Page 1 OPERATION & MAINTENANCE Paver finisher Svedala Demag DF 145 C DF 145 CS Type 438 / 439 Keep this manual for future reference Order number for this manual: D900981469 05-0107 438....439....
Page 2 VALUE QUALITY THE ORIGINAL Your Authorized Dynapac Dealer:...
Page 3: Table Of Contents
Allowed angle of rise and slope ............... 11 Allowed angle of driving up ..............11 DF 145 C weights (all weights in t) ............12 DF 145 CS weights (all weights in t) ............12 Performance data for the DF 145 C ............13 Performance data for the DF 145 CS ............
Page 4 EN standards ................... 21 Continuous sound level ................21 DF 145 C vehicle ................. 21 DF 145 CS vehicle ................21 Operating conditions during measurement ..........22 Measuring point configuration ..............22 Vibration acting on the entire body ............23 Vibrations acting on hands and arms ............
Page 5 D3.4 Operation ................. 1 Operating elements on the paver finisher ..........1 Batteries (71) ..................1 Battery main switch (72) ................ 1 Transport safeguards for the hopper (73) ..........2 Mechanical screed transport safeguard (to the left and the right beneath the driver’s seat) (74) ...............
Page 6 D4.14 Operation ................. 1 Preparation of operation ................1 Required devices and aids ..............1 Before starting work (in the morning or when starting paving) ....2 Checklist for the machine operator ............2 Starting the paver finisher ................4 Before starting the paver finisher ............
Page 7 Set-up and modification ............1 Special notes on safety ................1 Distribution auger ..................2 Height adjustment ..................2 For mechanical adjustment with ratchet ............ 2 With hydraulic adjustment (option) ............. 3 Auger extension ..................4 Mounting extension parts ................5 Offset screed position towards back ............
Page 8 F5.3 Maintenance - Engine ............. 1 Maintenance - Engine ................1 Maintenance intervals ................2 Points of maintenance ................4 Engine fuel tank (1) ................4 Engine lube-oil system (2) ..............5 Engine fuel system (3) ................7 Engine air filter (4) ................. 9 Coolant system of the engine (5) ............
Page 9 F8.6 Maintenance - Electronic system .......... 1 Maintenance - Electronic system ............... 1 Maintenance intervals ................2 Points of maintenance ................5 Batteries (1) ................... 5 Generator (2) ..................6 Adjustment of belt tightness ..............8 Replacement of belt ................9 Checking / adjusting belt tension: ............
Page 11: Preface
In the interest of continued development, the manufacturer reserves the right to make changes to the machine (which will not, however, change the essential features of the type of machine described) without updating the present operating instructions at the same time. Dynapac GmbH Wardenburg Ammerländer Strasse 93 D-26203 Wardenburg / Germany...
Page 12: General Safety Instructions
The following alerts, prohibitions and instructions refer to the risks to which people, machinery and environment are exposed. Ignoring these instructions, bans and commands may lead to fatal injuries! Furthermore, the Dynapac publication "Directives for the correct and specified appli- cation of pavers" shall also be observed. Warning instructions...
Page 13 Attention: risk of hand injury! Attention: hot surfaces or hot liquids! Warning, risk of falling off! Attention: hazardous batteries! Attention: materials harmful to health and irritating substances! Attention: flammable materials! Attention: gas bottles!
Page 14: Prohibitive Signs
Do not sprinkle with water! Do not extinguish with water! Do-it-yourself maintenance is prohibited! Maintenance can be performed by skilled professionals only! Contact the Dynapac service! Danger of fire: do not use open flame and no smoking! Do not turn on!
Page 15: Protective Gear
Protective gear The applicable local regulations may define the use of different protective gear! Observe these specifications! Protect your eyes with googles! Wear appropriate head protection! Protect your hearing with appropriate ear mufflers! Protect your feet with safety footwear! Always wear tight, conforming working coveralls! Wear visibility vest for good visibility! In case of polluted air, wear respiratory mask!
Page 16: Environmental Protection
Environmental protection The locally applicable acts, directives and waste disposal regulations shall be ob- served, even if the attention is not specifically directed to these. During cleaning, maintenance and repair operation the materials polluting water e.g.: - lubricants (oils, grease) - hydraulic oil - gas oil - coolant...
Page 17: Further Instructions
Further instructions Observe the manufacturer's and other instructions! e.g. the maintenance instructions of the engine manufacturer Description / figure in case of an electrically heated design! Description / figure in case of an electrically heated design!
Page 19: A Correct Use And Application
The “Guidelines for the Correct Use and Application of Paver finishers” compiled by Dynapac are included in the scope of delivery for the present machine. The guide- lines are part of the present operating instructions and must always be heeded. Na- tional regulations are fully applicable.
Page 21: B Vehicle Description
B Vehicle description Application The Svedala Demag DF 145 C / DF 145 CS paver finisher is a caterpillar paver fin- isher which is used for laying bituminous mixed material, roll-down or lean-mixed con- crete, track-laying ballast and unbound mineral aggregates for foundations for paving.
Page 22: Description Of Assemblies And Functions
Description of assemblies and functions DF145C_CS.wmf Denomination Auger Screed Operator’s platform Storage space for toolboxes on the left/right sides Paving thickness indicator Operating panel (can be moved to either side) Protective roof Working lights Material compartment (hopper) Truck push rollers Tube for sensor rod (direction indicator) and holder for levelling shoe Caterpillar drive...
Page 23: Vehicle
Vehicle Construction The paver finisher has a welded steel frame on which the individual components are mounted. The caterpillar drives compensate uneven areas on the ground; the suspension of the attached screed additionally helps to attain a high paving precision. The continuously adjustable hydrostatic travel drive allows the speed of the paver fin- isher to be matched to all work conditions.
Page 24 Travel drive: The continuously adjustable travel drive pumps are connected to the travel drive engines by means of high pressure hydraulic hoses. These oil motors drive the caterpillar chains via planetary gears that are mounted di- rectly inside the drive wheels of the caterpillar chains. Steering system/operator’s platform: The independent hydrostatic travel drives al- low the finisher to be turned on the spot.
Page 25 Automatic levelling/slope control system: The slope control system (option) al- lows the regulation of the traction point either on the LH or RH sides, by maintaining a difference defined against the opposite side. To determine the actual value, the two traction crossbeams are linked with a slope control rod.
Page 26: Danger Zones
Danger zones In these areas of the machine there is a danger of pulling in or crushing due to the rotating, transporting or moving parts!
Page 27: Safety Devices
Safety devices Safe operation is only possible when all operating and control elements are function- ing correctly and when all safety devices are in position. Check the function of these devices at regular intervals. (see chapter D, section 2.1). Emergency stop button - on the operating panel - on the two remote control units (op- F0005_A1.EPS...
Page 28: Main Switch (17)
Main switch (17) Hauptschalter_DF145C_CS.wmf Hopper transport safeguards (18) Hopperlock2.tif/Hopperlock_SK.eps Screed transport safeguards (19) Bohlensich_DF145.wmf Latch for protective roof (20) Dachkons_DF.bmp...
Page 29 DF145C_CS_side.jpg/Feuerlöscher.bmp No. Denomination 25 Fire fighting device 26 Engine hood 27 Lateral flaps 28 Walkway 29 Screed coverings 30 Screed warning light 31 Auger covers Accessories: - Wedges - Warning triangle - First-aid kit...
Page 30: Technical Data, Standard Configuration
Technical data, standard configuration Dimensions (all dimensions in mm) 2080 1000 3060 6440* 2320 2550 3300 *SB 30 635_side_DEM.bmp,635_front_DEM.bmp For the technical data of the screed, see the operating instructions of the screed. B 10...
Page 31: Allowed Angle Of Rise And Slope
Allowed angle of rise and slope max 15° max 15° max 15° DF145C_CS_side.jpg,DF145C_CS_front.bmp Before operating your machine in an inclined position (gradient, slope, lateral inclina- tion) which is above the specified limit value, please, consult with the customer serv- ice for your machine! Allowed angle of driving up max 14°...
Page 32: Df 145 C Weights (All Weights In T)
DF 145 C weights (all weights in t) Paver finisher without screed approx. 15.3 Paver finisher with screed: - EB 60 approx. 19.2 with extensions for max. working approx. width, additionally max.: with filled hopper approx. 14.2 additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.
Page 33: Performance Data For The Df 145 C
Performance data for the DF 145 C EB 51 2.55 2.00 5.10 8.80 EB 51+ 2.55 2.00 5.10 EB 60 3.00 2.45 6.00 9.70 EB 60+ 3.00 2.45 6.00 9.00 (E) SB 30 3.00 13.00 (gas) *High-compression screeds available on request...
Page 34: Performance Data For The Df 145 Cs
Performance data for the DF 145 CS EB 51 2.55 2.00 5.10 8.80 EB 51+ 2.55 2.00 5.10 EB 60 3.00 2.45 6.00 9.70 EB 60+ 3.00 2.45 6.00 9.00 (E) SB 30 3.00 13.50 (gas) *High-compression screeds available on request The maximum working width depends on the paving conditions! Travelling speed 0 - 5,0...
Page 35: Travel Drive/Traction Unit
Two separately driven caterpillar drives with rub- drive unit ber grouser chains Turning capacity Turning on the spot Speed See above DF 145 C engine Make/type Cummins QSB6.7-C205 Model 6-cylinder (water cooled) Diesel engine Performance 153 KW / 208 HP (at 1800 rpm)
Page 36: Material Compartment (Hopper)
5.12 Material compartment (hopper) Volume about 6.5 m = about 14.2 t Minimum inlet height, center 520 mm Minimum inlet height, outside 605 mm 5.13 Material transfer Conveyors Left and right side separately controllable Drive Hydrostatic, continuously controllable Conveying volume controller Fully automatic via configurable switching points 5.14 Material distribution...
Page 37: Screed Lifting Device
5.15 Screed lifting device At standstill: - Screed stop - Screed stop with pretensioning (max. pressure 50 bar) Special functions During paving: - Screed charging - Screed relieving (max. pressure 50 bar) Mechanical grade control system, Levelling system optional systems with and without slope control system 5.16 Electrical system...
Page 38: Location Of Instruction Labels And Identification Plates
Location of instruction labels and identification plates B 18...
Page 39 Denomination Label "Filler neck for diesel fuel" * Label "Filler neck for engine oil" * Label "Operating instructions" Warning label "Danger of squeezing!" ** Label "Securing or fixing points for crane transportation" ** Paver finisher identification label Plate "CE + noise level" (O) Warning plate "Fan danger!"...
Page 40: Identification Label For The Paver Finisher (6)
Identification label for the paver finisher (6) Fertiger3.tif Denomination Type of paver finisher Year of manufacture Serial number of the paver finisher series Max. permissible operating weight, incl. all extension parts, in kg Max. permissible load on the front axle, in kg Max.
Page 41: Standards
The noise emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6 draft, dated March, 1997, and ISO 4872. DF 145 C vehicle Sound pressure level at the operator’s position (at the height of the head):...
Page 42: Operating Conditions During Measurement
Operating conditions during measurement The diesel engine was running at maximum speed. The screed was in working posi- tion, lowered to a rubber mat. Tamper and vibration unit were operated at min. 50%, while the augers were operated at a minimum of 40% and the conveyors were oper- ated at a minimum of 10% of their maximum speed.
Page 43: Vibration Acting On The Entire Body
Vibration acting on the entire body When the machine is used properly, the weighted effective acceleration values at the driver’s seat of a = 0.5 m/s according to EN 1032-1995 draft are not exceeded. Vibrations acting on hands and arms When the machine is used properly, the weighted effective acceleration values at the driver’s seat of a = 2.5 m/s...
Page 45: C1.5 Transportation
C 1.5 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 automatic levelling system, auger limit switches, aprons, etc.).
Page 46: Transportation On Low-Bed Trailers
Transportation on low-bed trailers Reduce the paver finisher and the screed to their basic widths; also remove any at- tached side plates. The maximum approach angle is indicated in the section entitled "Technical Data"! Preparations - Prepare the paver finisher for transportation (see chapter D). - Remove all protruding or loose parts from the paver finisher and the screed (see also Screed operating instructions).
Page 47 Operation Switch Buttons Disabling the interlocking of opera- tion Close the hopper halves. Engage both hopper transport safe- guards. Lift the screed. Engage screed transport safeguards. Turn the preselecting regulator to zero. Move the drive lever forward. The levelling cylinder are in fully extended position.
Page 48: Drive Onto The Low-Bed Trailer
Drive onto the low-bed trailer Make sure that there are no persons in the danger area during loading. F0185_A1.TIF - Use the work gear and low engine speed to drive onto the low-bed trailer. - Lower the screed onto wooden blocks on the low-bed trailer. - Switch off the paver finisher.
Page 49: Secure The Paver Finisher In Its Position To The Low-Bed Trailer
Secure the paver finisher in its position to the low-bed trailer: - Use only proper and permitted load fastening devices. - Use the four securing points provided (1, 2). Depending on the equipment of the machine there can be further support points (3) on the auger frame (3)! - Wait until the exhaust extension pipe has cooled down;...
Page 50: Transportation
Transportation Reduce the paver finisher and the screed to their basic widths; also remove any at- tached side plates. Preparations - Prepare the paver finisher for transportation (see chapter D). - Remove all protruding or loose parts from the paver finisher and the screed (see also Screed operating instructions).
Page 51 Operation Switch Buttons Disabling the interlocking of opera- tion Close the hopper halves. Engage both hopper transport safeguards. Lift the screed. Engage screed transport safeguards. Turn the preselecting regulator to zero. Move the drive lever forward. The levelling cylinder are in fully extended position.
Page 52: Driving Mode
Driving mode Warning Marking Marking Set the Fast/Slow switch to "Hare". Turn the preselector to maximum. Use the drive lever to regulate the speed. Press the emergency stop button when a dangerous situation arises! C 1.5 8...
Page 53: Loading By Crane
Loading by crane Use only lifting gear that can bear the load. (See Chapter B for weights and dimensions). F0185_A1.TIF Four lifting eyes (1, 2) are provided for loading the vehicle with a crane. - Park the paver finisher and render it safe. - Engage the transport safeguards.
Page 54: Towing
Towing Heed all regulations and apply all safety measures applicable for towing heavy con- struction machines. The towing vehicle must be capable of securing the paver, even on slopes. Use only approved tow bars! If necessary, remove any attachments and extension parts from the paver finisher and the screed until the basic width has been attained.
Page 55 - Release lock nut (2), screw threaded dowel (3) into pump as far as possible and secure with lock nut. - Actuate lever (4) of hand pump until sufficient pressure has been built up and traction system brakes have been released.
Page 56 Following towing, unscrew the threaded dowel (3) a few turns again and lock with the lock nut (2). To make the machine ready for opera- tion after repair work, the high-pressure cartridges (1) must be screwed back firmly into place. The traction system brakes are no reac- tivated and the machine is secured against rolling.
Page 57: Safely Parking The Vehicle
Safely parking the vehicle When the equipment is parked at a loca- tion 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 (1) and take it with you –...
Page 59: D1.9 Operation
D 1.9 Operation Safety regulations Starting the engine, the traction drive, the conveyor, the auger, the screed or the lift- ing 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 forbid- den!
Page 60: Operating Elements
Operating elements Operating panel Bedienpult_konv_Kette_635_2.bmp/Element3_konv_Kette_C6.7.bmp/Element1_konv_Kette_635.bmp/Element2_konv_Kette_635.bmp/ D 1.9 2...
Page 61 Item Designation Brief description The steering wheel movement is transferred electrohydrauli- cally. Steering potenti- For precision adjustment, (position „0“ = straight ometer ahead) refer to adjustment for straight ahead travel. For turning on the spot, refer to switch (turning on the spot).
Page 62 Element2_konv_Kette_635.bmp/ D 1.9 4...
Page 63 Item Designation Brief description Starting is only possible when the drive lever is in the neutral position. All emergency stop buttons (on the operating panel Starter and the remote controls) must be pulled up. On some machines, the starter may remain engaged for 5 seconds after the Start switch has been enabled! Machine drive Hare: Travelling speed...
Page 64 Element2_konv_Kette_635.bmp/ D 1.9 6...
Page 65 Item Designation Brief description Key inserted: Ignition on Key pulled out: Ignition, engine off. Key positions: 0 Lights switched off Ignition switch and 1 Parking lights / rear lights, instrument panel lights lighting switch working floodlight, as applicable 2 Driving lights 3 Headlights Override the interlocking between 1 and 2 by depress- ing them.
Page 66 Element2_konv_Kette_635.bmp/ D 1.9 8...
Page 67 Item Designation Brief description The transport direction of the conveyor, applicable separately to both sides of the conveyor, can be switched to the opposite direction so that over a short distance it retracts the material directly before the auger. In this way the loss of material can Reverse be avoided during transport.
Page 68 Element2_konv_Kette_635.bmp/ D 1.9 10...
Page 69 Item Designation Brief description A Lift the screed. Screed position B Lock the screed (the position appropriate for inserting the transportation safeguard of the screed) C Lower the screed and set it to „Floating position“ During paving, the screed must always be in the float- ing position.
Page 70 Element2_konv_Kette_635.bmp/ D 1.9 12...
Page 71 Item Designation Brief description It sets the delay time of the prestressed start of the screed. Preselecting regu- The delay time must be set depending on the working lator „Pressure speed. load delay time to start paving“ High working speed - short delay time Low working speed - longer delay time A auto: with the drive lever turned on and using the ma-...
Page 72 Element3_konv_Kette_C6.7.bmp/Leuchtmodul_KONV_Kette_C6.7.bmp D 1.9 14...
Page 73 Item Designation Brief description With this the levelling cylinders can be controlled manually, if Levelling cylinder the levelling automatic system is switched off. on the right/left For this, the switch on the remote control shall be in „manual“ sides position. For continuous adjustment of the engine speed (when drive lever is at the stop).
Page 74 Element3_konv_Kette_C6.7.bmp/Leuchtmodul_KONV_Kette_C6.7.bmp D 1.9 16...
Page 75 Item Designation Brief description has no function Normal display up to 85 °C = 185 °F. In case of higher temperature stop the machine, (set Hydraulic oil ther- drive lever (9) to neutral position), and let the engine mometer cool at idling speed. Find the cause and eliminate the fault.
Page 76 Element3_konv_Kette_C6.7.bmp/Leuchtmodul_KONV_Kette_C6.7.bmp D 1.9 18...
Page 77 Item Designation Brief description After the ignition is turned on, it is on until the air required for combustion in the drive engine is heated up to the required Preheating signal temperature. lamp (amber) Start the engine only when the signal lamps are dark, this will reduce wear and ensure better starting prop- erties.
Page 78: Remote Control
Remote control Remote_konv_neu1.bmp With the help of the two remote controls - on the RH and LH sides of the screed - the functions available on the specific side of the paver finisher can be controlled. D 1.9 20...
Page 79: Front Side
Front side Item Designation Brief description Its function and use are similar to those of the emergency Emergency stop button (14) on the control panel. button (o) It is important in such dangerous situations, which cannot be overseen by the driver. Horn Its function is similar to the button (7) on the control panel.
Page 80: Reverse Side
Reverse side Remote_konv_neu1.bmp Item Designation Brief description Connection to the levelling automatic Connect the cable for the grade control unit here. system Connection to the end position switch of Connect the cable for the material limit switch here. the auger Cable for the remote Connect to the socket on the screed.
Page 81: D3.4 Operation
D3.4 Operation Operating elements on the paver finisher Batteries (71) The batteries of the 24 V system are lo- cated under the left maintenance flap. For the specifications, refer to chapter B, "Technical Data". For servicing, see chapter F. Heed the instructions when starting the paver finisher externally.
Page 82: 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. Item: - (a) - outside on the two hopper halves - (b) - in the hopper (o) Do not enter the hopper while the engine is running! Danger of being caught by...
Page 83: Mechanical Screed Transport Safeguard (To The Left And The Right Beneath The Driver's Seat) (74)
Mechanical screed transport safe- guard (to the left and the right be- neath the driver’s seat) (74) It is used to protect the lifted screed from inadvertent sinking. The screed trans- port safeguard must be inserted before transportation and when work is fin- ished.
Page 84: Separator Fluid Spraying System (80) (O)
Separator fluid spraying system (80) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. A Spray bottle with pressure pump B Spraying system with electric pump (81) Only switch on the spraying system when the diesel engine is running;...
Page 85: On / Off Switch For Additional Headlight In The Roof (85)
Further switch options for optional equipment features may be located on the central panel: On / off switch for additional head- light in the roof (85): Actuate switch (a) to switch on. On / off switch for filler pump fuel tank (85a) If the pump is actuated with the switch (a), the indicator lamp (b) lights up.
Page 86: On/Off Switch Of Working Lights (85D)
On/Off switch of working lights (85d): Actuate switch (a) to switch on. In the switch position "ON" the indicator lamp (b) is on. On/Off switch of rotary beacon (85e): Actuate switch (a) to switch on. In the switch position "ON" the indicator lamp (b) is on. If optionally available 230 V systems are installed, an additional switch cabinet is mounted on the paver finisher:...
Page 87: Locking Of The Collapsible Roof (Lh And Rh On The Roofs Console) (86)
Locking of the collapsible roof (LH and RH on the roofs console) (86) To lower the roof (for example during transport on a low bed trailer): - Loose the twistlock (A). - Pull the roof frame forward holding the clevis or the frame. - Arrest the twistlock in the second lock- ing hole.
Page 88: Hydraulic Folding Roof (87) (O)
Hydraulic folding roof (87) (o) The hydraulically folding roof is secured by means of a latch (A) at the rear sus- pension on the left and right sides of the machine. This must be released prior to lowering and raising. Once it has reached its terminal position, the roof must be secured with the latch again.
Page 89: Electric Setting Of The Transportation Volume Of The Conveyor (O) (88)
Electric setting of the transportation volume of the conveyor (o) (88) With this the transport volume of the conveyor can be adjusted when me- chanical limit switch or ultrasonic sensor is used. - The "0" position of the scale corre- sponds to the smallest adjustable vol- ume.
Page 90: Conveyor Limit Switches (89)
Conveyor limit switches (89): The mechanical conveyor limit switches (89) or the ultrasonic conveyor limit switches (89ao) control the material flow at the respective conveyor half. The conveyors should stop when the materi- al has roughly reached the area below the auger tube.
Page 91: 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 ad- justment and modify angle / height of the sensor.
Page 92: Pressure Control Valve For Screed Charging/Relieving (93) (O)
Pressure control valve for screed charging/relieving (93) (o) Used to adjust the pressure for addition- al charging/relieving of the screed. - See "screed charging/relieving de- vice". (Chapters "Operating Panel", "Opera- tion"). - Pressure display: see manometer (93b). Pressure control valve for screed stop with pretensioning (93a) (o) This valve is located beneath the right- hand bottom flap of the operator's plat-...
Page 93: Central Lubrication Unit (O) (100)
Central lubrication unit (o) (100) The central lubrication unit turns on in automatic mode when the drive engine starts. - Pumping time: 12 min - Duration of the break: 2 h It is prohibited to change the factory-set durations of pumping and break without consulting the technical customer serv- ice! Changing the duration of lubrication and...
Page 94: Particle Filter - Indicator Lamp (102) (O)
Particle filter – indicator lamp (102) The indicator lamp of the particle filter is found under the control track of the oper- ating panel. When observing the indicator lamp (a) it is essential (a): Partikellight.tif Indicator col- Operating condition Cause / action No counterpressure.
Page 95: Front And Side Window (O) (103)
Front and side window (o) (103) The front window can be folded up for the maintenance works performed at the tank. - Fold the front window by its handle (A) and lock it on the RH and LH sides with the two locks (B) in the upper po- sition.
Page 96: Adjustment Of Screed Eccentric (O) (104)
Adjustment of screed eccentric (o) (104) To pave thicker layers of material, if the piston rods in the levelling cylinder are operating close to their limit position and if the desired paving thickness cannot be reached, it is possible to alter the ap- proach angle of the screen by adjusting the eccentric.
Page 97: D4.14 Operation
D 4.14 Operation Preparation of 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 fluids (emulsion) and manual injector - Two filled propane gas bottles...
Page 98: Before Starting Work (In The Morning Or When Starting Paving)
Before starting work (in the morning or when starting paving) - Heed the safety instructions. - Check the personal protective equipment . - Take an inspection walk around the paver finisher and check for leaks and damag- - Install parts removed for transportation or for the night. - When screed is operated with the optional gas heating system, open the closing valves and the main shut-off valve.
Page 99 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 100: Starting The Paver Finisher
Starting the paver finisher Before starting the paver finisher Before starting the diesel engine and be- ginning operation, the following steps must be performed: - Daily maintenance of the paver finish- er (see chapter F) Check the operating hour counter to de- termine whether or not additional main- tenance work (such as monthly or yearly maintenance) must be performed.
Page 101: 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 102: After Starting
After starting To increase the engine speed: - Set speed adjuster (1) to medium speed. - Set the drive lever (2) to position 1 (slightly off the center position). Let the paver finisher warm up for ap- prox. 5 minutes if the engine is cold. Indicator lamps The following indicator lamps must be observed under all circumstances:...
Page 103 When the hydraulic oil is cold: - Set the conveyor switch (3) to "manu- al" and the auger switch (4) to "manu- al" (arrow). - Set speed adjuster (5) to medium speed and engange drive lever (6) un- til conveyor and auger start to operate. - Let the hydraulics warm up until the in- dicator lamp goes out.
Page 104: Preparations For Paving
Preparations for paving Separator fluid Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator fluid. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). F0147_A1.TIF Screed heater Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem- perature) before paving begins.
Page 105: Loading/Distributing Material
Loading/distributing material - Use switch (1) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (2) and the conveyor (3) to "auto". - Set the switches for the auger and the conveyor on the remote controls (if ap- plicable) to "auto".
Page 106 - Switch the conveyors on. The limit switches for the conveyors (89) or (89ao must switch off when the material has reached the area be- neath 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 screed.
Page 107: Starting For Paving
Starting for paving Element2_konv_Kette_635.bmp/Element1_konv_Kette_635.bmp/Tamprev.cdr/Vibrev.cdr/Remote_konv_neu1.bmp D 4.14 11...
Page 108 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: Switch Position Travel drive fast/slow slow ("Tortoise") Preselector On/Off On (lower) Engine speed (o) Maximum...
Page 109: Checks During Paving
Checks during paving The following points must be constantly observed during paving: Paver finisher 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 - Uniform material transport and distribution or supply to the screed;...
Page 110: Paving With "Screed Control At Paver Finisher Stop" And "Screed Charging/Relieving
Paving with "screed control at paver finisher stop" and "screed charging/re- lieving" General The screed hydraulics can be influenced in two ways to attain optimum paving re- sults: - Floating position with and without pretensioning with paver finisher halted, - screed charging or relieving with the paver finisher driving. Relieving reduces the screed weight and increases the traction force.
Page 111: Screed Charging/Relieving
Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Switch (1) has the following positions: A: Relieving (screed ‘lighter’) B: no function C: Charging (screed ‘heavier’) Screedswitch_al_oldl.bmp Switch positions "Screed charging/relieving" are only effective when the paver finish- er moves.
Page 112: Screed Stop With Prestressing
Screed stop with prestressing As for charging/relieving, a pressure of 2-50 bar can be individually applied to the screed lifting cylinders. This pressure can neutralize the weight of the screed to pre- vent the screed from sinking into the freshly laid material, thus supporting the screed stop function, especially in those situation where the screed relieving function is used.
Page 113: Set Pressure For Screed Charging Or Relieving
Set pressure for screed charging or relieving - Set the drive lever to the third catch from the centre position. - Set switch (1) to position A (relieving) or C (charging). - Use pressure regulation valve (93) to adjust the pressure and read it from the pressure gauge (93b).
Page 114: Interrupting/Terminating Operation
Interrupting/terminating operation During breaks (e.g. the material supply truck is late) - 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.
Page 115: When Work Is Finished
When work is finished - Run the paver finisher empty and stop - Lift the screed: set switch (1) to centre position, switch (2) to the top position and switch (3) to lifting. - Retract the screed parts to the basic screed width and lift the auger.
Page 116 Do not turn off main switch until 15 sec- onds after the ignition has been turned off! The engine electronics need this length of time to back up data. F0077/0078_A1.EPS - Read and check the operating hour meter (8) to determine whether main- tenance work must be performed (see chapter F).
Page 117: Malfunctions
Malfunctions Error code query for engine If a fault on the engine is detected and is signalled by one of the warning lamps (1) or (2), a code to which a defined fault is assigned can be displayed using the query switch (3).
Page 118 Example: PAUSE PAUSE Flash sequence: 3-Pause-5-Pause-2. Fault code: 352 If the output switch continues to be held in its upper position, the code is issued once again. Once the switch for error queries has returned to its 0 position, the warning lamp which signalled the fault lights up again.
Page 119: Fault Codes
Fault codes D 4.14 23...
Page 120 D 4.14 24...
Page 121 D 4.14 25...
Page 122 D 4.14 26...
Page 123 D 4.14 27...
Page 124 D 4.14 28...
Page 125 D 4.14 29...
Page 126: Problems During Paving
Problems during paving Problem Cause - change in the material temperature, demixing - 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 - grade control toggles between up and down Wavy surface...
Page 127 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 - paver finisher speed is too high - temperature of the material - change in the material temperature - moisture on the foundation...
Page 128: Malfunctions On The Paver Finisher Or Screed
Malfunctions on the paver finisher or screed Malfunction Cause Remedy See operating instructions for the At the diesel engine Diverse engine See "External starting" (start Batteries empty Diesel engine does assistance) not start Diverse see "Towing" Tamper is obstructed by Properly heat the screed cold bitumen Hydraulic oil level in the...
Page 129 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 charg- Switch must be in the center lifted ing is switched on position...
Page 130 Malfunction Cause Remedy Traction drive fuse defec- Replace (Fuse holder on the tive operating panel) Check potentiometer, cables, Power supply is interrupted connectors; replace if necessary Travel drive monitoring Replace (type-specific) defective Traction does not Electro-hydraulic servo unit Replace the servo unit work of the pump defective Check and adjust if necessary...
Page 131: Emergency Device/Steering, Travel Drive
Emergency device/steering, travel drive In case of a malfunction 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 caterpillar machine. To install the emergency device all plugs of the travel drive pump servo valves have to be replaced by the plugs of the emergency device.
Page 132 Following functions are located in the control unit: No. Denomination Mounting screws for holder plate Switch for preselection of the zero position and forward reverse movement Adjustment knob for speed control (Replace speed preselector) Steering knob Switch to turn the paver on the spot Function If the emergency device is connected all functions like engine speed, conveyor, au- ger, tamper and vibration have to be controlled by the drive lever.
Page 133 GREY Wiring harness for the BLACK drive pump on the left drive unit Marked YELLOW! 24 V / earth/ground control unit D 4.14 37...
Page 135: E02 Set-Up And Modification
E 02 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, au- ger, screed or lifting units. Unless otherwise specified, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Set the drive lever to the centre position and set the preselector to zero;...
Page 136: Distribution Auger
Distribution auger Height adjustment At layer height of up to 15 cm, the height of the auger (1) – measured from its low- er edge – should, depending on material mixture be approx. 5 cm (2 inches) above the material layer height, depend- ing on material mix.
Page 137: With Hydraulic Adjustment (Option)
With hydraulic adjustment (option) - Determine the currently set height of the auger crossbeam (left and right) by means of the scale (1). F0117_A1.EPS Actuate both switches (2) simultaneous- ly to avoid auger crossbeam warping. - Check whether the heights on the left and on the right are identical.
Page 138: Auger Extension
Auger extension E 02 4...
Page 139: Mounting Extension Parts
Mounting extension parts Sch_ver1.tif Sch_ver2.tif E 02 5...
Page 140 - Secure material shaft (5) with screws (6), washers (7) and nuts (8) to the basic unit. - The material shaft is adjustable to enable it to be aligned with the existing shaft. - To do this, unfasten nuts (9) and guide aperture (10) for the screw (6). - Fit auger shaft extension (11) to auger shaft of basic unit.
Page 141: Offset Screed Position Towards Back
Offset screed position towards back Depending on planing conditions and re- quirements, the crossbeam can be moved towards the back. This positional adjustment enlarges the material shaft between auger and screed. - Loosen the four fastening screws (1). - Remove the screws and move the ma- chine forwards.
Page 142: Screed
Screed The Screed operating instructions cover all work required for mounting, setting up and extending the screed. Electrical connections Establish the following connections when the mechanical components have been mounted and set up: Connect remote controls to socket (15) (on the screed). Socket.bmp Connect grade control to socket (16) (on the remote control...
Page 143: F1.0 Maintenance
F 1.0 Maintenance Notes regarding safety Maintenance work: Maintenance work may only be carried out when the engine is at a standstill. Secure the paver finisher and the attachments against inadvertent starting before be- ginning any maintenance work: - Set the drive lever to the center position and the speed preselector to zero. - Remove the traction drive fuse from the operating panel.
Page 145: F2.9 Maintenance Review
F 2.9 Maintenance review Maintenance review 6.2 8.6 F 2.9 1...
Page 146 Maintenance required after the following service hours Sub-units Chapter Conveyor F3.5 Auger F4.1 q q q q Drive engine F5.3 q q q Hydraulics F6.2 q q q q Drive units F7.7 q q q Electronics F8.6 Lubrication points Checking/stopping Maintenance required In this overview, you will find the maintenance intervals for optional machine equip- ment!
Page 147: F3.5 Maintenance - Conveyor
F 3.5 Maintenance - Conveyor Maintenance - Conveyor F 3.5 1...
Page 148: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - Conveyor chain - Check tightness - Conveyor chain - Adjust tightness - Conveyor drive - drive chains - Check chain tightness - Conveyor drive - drive chains - Adjust chain tightness - Conveyor planetary gear - Check oil level - Conveyor planetary gear - Top up oil...
Page 149: Chain Tightness Of The Conveyor (1)
Points of maintenance Chain tightness of the conveyor (1) Checking the chain tightness: For daily inspection look straight through under the bumper. When conveyor chain is correctly tensioned, the lower edge of the chain is approx. 4 cm below the lower edge of the chassis. The conveyor chains should not be too tight or too slack.
Page 150: Conveyor Drive - Drive Chains (2)
Conveyor drive - drive chains (2) To check the chain tension: - If the tension 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 locknut (B) slightly.
Page 151: Conveyor Drive Planetary Gear (Left And Right) (3)
Conveyor drive planetary gear (left and right) (3) - For oil level check unscrew and re- move the inspection bolt (A). When oil level is correct, the oil comes up to the lower edge of the inspection bore or a small amount of oil escapes through the aperture.
Page 153: F4.1 Maintenance - Auger
F 4.1 Maintenance - Auger Maintenance - auger sub-unit F 4.1 1...
Page 154: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - Auger - outer bearing Lubrication - Auger planetary gear oil level check - Auger planetary gear topping up the oil: - Auger planetary gear oil change - Auger drive chain checking of tightness - Auger drive chain adjustment of tightness - Auger drive case...
Page 155: Auger - Outer Bearing (1)
Points of maintenance Auger - outer bearing (1) The grease nipples are located on each side on the top of outer bearing. These are to be lubricated after work, to expel the eventually penetrated bitumin residue while hot and to keep the lubri- cation of the bearing.
Page 156: Drive Chain (3) Of The Transport Augers
For filling in the oil: - Unscrew inspection plug (A) and the filling plug (B). - Fill oil of the correct specification through the filling hole (B) until the oil level reaches the lower edge of the in- spection hole (A). - Replace the filling in plug (B) and the inspection plug (A).
Page 157 To rethighten the chains: - Release locking bolts (A). - Adjust the proper chain tightness with the threaded pins (B): - Tighten the threaded pins to 20 Nm using a torque wrench. - Thereafter, ease back the threaded pins by one full turn. - Retighten bolts (A).
Page 158: Auger Case (4)
Auger case (4) Checking the oil level In case of correct oil level, the oil is be- tween the two notches of the dipstick (A). F 4.1 6...
Page 159 For filling in the oil: - Unscrew the bolts (B) at the upper cover of the auger case. - Remove lid (C). - Fill in oil until the correct level is achieved. - Remount the lid. - Check the oil level once again using the dipstick.
Page 161: F5.3 Maintenance - Engine
F5.3 Maintenance - Engine Maintenance - Engine In addition to these maintenance instructions, the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances. All other main- tenance work and intervals noted in these instructions are also binding. F5.3 1...
Page 162: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - Fuel tank Check filling level - Fuel tank Refill with fuel - Fuel tank Clean the tank and system - Engine lube-oil system Check oil level - Engine lube-oil system Top up oil - Engine lube-oil system Change oil - Engine lube-oil system...
Page 163 Interval Points of maintenance Remark - Engine air filter Check air filter - Engine air filter Empty dust collecting bin - Engine air filter Air filter cartridge Clean / replace - Cooling system of the engine Check radiator fins - Cooling system of the engine Clean radiator fins - Cooling system of the engine Check level of the coolant...
Page 164 Points of maintenance Engine fuel tank (1) - Check the filling level on the gauge on the operating panel. Fill the fuel tank before each start of work so that the fuel system cannot "run dry" and this way the time consuming venting (bleeding) can be avoided.
Page 165: Engine Lube-Oil System (2)
Engine lube-oil system (2) Checking the oil level In case of correct oil level, the oil is be- tween the two notches of the dipstick (A). Check the oil level with a paver finisher standing on a flat area! If there is too much oil in the engine, the gaskets and seals may get damaged, while too little oil can lead to the over- heating of the oil and the damage of the...
Page 166 Changing the oil filter: As part of the oil change mount the new filter after the used oil was drained. - Untighten the filter (D) and clean its resting surface. - Apply thin coat of oil to the seal of the new filter and fill the filter with oil before mounting.
Page 167 Engine fuel system (3) The fuel filter system consists of three fil- ters: - Pre-filter (A) with water separator - Main filter (B) Depending on the machine, the pre-filter is in the engine compartment or under the tank lid! Pre-filter - draining of water Empty the collection bin by the specified intervals or when the engine electronic indicates a fault.
Page 168 Replacing of main filter: - Untighten the filter (B) and clean its resting surface. - Apply a thin coat of oil to the gasket of the new filter. - Tighten the filter by hand. After mounting the filter check for proper tightness during the trial run. Venting the filter: - Unscrew handwheel of the pump (E).
Page 169: Engine Air Filter (4)
Engine air filter (4) Emptying the dust collection bin - Empty the dust collection valve (B) on the air cleaner housing (A) by pressing the discharge port in the direction of the arrow. - Discharge the eventually compacted dust by pressing together the upper part of the valve.
Page 170: Coolant System Of The Engine (5)
Coolant system of the engine (5) Checking / topping up of coolant The coolant level is checked when the engine is cold. Make sure that the anti- freeze and anti-corrosive liquid us suffi- cient (-25 °C). When hot, the system is under pressure. When opening, there is a danger of scalding! - If necessary fill in sufficient amount of...
Page 171: Engine Exhaust System (7)
Engine exhaust system (7) Cleaning of particle filter As considerable amount of soot is accu- mulated in the filter, the cleaning must be performed under an appropriate suc- tion system. Clean the filter element removed with oil-free and grease-free pressure air! - Marking the flow of direction of the ex- haust gas on the filter case.
Page 173: F7.7 Maintenance - Drive Units
F 7.7 Maintenance – Drive units Maintenance – Drive units F 7.7 1...
Page 174: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - Chain tension - Check - Chain tension - Adjust - Planetary gear - Check oil level - Planetary gear - Top up oil - Planetary gear - Change oil Maintenance Maintenance during run-in period F 7.7 2...
Page 175: Chain Tightness (1)
Points of maintenance Chain tightness (1) Checking the chain tightness: If the chains/tracks are not tensioned sufficiently, they can slip out of their guide formed by rollers, drive gear and idler wheel, thereby increasing wear levels. If the chains/tracks are tensioned too tightly, this increases wear on the idler wheel and drive unit mounting, and also increases wear on track bolts and bushes.
Page 176: Planetary Gear (2)
Planetary gear (2) - For oil level check unscrew and re- move the inspection bolt (A). When oil level is correct, the oil comes up to the lower edge of the inspection bore or a small amount of oil escapes through the aperture.
Page 177: F6.2 Maintenance - Hydraulic System
F 6.2 Maintenance - Hydraulic system Maintenance - Hydraulic system F 6.2 1...
Page 178: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - Hydraulic oil tank - Check filling level - Hydraulic oil tank - Top up with oil - Hydraulic oil tank - Change oil and clean - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank - Intake / return hydraulic filter;...
Page 179 Points of maintenance Hydraulic oil tank (1) - Oil level check on dipstick (A). In case of retracted cylinders the oil level shall be at the upper mark. For filling in the oil: - Remove cap (B). - Fill in oil through the filling port until the required filling level is achieved on the dipstick (A).
Page 180: Suction/Return Flow Hydraulic Filter (2)
Suction/return flow hydraulic filter (2) Replace the filter cartridges if the (A) and (B) maintenance indicators reach the red mark. When changing the hydraulic oil, the fil- ters also need to be changed. - Unscrew the lid of the filter housing on the hydraulic tank and replace the fil- ter cartridge.
Page 181: High Pressure Filter (3)
High pressure filter (3) Replace the filter cartridge when the maintenance indicator (A) turns red. - Unscrew filter house (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge. - Replace the seal ring of the filter hous- ing.
Page 182 Pump distribution gear (4) - Check oil level on the viewing glass (A) (at the side of the distribution box). The oil level must be up to the center of the viewing glass. For filling in the oil: - Unscrew the filler screw (B). - Fill in oil through the filling port until the required filling level is achieved on the viewing glass (A).
Page 183: Hydraulic Hoses (5)
Hydraulic hoses (5) - Check the condition of the hydraulic hoses specifically. - Immediately replace the injured hos- The aged hoses may become porous and burst! Risk of accident! The numbers stamped in the joints of the hoses state the date of manufacture (A) and the maximum pressure (B) allowed for that hose.
Page 184: Auxiliary Flow Filter (6)
Auxiliary flow filter (6) Replacing filter element: - Unfasten screw connection on cover (A) then open the non-return valve briefly to lower the oil level in 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...
Page 185: F8.6 Maintenance - Electronic System
F 8.6 Maintenance - Electronic system Maintenance - Electronic system F 8.6 1...
Page 186: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark Filling level of battery electrolyte - check q Top up with distilled water Coat the battery poles with grease Maintenance Maintenance during run-in period F 8.6 2...
Page 187 Interval Points of maintenance Remark - Generator Also see the Checking of operation of the insula- operation tion monitoring manual of Check function the screed - Generator Visual checking for pollution or damage - Check the cooling air openings for pollution or clogging, clean as re- quired.
Page 188 Interval Points of maintenance Remark q Electric fuses Maintenance Maintenance during run-in period F 8.6 4...
Page 189: Points Of Maintenance
Points of maintenance Batteries (1) Maintenance of batteries The batteries are filled with the appropri- ate volume of electrolyte in the factory. The electrolyte level shall be up to the top mark. Top up with ion exchanged water only, when required! The shoes shall be free of oxyde and coated with special battery protection grease.
Page 190: Generator (2)
Generator (2) Checking of operation of the insulation monitoring Check insulation daily with operating machine and switched on connection sockets. - Turn on the electrical equipment with switch (1), indicator lamp (2) comes - Press testing button (3) and the in- scription "Insulation Fault"...
Page 191 Checking of ball bearings / Replace- ment of ball bearings Report the displayed fault code to the customer service of the paver finisher and they will discuss with you the steps to be taken. F 8.6 7...
Page 192: Adjustment Of Belt Tightness
Drive belts (V-belt) Checking belt tension The tightness of each belt shall be in- spected with a tightness checking instru- ment. Specified tension: - in case of first assembly: 550N - after the run-in period / maintenance interval: 400N Riemensp.tif Instructions for checking of tightness in the description of the tightness measuring instrument.
Page 193 Drive belt (toothed belt) Replacement of belt - Unfasten both lock nuts (A) from the clamping lock. - Rotate and open clamping lock (B) un- til belt (C) can be replaced. Pre-tension newly fitted belt using clam- ping lock (B). - Checking / adjusting belt tension Riemenspann.jpg F 8.6 9...
Page 194: Checking / Adjusting Belt Tension
- Retighten both lock nuts (A). Further instructions for checking of ten- sion - see description of the belt pre-ten- sioning test device. A belt pre-tensioning test device can be ordered from Dynapac as a spare part! Item number on request. Riemenspann.jpg F 8.6 10...
Page 195: Electric Fuses (3)
Electric fuses (3) Type of machine: Conventional electronics Fuses_635_konv.eps Main fuses Fuses in terminal box Relays in terminal box Main fuses (A) Lighting, engine Lighting, engine (o) F 8.6 11...
Page 196: Fuses In Terminal Box (B)
Fuses in terminal box (B) F5.5 Travel drive Travel drive Temperature control, electric heating Gas heating (o) Integrated receptacles Integrated receptacles Integrated receptacles Integrated receptacles Engine start 41.1 Engine feedback control 4.21 Engine feedback control Travel drive Spraying system Emulsion spraying system Diesel tank filler pump Rotary beacon Lighting on glassfibre-reinforced roof...
Page 197: Relays In Terminal Box (C)
Relays in terminal box (C) Engine speed adjustment Engine start 18.1 Screed warning hazard flasher, left 18.2 Screed hazard warning flasher, right Travel drive Compactor lift Screed function Screed function Engine feedback control Auxiliary emergency stop Engine Engine feedback control F 8.6 13...
Page 198: Fuses On Operating Panel
Fuses on operating panel Bedienpult_konv_Kette_635_2/Fuse1.tif/Fuse.bmp Fuse carrier (A) Engine start, start interlock, emergency stop, idle speed, reverse buzzer Locking relay, relay batt. 15+, monitoring equipment Levelling unit, screed stop Conveyor, auger, right Conveyor, auger, left Tamper, vibration Hoppers, lifting/lowering screed, extending/retracting screed, power supply screed, compactor lift (o), moving cab (o), lifting/lowering auger (o) Emergency stop...
Page 199: Relays In Operating Panel
Relays in operating panel Bedienpult_konv_Kette_635_Fuse3.wmf Relays Conveyor/auger, left Conveyor/auger, right Screed functions Emergency stop (VB805/1105, EB50,75) Engine stop Timer relay, rev. auger, left Timer relay, rev. auger, right 149.1 Priority circuit for extending/retracting sceed, right 149.2 Priority circuit for extending/retracting screed, left F 8.6 15...
Page 200: Type Of Machine: Plc Electronics
Type of machine: PLC electronics Terminal box Fuses_635_konv.eps Main fuses Fuses in terminal box Relays in terminal box Main fuses (A) Lighting, engine Lighting, engine (o) F 8.6 16...
Page 201: Fuses In Terminal Box
Fuses in terminal box F5.5 Travel drive, automatic steering system Travel drive Temperature control, electric heating Gas heating, power supply to screed Integrated receptacles Integrated receptacles Integrated receptacles Integrated receptacles Engine start Slave A51 Slave A52 Slave A53 Slave A54 Slave A55 Slave A56 (auxiliary functions) 41.1...
Page 202 Spraying system Emulsion spraying system Diesel tank filler pump Rotary beacon Lighting on glassfibre-reinforced roof Working lights (o ) Power supply, Master A1 Particulate filter (o) Asphalt fume control system (o) Seat heating Windscreen wiper Reserve, engine compartment lighting Power supply, Master A1 Lighted height scale F 8.6 18...
Page 203: Relays In Terminal Box (C)
Relays in terminal box (C) Engine start Horn Travel drive Start interlock Reverse buzzer Power supply to terminal 15 Engine feedback control F 8.6 19...
Page 204: Fuses On Operating Panel
Fuses on operating panel Bedienpult_SPS_Kette_635_2/Fuse1.tif/Fuse.bmp Fuse carrier (A) Emergency stop Monitoring equipment, relay batt. 15+,, Engine sensors Display power supply Keyboard power supply Free Free Screed power supply, moving cab (o) Free Fuse carrier (B) Free Horn, reverse buzzer Winscreen wiper (o), crowning adjustment High-beam headlights, left/right Working light, front right Working light, front left...
Page 205: F9.0 Maintenance - Points Of Lubrication
F 9.0 Maintenance - Points of lubrication Maintenance- Points of lubrication The information related to the lubrication points of the various sub-units are included in the specific maintenance descriptions and additional reading is recommended as follows. In case of applying a central lubrication unit (o) the number of the lubrication points may differ from the data provided in the description.
Page 206: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - Check the filling level of the lubri- cant tank q - Fill up the lubricant tank - Vent the central lubrication unit - Check the pressure limiting valve - Check the leakage of the lubri- cant at the consumer unit - Bearings Maintenance...
Page 207: Central Lubrication (1)
Points of maintenance Central lubrication (1) Danger of injuries! Do not reach into the tank when the pump is running. Operate the central lubrication system with a mounted safety valve only! During operation do not perform mainte- Handverl.jpg/Gefahr.jpg nance operations on the safety valve! The lubricant ejected may cause injuries as the equipment operates under high pres- sure! Make sure that the starting of the diesel engine should be prohibited while work is per-...
Page 208 Central lubrication unit Check the filling level The lubrication tank shall always be filled so that the system could not „run dry“ and the proper lubrication of the points of lubrication is ensured and there is no need for a time consuming venting operation.
Page 209 Vent the central lubrication unit The venting of the lubrication system be- comes necessary if the central lubrica- tion unit was operated with an empty lubrication tank. - Untighten the main line (a) of the lu- brication pump at the flow divider (b). - Start the operation of the central lu- brication unit with the refilled lubri- cant tank (c).
Page 210 Check the leakage of the lubricant at the consumer unit Check the continuity of all the lubrication canals at the consumers. - Disconnect the lubrication pipe (a) and fit a standard grease nipple (b). - Connect the grease gun (c) supplied with the machine to the grease nip- ple (b).
Page 211: Bearings (2)
Bearings (2) There are grease nipples on the bearing points of the hydraulic cylinder (one each, at the top and bottom) (a). Zylinder.bmp F 9.0 7...
Page 213: F10.0 Checks, Decommissioning
F 10.0 Checks, decommissioning Tests, check-up, cleaning, stopping F 10.0 1...
Page 214: Maintenance Intervals
Maintenance intervals Interval Points of maintenance Remark - General observation q - Checks by a specialist q - Cleaning q - Conservation of paver finisher Maintenance Maintenance during run-in period F 10.0 2...
Page 215: General Observation
General observation The daily practice includes the walk around the machine with checking the following items: - Are there injuries on the parts or control elements? - Are there leaks on the engine, the hydraulics, the gear box, etc.? - Are all the locking points secure (conveyor, auger, screed)? Repair the detected faults immediately in order to avoid risks of accidents and envi- ronmental pollution! Checks by a specialist...
Page 216: Cleaning
Cleaning - Clean all parts which come into contact with the material to be laid. - Spray the polluted parts with the separating agent spray equipment (o). Before cleaning with high pressure jet, lubricate all the bearings with grease as spec- ified.
Page 217: Conservation Of Paver Finisher
Conservation of paver finisher Downtime up to 6 months - Stop the machine in a place protected from intensive sunshine, wind, moisture and frost. - Lubricate all the lubrication points with grease as specified, use the optional central lubrication unit as appropriate. - Change the oil in the Diesel engine - Tightly seal the muffler of the exhaust pipe.
Page 219: F11.2 Lubricants And Operating Substances
F 11.2 Lubricants and operating sub- stances Lubricants and operating substances Use only the lubricants listed below or comparable qualities of well-known brands. Use only clean containers (inside and outside) for pouring oil or fuel in. Pay attention to the correct filling volumes (see the section "Filling volumes"). Incorrect oil or lubricant levels promote rapid wear and cause the paver finisher to fail.
Page 220: Hydraulic Oils
Hydraulic oils Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso HE 46 Total Fina Elf Total Biohydran SE 46 b) Mineral oil pressure fluids Manufacturer ISO viscosity class VG 46 Shell...
Page 221: Filling Volumes
Filling volumes Operating substance Volume Fuel tank Diesel fuel litres Hydraulic oil reservoir Hydraulic oils litres Diesel engine See Engine operating Engine oil (with oil filter change) instructions. Pump distribution gear Gear oil 90 litres Planetary gear - drive unit Gear oil 220 litres Planetary gear - conveyor...
Page 222: Notes On Changing Over From Mineral Oil To Synthetic Oil
Notes on changing over from mineral oil to synthetic oil / synthetic oil to min- eral oil Drive unit planetary gear Never mix synthetic oils with mineral oils! - Always drain used oil completely. Change the oil when the engine is at op- erating temperature.
Page 223 TRAINING/EDU- CATION We offer our Customers various training programmes on DYNAPAC equipment in our specialised training centre in our factory. We hold train- ing sessions also for special arrange- ments in addition to courses and programs held on fixed dates...
Page 224 Don’t hesitate to contact your local dealer for: service spare parts documentation accessories information about the complete Dynapac paving and planing range...

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