pressing button (F) to jump into the „Counter showing distance travelled“...
  • Page 73 Service program for workshop and mechanics (6) After choosing this subordinate a re- quest for a password input appears in neubild2.EPS the display. Only instructed personal is authorized for the further proceedings! - Return to the basic menu by pressing push button (A) - By pressing the (F) button, the follow- ing screed is called up and the pro- grammable controller software version...

  • Page 74: Diagnosing And Detecting Malfunction

    Additional information and adjustments / showing up via LC-display Adjustment of the RPM speed of the engine Comes up when pressing push button (26) of the operating panel. Bild79.EPS - Indicating the scheduled value as well as actual value of the RPM speed. To adjust the scheduled value, press push button (A) (figure becomes black and flashes), reset the value by working push button (D/E).
  • Page 75 In the case of the display indicating malfunction select this menu by pressing push button (F). The following information is given. Example: Bild14.Tif Pos. Description the part affected and its function electrical malfunction matching PLC-module controlled element matching terminal strip matching cable clamp colour of the cable D 35...
  • Page 76 Variations of malfunction (Pos 2) Meaning Graphic Parting of cable Short circuit Variations (Pos. 4) Meaning Graphic Ultrasound sensor/mechanical limit switch Potentiometer Valve Electronics unit for automatic drive D 36...
  • Page 77 Variations of malfunction (Pos 1) Meaning Graphic Auger L.H. lifting Auger L.H. lowering Auger R.H. lifting Auger R.H. lowering Levelling L.H. lifting Levelling L.H. lowering Levelling R.H. lifting Levelling R.H. lowering Hopper L.H. open Hopper L.H. close Hopper R.H. open Hopper R.H.
  • Page 78 Meaning Graphic Screed stop Tamper function Vibration function Left remote control Right remote control Screed L.H. extend Screed L.H. retract Screed R.H. extend Screed R.H. retract Starting Horn Travel drive pump Additional note „fuse“ Some error messages also make refer- ence to the relevant fuse (example F250.6).
  • Page 79 Variety of colours (Pos 7) Abbr. Meaning blue brown yellow green pink black lilac white Example: - Malfunction of the auger R.H. lower- ing. - Short circuit of the valve Y35B at the Bild21.Tif PLC-module A2 - Terminal strip X1, cable clamp 65, colour of the cable: green-red D 39...
  • Page 80 Automatic drive error message The electronics unit for the automatic drive has failed. Data connection with the master module 005.bmp is interrupted. First check whether fuse F5.1 is still intact. If the fuse has not caused the interrupt to the data connection, the diesel engine can be started (using an emergency start): - Engage button (1) (LED on).
  • Page 81 Further malfunction: Slave error - Slave defective (Example Slave A31) neubild4.EPS Gateway - Error in gateway Bild70.EPS - Error in engine electronics EMR Bil871.EPS Battery - Potential to low Bild_088.bmp Travelling speed - Potentiometer defective Bild_086.bmp Drive lever - Potentiometer defective Bild_087.bmp Steering potentiometer - Potentiometer defective...
  • Page 82 Sensor caterpillar drive right - Sensor defective Bild95a.EPS Sensor caterpillar drive left - Sensor defect Bil894a.EPS Travelling motion - Forward blocked Bild_089.bmp Travelling motion - Backward blocked Bild_090.bmp Travelling motion - Turning left blocked Bild_091.bmp Travelling motion - Turning right blocked Bild_092.bmp Travelling motion - Forward+backward blocked...

  • Page 83: Engine Error Messages

    Engine error messages If an error is found in the engine, this is signalled by the associated warning light (1) of the electronic engine control sys- tem (EMR) and at the same time dis- played in code on the display. Permanently lit warning light (1) (yel- low): there is an error in the engine.

  • Page 84: Coolant Level Too Low" Error Message

    Example: Explanation: The flashing warning light signals a serious error in the engine with an automatic and/ or essential engine stop. Display indicator: SPN: FMI: Cause: The sensor signals that the oil level is too low. Consequence: Speed restriction and possible engine shutdown, if the engine protec- tion shutdown function is activated.

  • Page 85: Remote Control

    Remote control SPSRemote.Tif D 45...
  • Page 86 Item Designation Brief description Function and application as with the emergency stop Emergency stop button (7) on the operating panel. button ( ) Important for dangerous situations when the driver’s ”sight” is restricted. Horn Function as for push-button (30) on the operating panel. Levelling cylinder Function and applications as for Levelling cylinder switch (25) on the operating panel...
  • Page 87 Bottom SPSRemote2.Tif Item Designation Brief description Socket for auto- Connect the cable for the grade control unit here. matic levelling unit Socket for auger Connect the cable for the material limit switch here. limit switch Cable for the Connect the plug to the screed remote control (see operating instructions for the screed).

  • Page 88: Emergency Program For Tdm-Failure

    Emergency program for TDM-failure To ensure the pavers operating ability during a display failure, an emergency program will be started automatic. Following setting and functions will be 2100 min adjusted and switched on: - Number of revolutions of the Diesel engine: 2100 min - Traction drive (1) slow (Turtle) - Operating main switch (2) OFF...
  • Page 89 Accessory the following function can be switched by using the remote controls: - Press button (1) to close the hopper. - Press button (2) to open the hopper. - Lifting the screed: - Switch off the LED bar (3) of auger and conveyor completely by using accompanying Minus-buttons (4).

  • Page 90: Special Functions

    Special functions Reversible conveyor The direction of transport of the convey- or can be changed over to the opposite direction to move material located just in front of the auger back slightly. Material losses, e.g. during transport operations can therefore be avoided. - Switch main function switch (16) over to „Off“...

  • Page 91: Operating Elements On The Paver Finisher

    Operating elements on the paver finisher Batteries (71) Located behind the right side cover are the batteries of the 24 V system. For the specifications, refer to chapter B, ”Technical Data”. For servicing, see chapter F. Heed the instructions when starting the finisher externally.

  • Page 92: Transport Safeguards For The Hopper (73)

    Transport safeguards for the hopper (73) Before parking or transporting the paver finisher, the hopper halves must be swung upwards and the transport safe- guards for the hopper must be inserted. Do not enter the hopper while the engine is running! Danger of being caught by the conveyor! Without transport safeguards inserted, the hopper halves will slowly open;...

  • Page 93: Seat Lock (Behind The Driver's Seat) (75)

    Seat lock (behind the driver’s seat) (75) Telescoping seats ( ) can be extended beyond the basic width of the paver fin- isher. They must be locked. The seats must not protrude from the ve- F169_A1.tif hicle during transportation. Push the seats back to the basic width of the paver finisher! - Pull out the locking button and move the seat;...

  • Page 94: Separator Fluid Spraying System (80) (O)

    Separator fluid spraying system (80) Used to spray the parts coming into contact with asphalt with a separator emulsion. A Spray bottle with pressure pump B Sprayer with electric pump (81) Only switch on the spraying system when the diesel engine is running; other- wise, the battery will be discharged.

  • Page 95: Conveyor Limit Switches (88) (Left And Right)

    Conveyor limit switches (88) (left and right): The mechanical conveyor limit switches (88) or the ultrasonic conveyor limit switches (89) control the material flow at the respective conveyor half. The con- veyors should stop when the material has roughly reached the area below the auger tube.

  • Page 96: Ultrasonic Auger Limit Switches (90) (Left And Right)

    Ultrasonic auger limit switches (90) (left and right) The limit switches control the material flow at the respective auger half. The ultrasonic sensor is mounted by means of an appropriate leverage to the side plate. Loose clamping lever for adjustment and modify angle / height of the sensor.

  • Page 97: Pressure Control Valve For Screed Charging/Relieving (93) (O)

    Pressure control valve for screed charging/relieving (93) ( ) Used to adjust the pressure for addition- F0105_A1.TIF al charging/relieving of the screed. - See ”screed charging/relieving device” (44). - Pressure display: see manometer (93b). Pressure control valve for screed stop with pretensioning (93a) ( ) This valve is located beneath the right-hand bottom flap of the operator´s platform.

  • Page 98: Operation

    Operation Preparing for operation Required devices and aids To avoid delays on site, check before starting work whether or not the following de- vices and aids are present: - Wheel loader for transporting heavy extendable parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separating agents (emulsion) and manual injector - Two filled propane gas bottles - Shovel and broom...

  • Page 99: Checklist For The Machine Operator

    Checklist for the machine operator Check! How? Emergency stop button Push in the button. on the operating panel The diesel engine and all running drives on both remote control units must stop immediately. The paver finisher must immediately fol- Steering low every steering wheel movement in a precise manner.
  • Page 100 Check! How? For larger working widths, the walkway Auger covers plates must be extended and the auger tunnels must be covered. For larger working widths, the walkway plates must be extended. Hinged walkway plates must be swung Screed covers and walkways down.

  • Page 101: Starting The Paver Finisher

    Starting the paver finisher Before starting the paver finisher Before starting the diesel engine and beginning operation, the following steps must be performed: - Daily maintenance of the paver finisher (see chapter F) Check the operating hour counter to determine whether or not additional mainte- nance work (such as monthly or yearly maintenance) must be performed.

  • Page 102: External Starting (Starting Aid)

    External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24 V system - Additional 24 V battery - Start device that is suitable for external starting (24 V/90 A).

  • Page 103: After Starting

    After starting To increase the engine speed: - Set the drive lever (9) to position 1 (slightly off the center position). - Increase the engine speed by press- ing button (21) on the operating panel. The engine speed will be increased to the preselected value.

  • Page 104: Indicator Lamps

    Indicator lamps The following indicator lamps must be observed under all circumstances: For further possible faults, refer to the operating instructions for the engine. Coolant check (43) Must go out after starting. If the light does not go out or lights up during operation: Kontrollleucht_KD.cdr switch off engine and check coolant level.

  • Page 105: Battery Charge Indicator (47)

    When the hydraulic oil is cold: - Set the conveyor switch (32) to „manual” and the auger switch (24) to „auto“. - The remote control has to be connect- ed and the same function have to be set to „auto“ - Set the drive lever (9) to position 1 - Press button (21) to increase the en- gine speed, the conveyor and the au-...

  • Page 106: Operation During Transportation

    Operation during transportation Lifting and securing the screed - Button (16) has to be switched off - Switch off the buttons (34) and lift the screed full by using button (33). - Extend the levelling cylinders full by using the buttons (25) and (27). The remote control has to be connect- ed and the same function has to be set to „manual“.

  • Page 107: Driving And Stopping The Finisher

    Driving and stopping the finisher - Set the Fast/Slow switch (17) to „Hare”. - Set the preselector traction drive (10) to mark 10 - For driving, carefully tilt the drive lever (22) forward or backward according to the drive direction desired. In case of an emergency, press the emergency stop button (7)! - To stop the finisher, set the drive lever...

  • Page 108: Preparations For Paving

    Preparations for paving Separating agent Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator emulsion. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). F147_A1.TIF Screed heater Switch on the screed heater ca. 15–30 minutes (depending on the ambient temp- erature) before paving begins.

  • Page 109: Loading/Distributing Material

    Loading/distributing material - Button (16) has to be switched off. - Use switch (13) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (24) and the conveyor (32) to „auto”. - Press button (15) to fill the machine for paving.

  • Page 110: Starting For Paving

    Starting for paving Element1_SPSC.cdr/Element2_SPSC.cdr/Tamprev.cdr/Vibrev.cdr/SPSRemote.Tif D 70...
  • Page 111 Set the switches, levers and controls listed below to the specified positions when the screed has reached its operating temperature and a sufficient amount of material lies in front of the screed: Item Switch Position Traction drive fast/slow Tortoise-operating speed Preselector traction drive Mark 6-7 Preparation for screed floating posi-...

  • Page 112: Checks During Paving

    Checks during paving The following points must be constantly observed during paving: Paver function - Screed heater - Tamper and vibration - Engine oil and hydraulic oil temperature - The screed parts must be retracted and extended in time when obstacles are in the way - Uniform material transport and distribution or supply to the screed;...

  • Page 113: Paving With Screed Stop And Screed Charging/Relieving

    Paving with screed stop and screed charging/relieving General The screed hydraulics can be influenced in two ways to attain optimum paving results: - Screed stop with and without pretensioning with the paver finisher halted, - Screed charging or relieving with the paver finisher driving. Relieving reduces the screed weight and increases the traction force.

  • Page 114: Screed Stop

    Screed stop The „screed stop” function is used to block the screed hydraulics to prevent the screed from lowering when the paver finisher stops during paving. The switches (34) have to be switched off - Automatic screed stop when the drive lever is in the center position - To lift the screed press button (45A) - To lower the screed press 1.5 sec.

  • Page 115: Adjusting The Pressure (O)

    Adjusting the pressure ( ) Pressure adjustments can only be made while the diesel engine is running. There- fore: - Start the diesel engine and set the traction controller (10) to zero (precau- tion against inadvertent advancing). - Set switch (33) to the floating position. For screed stop with pretensioning - Set the drive lever (9) to the center po- sition.

  • Page 116: Interrupting/Terminating Operation

    Interrupting/terminating operation During breaks - Determine the approximate duration. - When cooling down of the material be- low the minimum paving temperature must be expected, run the paver fin- isher empty and create an edge like the end of a layer. - Set the drive lever (9) to the center po- sition.

  • Page 117: When Work Is Finished

    When work is finished - Run the paver finisher empty and stop it. - Lift the screed by using button (33). - Retract the screed parts to the basic screed width and lift the auger. Where applicable, completely extend the lev- elling cylinders.
  • Page 118 - Read and check the operating hour meter to determine whether mainte- nance work must be performed (see chapter F). - Cover and lock the operating panel. qsb_096.bmp - Remove material residues from the screed and the paver finisher and spray all parts with separator fluid. D 78...

  • Page 119: Malfunctions

    Malfunctions Error codes for engine Explanation: FMI: Failure Mode Identifier SPN: Suspect Parameter number D 79...
  • Page 120 D 80...
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  • Page 124: Problems During Paving

    Problems during paving Problem Cause change in the material temperature, admixing wrong material composition incorrect operation of the roller incorrectly prepared foundation long standstill times between loads grade control reference line is not suitable grade control jumps to the reference line Wavy surface grade control toggles between up and down (”short waves”)
  • Page 125 Problem Cause temperature of the material screed extendable parts are incorrectly installed Cracks in the layer limit switch is not correctly set (outer strip) cold screed bottom plates are worn or warped finisher speed is too high temperature of the material change in the material temperature moisture on the foundation admixing...

  • Page 126: Malfunctions On The Paver Finisher Or Screed

    Malfunctions on the paver finisher or screed Malfunction Cause Remedy See operating instructions for At the diesel engine Diverse the engine See ”External starting” Batteries empty Diesel engine does (start assistance) not start Diverse see ”Towing” Tamper is obstructed by Properly heat the screed cold bitumen Hydraulic oil level in the...
  • Page 127 Malfunction Cause Remedy Control valve is defective Replace Hoppers lowers Leaking seals of the inadvertently Replace hydraulic cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot be Screed relieving or Switch must be in the center lifted charging is switched on position...
  • Page 128 Malfunction Cause Remedy Replace Traction drive fuse defective (Fuse holder on the operating panel) Check potentiometer, cables, Power supply is interrupted connectors; replace if necessary Traction drive monitoring Replace (type-specific) defective Traction does not work Electro-hydraulic servo unit Replace the servo unit of the pump defective Check and adjust if necessary Check the suction filter;...

  • Page 129: Emergency Device/Steering, Drive System

    Emergency device/steering, drive system In case of a male function in the electronic drive system it is possible to override the system by an emergency device. This emergency device is included in the tool set of every crawler machine. To install the emergency device all plugs of the drive pump servo valves have to be replaced by the plugs of the emergency device.
  • Page 130 Following functions are located in the steering unit: Pos. Designation Switch for preselection of the zero position and forward reverse movement Adjustment knob for speed control (Replace speed preselector 23) Steering knob (Replace steering 6) Switch to turn the paver on the spot (Replace switch 30) Function If the emergency device is connected all functions like engine speed, conveyor, au- ger, tamper and vibration have to be controlled by the forward reverse lever (22).
  • Page 131 Pump for right crawler Pump for left crawler Servo valves Black Grey Grey Black 24 V Steering unit Ground D 91...

  • Page 133: E Setting-Up And Field Replacement

    E Setting-up and field replacement Special safety information Persons can be injured if the engine, final drive, flight bar conveyor, spreader, screed or lifting devices are started unintentionally. Unless otherwise described, work must be carried out only with the engine stopped! - Securing the finisher to prevent unintentional starting: Move the driving lever into the centre position and turn the preselector control to zero;...

  • Page 134: Distribution Spreader

    Distribution spreader Height adjustment The height of the distribution spreader (1) – measured from its bottom edge – should be minimum 50 mm (2 inches) above the material laying height, de- pending on the material mix. Example: Laying thickness 10 cm Adjustment 15 cm from the ground F0130_A1.TIF...

  • Page 135: For Hydraulic Adjustment (Optional)

    For hydraulic adjustment (Optional) - Note the currently adjusted height of the screed beam - left and right - on the scale. - Push or pull the switches (2) on the operating panel to retract or extend the hydraulic cylinders. (Pavers eguiped with PLC system o) - Activate the spreader adjustment with the push button (2).

  • Page 136: Mounting Extensions

    Mounting extensions Sch_ver1.tif Sch_ver2.tif...
  • Page 137 - Fix material duct (5) with screws (6), washers (7) and nut (8) to the basic equip- ment. - The material duct is adjustable to enable adaptation to the existing duct. For this purpose, loosen nuts (9) and turn the fairlead (10) for the screw (6). - Mount spreader shaft extension (11) on the spreader shaft of the basic equipment.

  • Page 138: Screed

    Screed All work for mounting, setting-up and screed enlargement is described in the screed operating instructions. Electrical connections After mounting and adjustment of the mechanical assemblies, the following connections must be established: F0171.tif Connect remotes to socket (17) (at the screed). Connect grade transmitter to socket (18) (at remote).

  • Page 139: F Maintenance

    F Maintenance Safety information on maintenance Before starting maintenance, secure the finisher and mounting components against unauthorized restarting: - Move the driving lever into the centre position and turn the preselector control to zero. - Remove final drive lock in the operation panel. - Remove ignition key and battery switch.

  • Page 140: Maintenance Intervals

    Maintenance intervals Overview of assembliesn Pos. Maintenance location Engine Pump distribution gear Engine - lubricating oil Oil filter Air cleaner Water cooler Upstream fuel filter / fuel filter V-belt Engine mounting Hoses and hose connections 1.10 Fuel tank Hydraulic system Hydraulic tank Main filter / return flow filter Oil cooler...
  • Page 141 Pos. Maintenance location Miscellaneous Visual inspection Crossbeam guide Nuts and bolts Moving parts Electrical system Batteries...

  • Page 142: First Maintenance (100 Operating Hours)

    1.3 1.2 1.10 First maintenance (100 operating hours) Item Maintenance point Maintenance work Pump distribution gear Change oil Hoses and screw connections Visual inspections Hydraulic tank Change main filter High pressure filter Change main filter Track groups Check tension Conveyor drive transmission Change oil Conveyor chain Check tension...

  • Page 143: Daily (Or Every 10 Operating Hours)

    1.3 1.2 1.10 Daily (or every 10 operating hours) Item Maintenance point Maintenance work Engine - lubricating oil Check oil level Air filter Check function, clean Water cooler Check fluid level Hydraulic tank Check oil level High pressure filter Inspect for fouling, change filter Lubrication Center conveyor bearing Lubrication...

  • Page 144: Weekly Or Every 50 Operating Hours

    1.3 1.2 1.10 Weekly or every 50 operating hours Item Maintenance point Maintenance work Pump distributor gear Check oil level and refill if necessary Fuel filter Check and if necessary drain water Flight bar conveyor gear Check oil level and refill if necessary Side bar guide Clean...

  • Page 145: 14 Daily Or Every 100 Operating Hours

    1.3 1.2 1.10 14 daily or every 100 operating hours Item Maintenance point Maintenance work Check function, clean Engine cooling system and hydraulics maintenance according to engine manufacturer’s documentation Track groups Check tension Conveyor chain Check tension Planetary gear Check oil level - Spreader Drive chains of conveyor augers Check tension...

  • Page 146: Monthly Or Every 250 Operating Hours

    1.3 1.2 1.10 Monthly or every 250 operating hours Item Maintenance point Maintenance work Engine suspensions Check Conveyor drive transmission Check oil level Auger box Check oil level...

  • Page 147: Every 3 Months Or Every 500 Operating Hours

    1.3 1.2 1.10 Every 3 months or every 500 operating hours Item Maintenance point Maintenance work Engine - lubricating Change oil Oil filter (cups) Change filter cartridge Hydraulic tank Clean filling and vent filter Check all operating-relevant nuts and bolts for tightness Nuts and bolts and retighten if necessary.

  • Page 148: Annually Or Every 1000 Operating Hours

    1.10 Annually or every 1000 operating hours Item Maintenance point Maintenance work Pump distributor gear Change oil Air filter Change filter insert Fuel filter Change fuel filter cartridge Upstream fuel filter and/orfilter element Check tension, if necessary Fan and alternator belt replace Hoses and screw connections Check, replace if necessary...

  • Page 149: Every 2 Years Or Every 2000 Operating Hours

    1.3 1.2 1.10 Every 2 years or every 2000 operating hours Item Maintenance point Maintenance work Air filter Change safety cartridge Water cooler Replace coolant Fan and alternator belt Replace belt Hydraulic tank Change oil F 11...

  • Page 150: If Necessary

    1.3 1.2 1.10 2.10 If necessary Item Maintenance point Maintenance work Conveyor drive trans- Refill oil mission 1.10 Fuel tank Drain water and sediment Idler Check and refill oil F 12...

  • Page 151: Inspection And Lubrication Points

    2.11 Inspection and lubrication points Pump distributor gear (1.1) The check screw (1) serves for checking the oil level. Once the screw has been unscrewed, a little oil should run out. If this is not the case, top up oil via filler aperture (2). Cleanliness must be observed! Oil change: The oil change should take place at op-...

  • Page 152: Lubricating Oil - Engine (1.2)

    Lubricating oil - engine (1.2) Oil level check Before starting work, always use dipstick (1) to check oil level in engine. Undertake oil check with paver finisher on level ground! - If necessary, fill up oil via filler aperture (2). Too much oil in engine damages gaskets;...

  • Page 153: Engine - Oil Filter (1.3)

    Engine - oil filter (1.3) The new filter is inserted during an oil change once the used oil has been drained out. - Use a filter belt or wrench on hex to loosen lubricating oil filter cover (1) and unscrew (turn anti-clockwise). - Carefully loosen paper filter cartridge (3) from guide (4) by moving upwards.

  • Page 154: Air Cleaner (1.4)

    Air cleaner (1.4) The level of air cleaner (1) contamina- tion depends on the dust content of the air. Filter maintenance is needed if the red service box (3) can be clearly seen on the maintenance indicator (2) when the engine is at a standstill.

  • Page 155: Cooling System Engine And Hydraulics (1.5)

    Cooling system engine and hydraulics (1.5) The machine is fitted with water, hydraulic and charged air coolers. Water cooler Always check the coolant (water) level when cold. Ensure there is sufficient an- tifreeze and anti-corrosion agent (- 25°C). The perfect level is 6 cm below the seal- ing face of the seal cover.

  • Page 156: Engine - Fuel Filter (1.6)

    Engine - fuel filter (1.6) The fuel filter system consists of two fil- ters: - Upstream filter with water separator (1) on fuel tank - Main filter (2) on engine block Draining upstream filter - water: The upstream filter has a tank (3) in which the water collected is captured.

  • Page 157: Main Filter - Replacing Filter Cartridge

    Main filter - replacing filter cartridge - Use a filter belt or wrench to loosen fuel filter cover (6) on hex and unscrew (anti-clockwise). - Carefully loosen paper filter cartridge (8) from guide (9) by moving upwards - Collect any fuel which escapes. - Change paper filter cartridge (8).

  • Page 158: V-Belt And Notched V-Belt (1.7)

    V-belt and notched v-belt (1.7) - For checking and adjusting the belts see engine’s operating instructions. New V-belts stretch and must be reten- sioned after an operating time of 15-20 minutes. Engine mounting (1.8) Check the engine mounting specifically for damage and secure fixture. If necessary, any damaged parts should be replaced.

  • Page 159: Fuel Tank (1.10)

    Fuel tank (1.10) To drain water and sediment: - Provide collecting container. - Unscrew drain screw (87). - Drain about 1 l fuel into the collecting container. Collected fuel must be disposed off in accordance with the national regula- tions. Kraftank.tif F 21...

  • Page 160: Hydraulic Oil Tank (2.1)

    Hydraulic oil tank (2.1) Check the oil level at the dipstick (1). The oil must be at the upper notch with the cylinders retracted. The oil tank vent must be cleaned regu- larly to remove dust and dirt. Clean oil cooler surfaces (see also engine opera- tion instructions).

  • Page 161: High Pressure Filter (2.4)

    High pressure filter (2.4) A total of 5 high pressure filters can be found at several places in the hydraulic system (behind bottom lid, side flaps). The filter elements should be replaced when the maintenance indicator (1) is displaying red. - Unscrew filter housing (2).

  • Page 162: Track Group (3.1)

    Track group (3.1) Spannket.tif Only carry out maintenance work on the track group with the engine switched off. - Unscrew screws (1). - Remove cover (2). - Screw head piece for flat nipple (tool box) to the grease gun. - Inject grease into the chain tensioner with the grease gun until the grease starts to discharge from the pressure control valve.

  • Page 163: Conveyor Drive Transmission (3.2)

    Conveyor drive transmission (3.2) - To check the oil level, unscrew check screw (1). With the correct oil level, the oil is just below the bottom edge of the check hole or only a small amount of oil discharg- es from the opening. To fill oil: - Unscrew filling screw (1).

  • Page 164: Conveyor Chain (4.1)

    Conveyor chain (4.1) With a correctly tensioned conveyor chain, the bottom edge of the chain is located about 4 cm below the frame bottom edge. For retensioning the chains, fill the ten- sioner at the lubricating nipple (1) on the left and right with the grease gun until the necessary chain tension is reached.

  • Page 165: Conveyor Drive Transmission (4.3)

    Conveyor drive transmission (4.3) The conveyor gears are located under the footplate of the control panel. Check oil level: Only before start of work. The oil level must reach the top notch of the dipstick (1). Top up oil: Through oil filler neck (3) once seal cover (2) has been removed.

  • Page 166: Auger Planetary Gear (4.4)

    Auger planetary gear (4.4) Schneckantr..jpg - To check the oil level, unscrew check screw (1). With a correct oil level, the oil is just below the bottom edge of the check hole or only a small amount of oil discharges from the opening. To top up oil: - Unscrew check screw (1) and filling screw (2).

  • Page 167: Conveyor Auger Drive Chains (4.5)

    Conveyor auger drive chains (4.5) Only carry out maintenance work on the drive chains with the engine switched off. To retension the chains: - Loosen fixing screws (1). - Adjust correct chain tension with screws (2). - Tighten threading dowels with a torque wrench to 20 Nm.

  • Page 168: Auger Box (4.6)

    Auger box (4.6) Check oil level When the oil level is between the two marks on the dipstick (1) it is correct. To fill up oil: - Unscrew screws (2) from top cover of auger box. - Take off cover (3). - Fill up oil to correct level.

  • Page 169: Outer Auger Bearing (4.7)

    Outer auger bearing (4.7) The grease nipples are located on each side at the top of the outer auger bear- ings. These nipples must be lubricated each time work is finished to force out any bi- tumen residues that might have entered and to supply the bearings with a fresh filling of grease.

  • Page 170: Nuts And Bolts (5.3)

    Nuts and bolts (5.3) Check bolt connections, especially on driven gears as well as securing points and hy- draulics, if necessary tighten. Tightening torques Maximum tightening torque for shaft bolts with metric ISO standard threads 10.9 12.9 Tightening Tightening Tightening Preload Preload Preload...

  • Page 171: Battery (6.1)

    Battery (6.1) The zero-maintenance batteries can be found under the right-hand lateral flap - Check cable connections (securing, pin grease). Bat115.jpg F 33...

  • Page 172: Fuels And Lubricants

    Fuels and lubricants Only use the specified lubricants or equivalent qualities of known brands. Only use containers to fill oil or fuel that are clean inside and out. Observe capacities (see Section”Capacities”) Incorrect oil or lubricant levels promote rapid wear and machine failure. Esso Fina Mobil...

  • Page 173: Hydraulic Oils

    Hydraulic oils Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO category of viscosity VG 46 Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso HE 46 b) Mineral oils Manufacturer ISO category of viscosity VG 46 Shell Tellus Oil 46 When changing over from mineral oil to biodegradable oils, please cotact the advice...

  • Page 174: Capacities

    Capacities Fuel/lubricant Quantity Fuel tank Diesel fuel litre Hydraulic oil tank Hydraulic oil litre Diesel engine Engine oil 13.0 litre (with oil filter replacement) Pump distributor gear Gear oil 90 litre Planetary gear Gear oil 220 litre Track group Conveyor chain gear (per side) Gear oil 220 litre Auger box...

  • Page 175: Electric Fuses

    Electric Fuses Main fuses (next to the batteries) 50 A - F3.1 Overall electric system - F3.2 not in use Fuses in main terminal box (next to fuel tank) Fuse box (2) F5... F7... F44... F45... QSBFuse2_SPS.cdr QSBFuse.tif F5.1 - F5.8 Travel drive Sensors / BB3 Starter...

  • Page 176: Fuses On Control Panel

    Fuses on control panel Element3_SPSC.cdr Fuse box (3) Fuse1.Tif F1.1 - F1.8 Combustion engine / EMERGENCY-STOP Indicator lamps Control module A1 / display / voltage converter / Conveyor controller Back-up fuse Slave 1-3 Back-up fuse Slave 4-6 Roof-mounted headlight ( Remote control / slope / Back-up fuse for display ST/VIB EMR control unit...
  • Page 177 Fuse box (4) Fuse1.Tif F2.1 - F2.8 not in use Horn Windscreen wiper not in use Headlight, front right Headlamp, front left / fittings lighting not in use not in use F 39...

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