Fayat Group DYNAPAC F2500C Application, Operation & Maintenance
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Fayat Group DYNAPAC F2500C Application, Operation & Maintenance

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OPERATION & MAINTENANCE
Paver Finisher
F2500C / F2500CS
Type 890 / 891
05-0419
4812073969

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Summary of Contents for Fayat Group DYNAPAC F2500C

  • Page 1 OPERATION & MAINTENANCE Paver Finisher F2500C / F2500CS Type 890 / 891 05-0419 4812073969...
  • Page 2 www.dynapac.com...

  • Page 3: Table Of Contents

    Table of contents Preface ..................1 General safety instructions ................ 2 Laws, guidelines, accident prevention regulations ........2 Safety signs, signal words ................. 3 "Danger"! ....................3 "Warning" ! ..................... 3 "Caution" ! ....................3 "Note" ! ....................3 Other supplementary information ............... 3 Warnings ....................
  • Page 4 5.16 Electrical system ..................17 5.17 Permissible temperature ranges ..............17 Identification points ...................18 Warning signs ...................21 Information signs ..................24 CE marking ....................26 Instructive symbols, prohibitive symbols, warning symbols .....27 Danger symbols ..................28 Further warnings and operating instructions ..........29 Identification label for the paver finisher (41) ........31 Explanation of 17-digit PIN serial number ..........32 Engine type plate ..................33...
  • Page 5 Operation ................. 1 Safety regulations ..................1 Controls ...................... 3 Operating panel ..................3 Truck-Assist-System (o) ................34 Remote control ..................40 Mode of operation ..............1 Operating elements on the paver finisher ..........1 Control elements on the operator's control station ........1 Protective roof (o) ..................
  • Page 6 Pressure control valve for paving stop with relieving ......32 Manometer for screed charging/relieving ..........32 Central lubricating system (o): .............33 Track clearer, mechanical (o) ...............34 Lane clearer, electric (o) ..............35 Screed eccentric adjustment ..............36 Push roller crossbar, adjustable ............37 Push roller crossbar, hydraulically extendable (o) .......38 Push roller damping, hydraulic (o) ............38 Fire extinguisher (o) ................39 First-aid kit (o) ..................39...
  • Page 7 Screed charging/relieving ..............27 Screed control with paver finisher stop / in paving operation (screed stop / floating stop / floating paving) ........27 Screed control with paver finisher stop - floating stop with relief ..29 Adjusting the pressure ................. 29 Set pressure for screed charging or relieving ........
  • Page 8 Offsetting the screed ................25 Levelling ....................26 Slope controller ..................26 Fitting the height sensing device ..............27 Mounting the grade control system ............27 Setting up the sensor arm ................28 Big ski 9 m, big ski 13 m ................29 Mounting the big ski bracket on the crossbeam ........31 Mounting the swivel arms ..............32 Mounting the centre element ..............33 Extending the big ski ................34...
  • Page 9 Operation with a feeder with slewing belt ..........68 Preparations for paving ................ 68 Separator fluid ..................68 Cleaning the bucket ................69 Screed ...................... 70 13.1 Electrical connections side board - screed - Conventional version ..70 13.2 Electrical connections side board - screed PLC version ......72 Maintenance ................
  • Page 10 Maintenance - hydraulic system ..........1 Maintenance - hydraulic system ..............1 Maintenance intervals ................4 Points of maintenance ................6 Hydraulic oil tank (1) ................6 Suction/return flow hydraulic filter (2) .............8 Bleeding the filter ...................9 Ventilation filter ..................9 High-pressure filter (3) .................10 Pump distribution gear (4) ..............11 Bleeder ....................12 Hydraulic hoses (5) ................13...
  • Page 11 F100 Tests, stopping ............... 1 Tests, checks, cleaning, stopping .............. 1 Maintenance intervals ................2 General visual inspection ................3 Check that the bolts and nuts fit firmly ............3 Inspection by an expert ................4 Cleaning ..................... 5 Cleaning the hopper ................... 6 Cleaning the conveyor and auger ..............

  • Page 13: Preface

    V Preface Translation of the original operating instructions. If the vehicle is to be operated safely, the information provided in these operating in- structions will be required. The information is provided in a concise, clearly structured form. The individual chapters are arranged in alphabetical order. and every chapter starts with page 1.

  • Page 14: General Safety Instructions

    General safety instructions Laws, guidelines, accident prevention regulations The locally applicable laws, guidelines and accident prevention regulations must al- ways be observed, even if these are not expressly named here. The user himself/herself is responsible for compliance with the resulting regulations and measures! The following warnings, prohibitive symbols and instructive symbols indicate dangers for persons, the vehicle and the environment due to residual risks when operating the...

  • Page 15: Safety Signs, Signal Words

    Safety signs, signal words In the safety instructions, the signal words "Danger", "Warning", "Caution", "Note" are positioned in the coloured title block. They follow a certain hierarchy; in combination with the warning symbol, they indicate the severity of the danger or the type of note. "Danger"! DANGER Danger of personal injury.

  • Page 16: Warnings

    Warnings Warning on a dangerous area or hazard! Failure to observe the warnings can result in life-threatening inju- ries! Warning on danger of being pulled in! In this working area/on this element there is a danger of being pulled in by rotating or conveying elements! Only carry out activities with elements switched off! Warning on dangerous electrical voltage! All maintenance and repair work on the screed's electrical system...
  • Page 17 Warning on danger of falling! Warning on dangers posed by batteries! Warning on hazardous or irritating substances! Warning on substances which constitute a fire hazard! Warning on gas bottles!

  • Page 18: Prohibitive Symbols

    Prohibitive symbols Opening/walking on/reaching in/carrying out/setting up are prohibit- ed during operation or while the drive engine is running! Do not start engine/drive! Maintenance and repair work may only be carried out with the diesel engine shut down! Spraying with water is prohibited! Extinguishing with water is prohibited! Unauthorised maintenance is prohibited! Only qualified experts may conduct maintenance!

  • Page 19: Protective Equipment

    Protective equipment Locally applicable regulations may require the wearing of various safety equipment! Always observe these regulations! Wear safety goggles to protect your eyes! Wear suitable head protection! Wear suitable hearing protection to protect your hearing! Wear suitable safety gloves to protect your hands! Wear safety shoes to protect your feet! Always wear close-fitting work clothing! Wear a warning vest to be seen in time to avoid accidents!

  • Page 20: Environmental Protection

    Environmental protection The locally applicable laws, guidelines and accident prevention regulations for the proper recycling and disposal of waste must always be observed, even if these are not expressly named here. Water-endangering substances like: - Lubricants (oil, grease) - Hydraulic oil - Diesel fuel - Coolant - Cleaning liquids...

  • Page 21: Additional Information

    Additional information Also observe the manufacturer's documentation and additional doc- umentation! For example, the maintenance instructions of the engine manufac- turer Description / depiction applicable when equipped with gas heater! Description / depiction applicable when equipped with electric heat- t Used to indicate standard equipment. o Used to indicate optional equipment.

  • Page 22: Ce Identification And Declaration Of Conformity

    CE identification and Declaration of Conformity (only applies to machines sold in the EU/EEC) This machine has CE identification. This identification says that the machine fulfils the basic health and safety requirements pursuant to the Machinery Directive 2006/42/ EC together with all other valid regulations. The scope of supply of the machine in- cludes a Declaration of Conformity as specified in the valid regulations and amend- ments together with harmonised standards and other valid provisions.

  • Page 23: Residual Risks

    Residual risks These are risks that remain even if all possible measures and safety precautions have been taken to help minimise dangers (risks) or to reduce their probability and scope to zero. Residual risks in the form of - Danger to life and limb of persons at the machine - Danger to the environment posed by the machine - Damage to property and restricted output and functionality of the machine - Damage to property in the operating range of the machine...

  • Page 24: Sensibly Predictable Incorrect Usage

    Sensibly predictable incorrect usage Every kind of sensibly predictable incorrect usage of the machine constitutes misuse. Incorrect usage makes the manufacturer's warranty null and void: the operator bears sole responsibility. Sensibly predictable incorrect usage of the machine includes: - presence in the danger zone of the machine - transporting persons - leaving the operator's platform while the machine is operating - removing protection or safety devices...

  • Page 25: A Correct Use And Application

    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 guidelines are part of the present operating instructions and must always be heeded. National regulations are fully applicable.

  • Page 27: B Vehicle Description

    B Vehicle description Application The Dynapac F2500C / F2500CS paver finisher is a paver finisher with a caterpillar drive which is used for paving bituminous mixed material, roll-down or lean-mixed concrete, track-laying ballast and unbound mineral aggregates for foundations for paving.

  • Page 28: Description Of Assemblies And Functions

    Description of assemblies and functions Item Designation Material compartment (hopper) Truck push rollers Tube for sensor rod (direction indicator) and holder for levelling shoe Caterpillar drive Levelling cylinder for paving thickness Traction roller Crossbeam pull bar Paving thickness indicator Crossbeam Travel drive of the caterpillar drive Auger Screed...

  • Page 29: 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 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 30 Engine: The paver finisher is driven by a water cooled diesel engine. For further de- tails see the technical data and the engine's instruction manual. Drive unit: Both caterpillar drives are directly driven by separate drives. They operate directly, without any drive chains which require maintenance or servicing. The tension of the caterpillar chains can be readjusted using tensioners.
  • Page 31 Material compartment (hopper): The hopper inlet is equipped with a conveyor sys- tem that empties the hopper and transfers the material to the auger. The hopper can hold approx. 15.0 t. To facilitate emptying and achieve even material transfer, each of the lateral covers of the hopper can be hydraulically folded in.
  • Page 32 Levelling/slope control system: The slope control system (o) allows the traction point to be regulated at the left-hand or the right-hand side with a defined difference to the opposite side. To determine the actual value, the two traction crossbeams are linked with a slope control rod.

  • Page 33: Danger Zones

    Danger zones WARNING Danger for persons in the danger zone Persons in the danger zone can suffer severe or fatal inju- ries from movements and functions of the vehicle! - Remaining in the vehicle's danger zone during operation is prohibited! - During operation, only the vehicle operator and the screed personnel are allowed on the vehicle or in the danger zone.

  • Page 34: Safety Devices

    Safety devices 4 5 6 7...
  • Page 35 Item Designation Hopper transport safeguard Crossbeam lock, mechanical / hydraulic (o) Main switch Emergency stop button Horn Ignition key Lights Protective roof latch (o) Fire extinguisher (o) Screed warning light (o) Covers, lateral flaps, coverings Rotary beacon (o) Located on both sides of the vehicle Safe operation is only possible when all operating and control elements are function- ing correctly and when all safety devices are in position.

  • Page 36: Technical Data, Standard Configuration

    Technical data, standard configuration Dimensions (all dimensions in mm) 2125 2900 6145 6400 1990 2550 3290 3400 For screed technical data, refer to the screed operating instructions. B 10...

  • Page 37: Allowed Angle Of Rise And Slope

    Allowed angle of rise and slope max. 15° max. 15° max. 15° max. 15° Before operating your vehicle in an inclined position (gradient, slope, lateral inclina- tion) which is above the specified limit value, please consult the customer service de- partment for your vehicle! Permissible approach angle max.

  • Page 38: Weights F2500C (All Weights In T)

    Weights F2500C (all weights in t) Paver finisher without screed approx. 14.5 Paver finisher with screed: - V5100 approx. 18.2 With extension parts for max. approx. xxx working width, additionally max. With filled hopper approx. 15.0 Additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.

  • Page 39: Performance Data F2500C

    Performance data F2500C V5100TV 2.55 2.00 5.10 8.10 Transport speed 0 - 4 km/h Operating speed 0 - 30 m/min Paving height -150 - 320 Max. grain size Theoretical paving performance B 13...

  • Page 40: Performance Data F2500Cs

    Performance data F2500CS V5100TV 2.55 2.00 5.10 8.10 V6000TV 3.00 2.00 6.00 9.00 Transport speed 0 - 4 km/h Operating speed 0 - 30 m/min Paving height -150 - 320 Max. grain size Theoretical paving performance B 14...

  • Page 41: Travel Drive/Traction Unit

    Travel drive/traction unit Drive Hydrostatic drive, continuously controllable Two separately driven caterpillar drives with rub- Drive unit ber grouser chains Turning capacity Turning on the spot Speed See above Engine F2500C Make/type Cummins QSB 6.7-C173 Version 6-cylinder diesel engine (water-cooled) Performance 110 kW / 150 hp (at 2200 rpm) Pollutant emissions...

  • Page 42: Material Compartment (Hopper)

    5.12 Material compartment (hopper) Volume Approx. 6.5 m = approx. 15.0 t Minimum inlet height, centre 555 mm Minimum inlet height, outside 560 mm Hopper width, outside, open 3610 mm 5.13 Material transfer Type Dual conveyor belt Width 2 x 655 mm Conveyors Left and right auger separately controllable Drive...

  • Page 43: Screed Lifting Device

    5.15 Screed lifting device At standstill: - Screed stop - Screed stop with pretensioning (max. pressure 40 bar) Special functions During paving: - Screed charging - Screed relieving (max. pressure 40 bar) Mechanical grade control Levelling system Optional systems with and without slope control 5.16 Electrical system On-board voltage...

  • Page 44: Identification Points

    Identification points CAUTION Danger due to missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries! - Never remove any warnings or information signs from the vehicle. - Damaged or lost warning or information signs must be replaced immediately.
  • Page 45 B 19...
  • Page 46 xxxxxxxxxxxxxxxxx B 20...

  • Page 47: Warning Signs

    Warning signs Pictogram Meaning - Warning - Operating instructions! Danger due to improper operation. The vehicle personnel must have read and understood the safety, operating and maintenance instructions for the ve- hicle before the vehicle is put into opera- tion! Failure to comply with the operating and warning instructions can cause se- vere or fatal injuries.
  • Page 48 Pictogram Meaning - Warning - Danger of crushing fingers and hands due to moving, accessible vehicle parts! Crushing points can cause severe injuries with the loss of parts of the fingers or hand. Keep your hands at a safe distance from the danger area! - Warning - Spring-loaded part! Performing work incorrectly can cause...
  • Page 49 Pictogram Meaning - Warning - Hazard from hydraulic reservoir and from hydraulic oil under pressure! Escaping hydraulic oil under pressure can pierce the skin and enter into the body, causing severe or fatal injuries. Always observe the operating instructions! - Warning - Danger from tyres filled with water! Handling tyres filled with water incorrect- ly can cause severe to fatal injuries.

  • Page 50: Information Signs

    Information signs Pictogram Meaning - Operating Instructions Position of the storage compartment. - Lifting point Lifting the machine is only permitted at these lifting points! - Lashing point Lashing the machine is only permitted at these points! - Main battery switch Position of the main battery switch.
  • Page 51 Pictogram Meaning - Engine oil Position of the filling and control point. - Engine coolant Position of the filling and control point. - Hydraulic oil Position of the filling point. - Hydraulic oil level Position of the control point. - Engine oil drainage point Position of the drainage point.

  • Page 52: Ce Marking

    Pictogram Meaning - Tamper speed adjuster Position of the speed adjuster. - Vibration, speed adjuster Position of the speed adjuster. CE marking No. Pictogram Meaning - CE, sound output level B 26...

  • Page 53: Instructive Symbols, Prohibitive Symbols, Warning Symbols

    Instructive symbols, prohibitive symbols, warning symbols No. Pictogram Meaning - Wear ear protectors - Do not enter the area! - Do not spray the area or component with water! - Warning on dangers posed by batteries! - First aid kit B 27...

  • Page 54: Danger Symbols

    Danger symbols No. Pictogram Meaning - XN: Danger to health! This substance can damage your health when absorbed in the body! Substance irritating to skin, eyes and res- piratory system; can cause inflammation. Avoid contact with the human body; also avoid inhaling the vapours and seek med- ical advice if feeling unwell.

  • Page 55: Further Warnings And Operating Instructions

    Further warnings and operating instructions Pictogram Meaning - Warning - Hazard from unsupported screed! If the screed sags, this can cause severe or fatal injuries! Insert crossbeam lock only at crown adjustment "zero". Cross- beam lock only for transportation! Do not enter or work under screed only secured with crossbeam lock for transportation! - Attention - danger of high voltage in...
  • Page 56 Pictogram Meaning - Overview "Tyre pressure / working width / speed preselection" - Overview "Tyre pressure / working width / speed preselection" - Engine start - All switches in neutral! The engine cannot be started when functions are switched on. Always observe the operating instructions! B 30...

  • Page 57: Identification Label For The Paver Finisher (41)

    Identification label for the paver finisher (41) Item Designation Vehicle designation Designation type Year of construction Serial number (product identification number (PIN)) Operating mass, incl. all extension parts, in kg Maximum permitted total mass in kg Maximum permitted axle load kg - axle 1 Maximum permitted axle load kg - axle 2 Maximum permitted axle load kg - axle 3 Nominal power in kW...

  • Page 58: Explanation Of 17-Digit Pin Serial Number

    Explanation of 17-digit PIN serial number >10002014JHG002076< - Manufacturer - Family/Model - Code letter - Serial number B 32...

  • Page 59: Engine Type Plate

    Engine type plate The engine type plate (1) is affixed on top of the engine. The type plate states the engine type, serial number and engine data. Please state the engine number of the engine when ordering spare parts. See also operating instructions for the engine. B 33...

  • Page 60: Standards

    EN standards Continuous sound pressure F2500C, Cummins QSB 6.7-C173 The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protectors are used, hearing can be impaired. The sound emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6:2006 and ISO 4872.

  • Page 61: Continuous Sound Pressure F2500Cs, Cummins Qsb 6.7-C173

    Continuous sound pressure F2500CS, Cummins QSB 6.7-C173 The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protectors are used, hearing can be impaired. The sound emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6:2006 and ISO 4872.

  • Page 62: Vibration Acting On The Entire Body

    Vibration acting on the entire body When the vehicle is used properly, the weighted effective acceleration values at the driver’s seat of a = 0.5 m/s according to DIN EN 1032 are not exceeded. Vibrations acting on hands and arms When the vehicle is used properly, the weighted effective acceleration values at the driver’s seat of a = 2.5 m/s...

  • Page 63: C10 Transportation

    C 10 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 64 WARNING Danger due to vehicle loading Loading or unloading the vehicle onto or from another vehi- cle poses a potential risk of accident. Vehicles can tip over on driving onto the low-bed trailer and cause severe to fatal injuries! - The transportation vehicle must always meet the requirements for transportation and be designed for this.
  • Page 65 WARNING Danger due to incorrect directing of the vehicle A banksman must be used when visibility is impaired on roads or transport roads and when loading the vehicle. Incorrectly implemented or misunderstood directions given by the banksman can cause severe to fatal injuries! The banksmen assigned for directing vehicles may only consist of personnel - who have been trained for directing machines and can...

  • Page 66: 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"! Check the fill level of the operating substances so that these do not escape when driv- ing on an incline.
  • Page 67 Operation Travelling direction - Close the hopper lids. - Engage both hopper transport safeguards. - Lift the screed. - Insert the transportation safeguards of the screed. - Fully extend the levelling cylinder. - Retract the screed parts until the screed matches the basic width of the paver finisher.

  • Page 68: Securing The Load

    Securing the load The following instructions for securing the load on the low-bed trailer consist merely in examples of how to secure the load correctly. Always comply with the local regulations for securing the load and for correct use of load securing equipment.

  • Page 69: 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. NOTE Caution! Possible collision of parts - When driving up inclines, lock the lane clearer in the upper position. - Use the work gear and low engine speeds to drive onto the low-bed trailer. C 10 7...

  • Page 70: Lashing Equipment

    Lashing equipment Use the load securing equipment, lashing straps and chains belonging to the vehicle. Additional shackles, eyebolts, edge guards and non-slip mats may be needed de- pending on the type of load securing equipment. Always comply with the stated values for permitted lashing force and load rating! Always tighten the lashing chains and straps hand-tight (100-150 daN).

  • Page 71: Loading

    Loading Pay attention to load distribution during loading! In some vehicles, the kingpin load is too low so that the load has to be positioned fur- ther to the back of the vehicle (A). Always heed the details regarding load distribution stipulated for the vehicle together with the centre of gravity of the paver finisher.

  • Page 72: Preparing The Vehicle

    Preparing the vehicle After the vehicle has been positioned on the low-loader, the following preparations must be carried out: - For movable platform: Set the retaining bolt properly (1). - Close the hopper and set the hopper transport safeguards (2) on both sides. - Position the non-slip mats under the screed across the whole width of the vehicle (3) and lower the screed.

  • Page 73: Securing The Load

    Securing the load Securing at the sides Diagonal lashing secures the paver finisher at the sides using the lashing points on the paver finisher and on the low-load trailer. Fasten the lashing chains as shown. Securing at the front Diagonal lashing secures the paver finisher at the front using the lashing points on the paver finisher and on the low-load trailer.

  • Page 74: Securing At The Rear - Screed With Side Board

    Securing at the rear - screed with side board Diagonal lashing secures the paver finisher at the rear, at right angles to the direction of travel using the lashing points on the paver finisher (eyebolts) and on the low-load trailer. Fasten the lashing straps as shown. Screw the supplied eyebolts first of all in the holes provided in the arms.

  • Page 75: Securing At The Rear - Screed Without Side Board

    Securing at the rear - screed without side board Step 1: fasten lashing straps Diagonal lashing secures the paver finisher at the rear using the lashing points on the paver finisher and on the low-load trailer. Fasten the lashing straps as shown. Step 2: fasten lashing chains Diagonal lashing secures the paver finisher at the rear using the lashing points on the paver finisher and on the low-load trailer.

  • Page 76: After Transportation

    After transportation - Remove the attachment devices. - Raise protective roof: See section entitled "Protective roof" - Lift the screed to the transportation position. - Start the engine and drive the vehicle in working gear from the trailer with low engine revs/speed.

  • Page 77: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and...
  • Page 78 The protective roof can be raised and lowered electrically. The exhaust pipe is lowered or raised to- gether with the roof. - Tighten bolts (1) on both sides of the roof. - Operate the switch (2) until the roof has reached the upper or lower limit position.

  • Page 79: 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 overlaying or loose parts from finisher and screed (see also operating instructions for the screed).
  • Page 80 Operation Travelling direction - Close the hopper lids. - Engage both hopper transport safeguards. - Lift the screed. - Insert the transportation safeguards of the screed. - Fully extend the levelling cylinder. - Retract the screed parts until the screed matches the basic width of the paver finisher.

  • Page 81: Driving Mode

    Driving mode Operation Travelling direction - Set the fast/slow switch to "Hare" if necessary. - Turn the preselector to "zero". - Swivel the drive lever to maximum. The vehicle already advances slightly on deflecting the drive lever! - Adjust required vehicle speed with the preselector.

  • Page 82: Loading By Crane

    Loading by crane WARNING Danger from suspended loads Crane and/or lifted vehicle can tip when lifted and cause injuries! - The vehicle may only be raised at the marked lifting points. - Heed the operating weight of the vehicle. - Do not enter the danger zone. - Use only lifting gear that can bear the load.
  • Page 83 Example: Four lifting eyes (1, 2) are provided for loading the vehicle with a crane. Depending on the type of screed which is used, the paver finisher's centre of gravity, with the screed mounted, is located in area (3) of the vehicle. - Secure vehicle wherever it is parked up.
  • Page 84 See section entitled "Protective roof" - Attach lifting gear to the four attachment points (1, 2). The max. permissible attachment point load at the attachment points is 73.5 kN. The permissible load applies in the vertical direction! Make sure that the paver finisher remains in a horizontal position during transportation! C 10 22...

  • Page 85: 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 finisher, even on slopes. Use only approved tow bars! If necessary, remove any attachments and accessories from the paver finisher and the screed until the basic width has been attained.
  • Page 86 A hand pump (5) is located in the engine compartment (left side); it must be actuated to be able to tow the machine. Pressure for releasing the traction system brakes is built up with the hand pump. - Push knob (6) into the valve body. While pumping (next step), check that the knob remains in the pressed position.

  • Page 87: 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 unauthorised 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 88: Lifting The Vehicle With Hydraulic Lifts, Lifting Points

    Lifting the vehicle with hydraulic lifts, lifting points The hydraulic lift must be rated for at least 10t. Always choose a horizontal surface with adequate load rating as installation surface for the hydraulic lift! Make sure that the hydraulic lift is securely and correctly positioned! The hydraulic lift is only intended to lift a load and not as a support.

  • Page 89: D10 Operation

    D 10 Operation Safety regulations Starting the engine, the travel 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 beneath 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! Unless otherwise specified, the controls may only be actuated when the en-...
  • Page 90 DANGER Danger due to improper operation Improper operation of the vehicles can cause severe to fatal injuries! - The vehicle may only be used in the proper manner for its intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves famil- iar with the contents of the operating instructions.

  • Page 91: Controls

    Controls Operating panel All detent switch functions that can pose a hazard when the diesel engine starts up (turning to the side, conveying function of auger and conveyor) prevent the engine from starting (start inhibit) when switched on or when set to "MANUAL" or "AUTO". These functions must be "Straight-ahead travel"...
  • Page 92 D 10 4...
  • Page 93 Item Designation Brief description Lights up instrument panel A/B when the parking light Lights is switched on Press in an emergency (danger to persons, impending colli- sion, etc.)! Pressing the emergency stop button switches off the en- gine, the drives and the steering system. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents!
  • Page 94 D 10 6...
  • Page 95 Item Designation Brief description On actuation, the starter is in operation. Starter All emergency stop buttons (on the operating panel and the remote controls) must be pulled out. For switching on the paver finisher functions and for continu- ously regulating the road speed – forward or reverse. Centre position: Engine in neutral;...
  • Page 96 D 10 8...
  • Page 97 Item Designation Brief description To activate the ignition voltage by turning the key. - Switch off by turning the key back to its starting position. On shutting off the vehicle, first switch off the ignition, then deactivate the main switch. Ignition lock Before the main battery switch is deactivated, a period of at least 100 seconds must elapse after switching off...
  • Page 98 D 10 10...
  • Page 99 Item Designation Brief description Pushbutton function: - Upper switch position: Close left hopper lid. Open / close left - Lower switch position: hopper Open left hopper lid. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - Upper switch position: Close right hopper lid.
  • Page 100 D 10 12...
  • Page 101 Item Designation Brief description Detent switch function: -Operating mode "AUTO": The conveying func- tion of the left half of the auger is switched on when the drive lever is swivelled out and is con- tinuously controlled via the material limit switches. Left auger - -Operating mode "OFF": The conveying func- Operating mode...
  • Page 102 D 10 14...
  • Page 103 Item Designation Brief description Pushbutton function: - Left switch position: Manual start of the conveying function, Conveying direction outwards. - Right switch position: Manual start of the conveying function, Left auger Conveying direction inwards. "MANUAL" conveying For manual triggering, the auger function must be direction switched to "AUTO"...
  • Page 104 D 10 16...
  • Page 105 Item Designation Brief description Pushbutton function: - Left switch position: Extend left half of screed. Retract / extend - Right switch position: left screed Retract left half of screed. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - Left switch position: Retract right half of screed.
  • Page 106 D 10 18...
  • Page 107 Item Designation Brief description Detent switch function: -Operating mode "AUTO": The conveying func- tion of the left conveyor is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switches. Left conveyor - -Operating mode "OFF": The conveying func- Operating mode tion of the left conveyor is switched off.
  • Page 108 D 10 20...
  • Page 109 Item Designation Brief description Detent switch function: - Upper switch position: Screed stop (floating position OFF): Screed is hy- draulically blocked in position. - Lower switch position: Lower screed + floating position: Screed is lowered and held in the floating position when the drive lever Screed stop (float- is swivelled out.
  • Page 110 D 10 22...
  • Page 111 Item Designation Brief description Detent switch function: -Operating mode "AUTO": Screed vibration is Vibration - switched on when the drive lever is swivelled out. Operating mode "AUTO" / -Operating mode "OFF": Screed vibration is "OFF" / switched off. "MANUAL" -Operating mode "MANUAL": Screed vibration is switched on constantly.
  • Page 112 D 10 24...
  • Page 113 Item Designation Brief description Pushbutton function: - Upper switch position: Retract left levelling cylinder. Retract / extend left levelling - Lower switch position: cylinder Extend left levelling cylinder. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - Upper switch position: Retract right levelling cylinder.
  • Page 114 D 10 26...
  • Page 115 Item Designation Brief description Not used Detent switch function: - Upper switch position: Front working Front working lights ON. lights - Lower switch position: ON / OFF Front working lights OFF. Avoid dazzling other road users! Detent switch function: - Upper switch position: Rear working Rear working lights ON.
  • Page 116 D 10 28...
  • Page 117 Item Designation Brief description If a fault discovered on the drive engine is indicated by one of the warning lamps, a code assigned to a defined defect can be called up. Pushbutton function: - Upper switch position: Error / malfunction Call the fault code.
  • Page 118 D 10 30...
  • Page 119 Item Designation Brief description Not used Not used Lights up when a serious error has occurred on the engine. The engine is automatically shut down for safety. Error message The error code can be retrieved using the "Call up er- with engine stop ror/malfunction"...
  • Page 120 D 10 32...
  • Page 121 Item Designation Brief description Battery charge in- Must go out after starting when the engine revs up. dicator (red) If the light does not go out, switch off the engine Not used Indicates that there is a drive engine fault. Depending on the type of fault, the vehicle can temporarily continue to be operat- ed or, in the case of serious faults, should be shut down im- mediately to prevent further damage from occurring.

  • Page 122: Truck-Assist-System (O)

    Truck-Assist-System ( D 10 34...
  • Page 123 The Truck Assist system is used for communication between the driver of the paver and the driver of the material truck. The corresponding signal system shows the truck driver which action to perform (reversing / stop / tip material / depart). Caution! Possible material damage through NOTE insufficient instruction...
  • Page 124 D 10 36...
  • Page 125 Item Designation Brief description LED display Pushbutton function with LED feedback: - To change over to the "Start Tipping" signal. (YELLOW SIGNAL, running light as- cending) - Press button again to change signal Tell truck over to "Pause". to "Start (YELLOW SIGNAL, flashing).
  • Page 126 D 10 38...
  • Page 127 Item Designation Brief description LED display Pushbutton function with LED feedback: - The "Truck Assist" function runs auto- matically. - Switch OFF by pressing the button again - Press button (84) to request a truck with material / Release for truck to approach (GREEN SIGNAL) The truck is detected by a laser sensor at...

  • Page 128: Remote Control

    Remote control Depending on the side of the machine (left/right), the function switches only control the corresponding function on the particular side of the machine. Important! Do not disconnect remote controls with emergency stop button during op- eration! This causes the paver finisher to be shut down! D 10 40...
  • Page 129 Item Designation Brief description Press in an emergency (danger to persons, impending colli- sion, etc.)! Pressing the emergency stop button switches off the en- gine, the drives and the steering system. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents! button...
  • Page 130 D 10 42...
  • Page 131 Item Designation Brief description Pushbutton function: - Upper switch position: Retract left / right levelling cylinder. Retract / extend left / right levelling - Lower switch position: cylinder Extend left / right levelling cylinder. On actuation, heed danger zones of moving parts of the vehicle! Detent switch function: - Upper switch position:...
  • Page 132 D 10 44...

  • Page 133: D30 Mode Of Operation

    D 30 Mode of operation Operating elements on the paver finisher Control elements on the operator's control station WARNING Danger of falling from the vehicle Entering and leaving the vehicle and the driver's seat dur- ing operation poses a risk of falling from the vehicle, which can cause severe to fatal injuries! - During operation, the operator must be at the intended driver's seat and be seated properly.

  • Page 134: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and...
  • Page 135 The protective roof can be raised and lowered electrically. The exhaust pipe is lowered or raised to- gether with the roof. - Tighten bolts (1) on both sides of the roof. - Operate the switch (2) until the roof has reached the upper or lower limit position.

  • Page 136: Ladder

    Ladder The ladder is used to access the control platform. The ladder can be secured in the top position: - have the ladder raised by a second person. Set the latch (1) on both sides of the ladder to the intended position. The ladder must not be locked when driving or paving! Storage space...

  • Page 137: Control Platform, Moveable (O)

    Control platform, moveable (o) D 30 5...

  • Page 138: Control Platform Lock (O)

    The control platform can be hydraulically shifted beyond the left/right outer edge of the vehicle, providing the driver with a better view of the paving area in this position. During transportation in road traffic and when transporting the vehicle on transport- ers, the control panel must be secured in the central position! Actuating the platform shift function: see operating panel.

  • Page 139: Operating Panel

    Operating panel The operating panel can be adjusted to the various operating positions: left/right, sit- ting/standing. The entire operating panel can be swivelled for operation beyond the outer edge of the vehicle. Make sure it is latched properly! Only adjust the operating position whilst the vehicle is stationary! Pushing the operating panel: - Release panel latch (2) and slide panel console to the desired position using the handle (3).

  • Page 140: Protective Roof (O)

    Protective roof (o) D 30 8...

  • Page 141: Windscreen Wiper

    CAUTION Risk of crushing hands When closing the spring-loaded front and side windows, there is a risk of crushing which can cause injuries! - Do not reach into the danger zone. - Set the latches correctly. - Comply with further instructions in the safety manual. The protective roof is equipped with an additional front window and two side windows.

  • Page 142: Emergency Actuation Control Platform, Movable

    Emergency actuation control platform, movable If the control platform cannot be moved hydraulically, it can be pushed back to its central position by hand. - Remove the screw cap (1) (next to the right footwell window). - Remove screw (2). This undoes the connection between the platform and the frame so that the plat- form can be moved.

  • Page 143: Seat Console

    Seat console The seat consoles can be swivelled for operation beyond the outer edge of the vehicle. - Press latch (1), swivel seat console to the desired position and allow latch to engage again. - Fold hinged step (2) down if necessary.

  • Page 144: Driver's Seat, Type I

    Driver's seat, type I To avoid damage to health, the individu- al seat settings should be checked and adjusted before starting the vehicle. After locking the individual elements, it must no longer be possible to shift then to another position. - Weight setting (1): The relevant driv- er's weight should be set by turning the weight adjustment lever when the...

  • Page 145: Driver's Seat, Type Ii

    Driver's seat, type II To avoid damage to health, the individu- al seat settings should be checked and adjusted before starting the vehicle. After locking the individual elements, it must no longer be possible to shift then to another position. - Horizontal setting (1).

  • Page 146: Fuse Box

    Fuse box The terminal box, which contains all fus- es and relays, etc. is located beneath the central control platform floor panel. An assignment plan for fuses and relays can be found in chapter F8. D 30 14...

  • Page 147: Batteries

    Batteries The batteries (1) of the 24 V system are located in the vehicle footwell. For the specifications, refer to chapter B, "Technical Data". For maintenance, see chapter "F". External starting only according to the instructions (see section "Starting the paver finisher, external starting...

  • Page 148: Hopper Transport Safeguard

    Hopper transport safeguard Before transporting or in order to park the paver finisher, the hopper halves must be swung upwards and the trans- port safeguards for the hopper must be inserted on both sides of the vehicle. - Pull the locking pin (1) and place the transport safeguard (2) with the handle above the hopper cylinder's piston rod.

  • Page 149: Screed Lock, Hydraulic (O)

    Screed lock, hydraulic (o) The screed locks must additionally be extended on both sides of the vehicle prior transportation with screed lifted. Transportation with unsecured screed leads to a risk of accidents! - Lift the screed. - Activate the function on the operating panel.

  • Page 150: Paving Thickness Indicator

    Paving thickness indicator Two scales, on which the currently set paving thickness can be read off, are lo- cated on the left and right sides of the vehicle. - Loosen the clamping bolt (1) to change the position of the indicator. In normal paving situations, the same paving thickness should be set on both sides of the vehicle!

  • Page 151: Auger Lighting (O)

    Auger lighting (o) Two swivelling headlights (1) are located on the auger box for illuminating the au- ger compartment. - They are engaged together with the working lights. These are activated together with the other working lights on the operating panel! Engine compartment lighting (o) The engine compartment lighting can be activated...

  • Page 152: Led Working Light (O)

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

  • Page 153: Watt Spotlight (O)

    500 watt spotlight (o) There are two halogen spotlights (2) at the front of the machine and also at the back. Always align the working lights to avoid dazzling the operating personnel or oth- er road users! Danger of burning! The working lights get very hot! Do not touch working lights that are switched on or hot!

  • Page 154: Auger Height Adjustment Ratchet (O)

    Auger height adjustment ratchet (o) For mechanical adjustment of the auger height - Set the ratchet direction lever (1) to the clockwise or anti-clockwise direc- tion. Turning anti-clockwise lowers the auger, turning clockwise lifts the auger. - Actuate the ratchet lever (2) - Set the desired height by alternately actuating the left and right ratchets.

  • Page 155: Sensor Rod / Sensor Rod Extension

    Sensor rod / sensor rod extension The sensor rod acts as an orientation aid for the vehicle driver during paving. Along the defined paving route, the vehicle driver can use the sensor rod to follow a tensioned reference wire or another marking. The sensor rod runs along the reference wire or over the marking.
  • Page 156 - Once the sensor rod has been set to the desired width, the clamping bolts (2) must be tightened again. - The inserted sensor rod extension is secured with the bolts (4). Depending on the side of the vehicle on which the sensor rod extension is used, the entire sensor rod may have to be removed and re-inserted on the other side of the vehicle! - After releasing the wing nuts (5), the end section of the sensor rod extension (6)

  • Page 157: Manual Separator Fluid Spray (O)

    Manual separator fluid spray (o) Used to spray the parts coming into contact with asphalt with a separator emulsion. - Remove the spray (1) from its bracket. - Build up pressure by actuating the pump lever (2). - The pressure is indicated on the ma- nometer (3).

  • Page 158: Separator Fluid Spraying System (O)

    Separator fluid spraying system (o) Used to spray the parts coming into contact with asphalt with a separator emulsion. Variant (A): hose package Variant (B): Hose reeling device - Possibly connect the spray hose (1) with the connecting piece (2). Only switch on the spraying system when the diesel engine is running;...

  • Page 159: Conveyor Limit Switches - Plc Version

    Conveyor limit switches - PLC version The mechanical conveyor limit switch- es (1) or the ultrasonic conveyor limit switches (2) control the material flow on the relevant half of the conveyor. The conveyors should stop when the material has roughly reached the area below the auger tube.

  • Page 160: Conveyor Limit Switches - Conventional Version

    Conveyor limit switches - conventional version The mechanical conveyor limit switch- es (1) control the material flow on the relevant half of the conveyor. The con- veyors should stop when the material has roughly reached the area below the auger tube. This requires that the auger height has been adjusted correctly (see chapter E).

  • Page 161: Ultrasonic Auger Limit Switches (Left And Right) - Plc Version

    Ultrasonic auger limit switches (left and right) - PLC version The limit switches control the material flow at the relevant half of the auger without contact. The ultrasonic sensor (1) is secured to the side shield via a bracket (2). - To adjust, release the clamping lever / stop screw...

  • Page 162: Ultrasonic Auger Limit Switches (Left And Right) - Conventional Version

    Ultrasonic auger limit switches (left and right) - conventional version The limit switches control the material flow at the relevant half of the auger without contact. The ultrasonic sensor (1) is secured to the side shield via a bracket (2). - To adjust the sensor angle, loosen the clamps (3) and swivel the bracket.

  • Page 163: Volt / 12 Volt Sockets (O)

    24 volt / 12 volt sockets (o) A socket (1) is located behind the left/right seat consoles. Additional working lights can be connected here, for example. - Right seat console: 12V socket - Left seat console: 24V socket Voltage is present when the main switch is switched on.

  • Page 164: Pressure Control Valve For Screed Charging/Relieving

    Pressure control valve for screed charging/relieving A valve (1) is used to set the pressure for additional screed charging/relieving. Switching on, see screed charging/re- lieving (chapter "Operating panel", "Operation"). - For pressure indication, see manome- ter (3). Pressure control valve for paving stop with relieving Valve (2) is used to set the pressure for "Screed control with paver finisher stop - float- ing stop with relieving".

  • Page 165: Central Lubricating System (O)

    Central lubricating system (o): The automatic mode of the central lubri- cation system is activated as soon as the compacting elements of the screed are engaged. The pumping interval adjusted in the factory must be modified to the paving situation. Changing the duration of lubrication and breaks may be necessary when laying mineral or cement bound material mix.

  • Page 166: Track Clearer, Mechanical (O)

    Track clearer, mechanical (o) A swivelling lane clearer (1), which de- flects small obstacles away to one side, is located in front of both drive units. The lane clearers should only be swiv- elled down during paving. - Swivel the lane clearer (1) up and se- cure in the uppermost position with a shackle (2).

  • Page 167: Lane Clearer, Electric (O)

    Lane clearer, electric (o) A swivelling lane clearer (1), which de- flects small obstacles away to one side, is located in front of both drive units. The lane clearers should only be swiv- elled down during paving. The lane clearers are raised and lowered electrically (operating panel...

  • Page 168: Screed Eccentric Adjustment

    Screed eccentric adjustment 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 screed by adjusting the eccentric.

  • Page 169: Push Roller Crossbar, Adjustable

    Push roller crossbar, adjustable For adaptation to various truck design types, the push roller crossbar (1) can be shifted to two positions. The adjustment travel is 90 mm. - Close the hopper halves to lift the hop- per flap (2). - After removing the bolts (4), remove the locking plate (3) on the lower side of the crossbar.

  • Page 170: Push Roller Crossbar, Hydraulically Extendable (O)

    Push roller crossbar, hydraulically extendable (o) For adaptation to various truck design types, the push roller crossbar (1) can be retracted and extended hydraulically. The max. adjustment travel is 90 mm. - Activate the function on the operating panel as necessary. Extending the push roller increases the transportation length of the paver finisher.

  • Page 171: Fire Extinguisher (O)

    Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with operation of the fire extin- guisher (2). Observe the inspection interval for the fire extinguisher! First-aid kit (o) Any dressings that have been used must be replaced immediately! Heed the expiry date of the first-aid kit! D 30 39...

  • Page 172: Rotary Beacon (O)

    Rotary beacon (o) The function of the rotary beacon must be checked daily before starting work. - Place the rotary beacon onto the plug- in contact and secure with a wing bolt (1). - Raise the bracket (2), swivel to the outer position and allow to en- gage there - Slide the rotary beacon with the...

  • Page 173: Fuelling Pump (O)

    Fuelling pump (o) The fuelling pump must only be used to pump diesel fuel. Foreign bodies which are larger than the mesh size of the intake cage (1) lead to damage. An intake cage must therefore always be used. Each time fuelling is carried out, the in- take cage (1) must be checked for dam- age, and must be replaced if damaged.

  • Page 174: Illuminated Balloon (O)

    Illuminated balloon (o) D 30 42...
  • Page 175 The illuminated balloon generates shadow-reducing and anti-dazzle light. The illuminated balloon makes the paver finisher higher and wider. Note the passage height of bridges and tunnels and the enlarged vehicle width. Always disconnect the power supply before working on the illuminated balloon! Never look directly in the balloon when it is switched on! The illuminated balloon must not be used in the vicinity of highly flammable materials (e.g.

  • Page 176: Installation And Operation

    Installation and operation CAUTION Danger due to electric shock Electric shock can cause severe or fatal injuries - The Powermoon must always be completely unpacked, assembled and aligned before it is connected to the power grid and switched on! CAUTION Danger of squeezing! Fingers or hands can get clamped between the bracket and the holding tube!

  • Page 177: Decommissioning

    Activation is carried out on the switch cabinet. When equipped with an electric screed, it is possible for the lamps to flicker irregularly during the heating-up phase with simul- taneous operation of 500 watt spotlights (o) and the illuminated balloon (o). Preferably only one type of lighting should be used during the heating-up phase.

  • Page 178: Truck Assist (O)

    Truck Assist (o) The Truck Assist system is used for communication between the driver of the paver and the driver of the material truck. The corresponding signal system shows the truck driver which action to perform (reversing / stop / tip material / depart). The system consists of: - Two LED light bars (1) as a signal for the truck driver and a laser sensor (2) for de- tecting the truck.

  • Page 179: Cool Box (O)

    Cool box (o) The cool box can be used to keep food cold and warm. - Insert the cool box (1) in the corre- sponding holder (2). - Connect up to the corresponding socket on the control platform for the necessary power supply.
  • Page 180 D 30 48...

  • Page 181: D40 Mode Of Operation

    D 40 Mode of 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 extension parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separator fluids (emulsion) and manual injector...
  • Page 182 CAUTION Danger due to restricted vision Restricted vision poses a risk of injury! - Before starting work, arrange the intended driver's seat to ensure adequate vision. - Signalmen must be used when vision is restricted, also to the sides and when reversing. - Only reliable persons may be used as signalmen who must have been received instructions about their task before taking up their activity.

  • Page 183: 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 damages. - 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 184 Check! How? For larger working widths, the walkway Auger coverings plates must be extended and the auger tunnels must be covered. Folding walkways must be present at the basic screed and all extension parts and folded down accordingly. Screed covers and walkways Check that the side shields, the side plates and the covers are securely seated.
  • Page 185 D 40 5...

  • Page 186: 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 187 D 40 7...

  • Page 188: 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 24V system - Additional 24V battery - Start device that is suitable for external starting (24 V/90 A).
  • Page 189 - If necessary, start the engine of the vehicle supplying power and leave to run for a while. Now try to start the other vehicle: - Press the starter button (10) to start the engine. Run the starter continuously for a maximum of 30 seconds, then take a break for 2 minutes! - If the engine still has not started after two attempts, ascertain the cause! - If the engine starts up: disconnect the starting aid cable again in reverse order.
  • Page 190 D 40 10...

  • Page 191: After Starting

    After starting Let the paver finisher warm up for approx. 5 minutes if the engine is cold. D 40 11...
  • Page 192 D 40 12...

  • Page 193: Observe Indicator Lamps

    Observe indicator lamps The following indicator lamps must be observed under all circumstances: For further possible faults, see Engine's operating instructions. Engine coolant temperature check (1) Lights up when the engine temperature is outside of the permissible range. Stop the paver finisher (drive lever to the centre position), let the engine cool down while idling.
  • Page 194 D 40 14...

  • Page 195: Preparation For Transportation

    Preparation for transportation - Use switch (1) to close the hopper. - Engage both hopper transport safeguards. - Lift the screed completely using switch (2), set the crossbeam lock. - Turn the travel drive preselector (3) to zero. - Fully extend the levelling cylinders with the switch (5). To extend the levelling cylinders, levelling operating mode (6) must be switched to "MANUAL"...
  • Page 196 D 40 16...

  • Page 197: Driving And Stopping The Paver Finisher

    Driving and stopping the paver finisher - Set the travel drive to the desired speed level, fast/slow (1). - Upper switch position: transport speed (hare) - Lower switch position: operating speed (tortoise) - Turn the travel drive preselector (2) to medium speed. - For driving, carefully tilt the drive lever (3) forward or backward according to the drive direction desired.

  • Page 198: 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!). Screed heater system Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem- perature) before paving begins.
  • Page 199 Direction marks To ensure straight paving, a direction mark must be present or established (road edge, chalk lines or similar). - Slide the operating panel to the de- sired side and secure it. - Pull the direction indicator out of the bumper (arrow) and adjust it ac- cordingly.
  • Page 200 D 40 20...

  • Page 201: Loading/Conveying Material

    Loading/conveying 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 applica- ble) to "auto".
  • Page 202 D 40 22...

  • Page 203: Starting For Paving

    Starting for paving 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 Travelling direction Position Drive lever Centre position Travel drive fast / slow Slow ("tortoise")

  • Page 204: Checks During Paving

    Checks during paving The following points must be constantly observed during paving: Paver function - Screed heater system - 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 205: Paving With "Screed Control At Paver Finisher Stop" And "Screed Charging/Relieving

    Paving with "screed control at paver finisher stop" and "screed charging/relieving" General The screed hydraulics can be influenced in three different ways to attain optimum paving results: - floating stop with relief when the paver finisher is halting, - floating paving when the paver finisher is driving, - floating paving with screed charging or relieving when the paver finisher is driving.
  • Page 206 D 40 26...

  • Page 207: 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: function OFF C: Charging (screed ‘heavier’) Switch positions "Screed charging/relieving" are only effective when the paver finish- er moves.
  • Page 208 D 40 28...

  • Page 209: Screed Control With Paver Finisher Stop - Floating Stop With Relief

    Screed control with paver finisher stop - floating stop with relief As for charging/relieving, a pressure of 2-50 bar can be individually applied to the screed lifting cylinders. This pressure acts to combat the weight of the screed to pre- vent the screed from sinking into the freshly laid material.
  • Page 210 D 40 30...

  • Page 211: Setting Pressure For Screed Control With Paver Finisher Stop - Floating Stop With Relief

    Setting pressure for screed control with paver finisher stop - floating stop with relief - Set the drive lever (4) to the centre position. - Set switch (2) to position C. - Set the pressure using pressure regu- lating valve (7); read the pressure off at the manometer (6).
  • Page 212 D 40 32...

  • Page 213: Interrupting/Terminating Operation

    Interrupting/terminating operation During breaks in paving (e.g. delay due to material trucks) - Determine the approximate duration. - When cooling down of the material below the minimum paving temperature must be expected, run the paver finisher empty and create an edge like the end of a layer. - Set the drive lever (1) to the centre position.
  • Page 214 D 40 34...

  • Page 215: When Work Is Finished

    When work is finished - Run the paver finisher empty and stop it. - Move the drive lever (1) to the central position, set preselector (2) to "0" and set the speed adjuster (3) to minimum. - Switch the auger, conveyor, tamper and vibration functions "OFF". - Lift the screed: set switch (4) to centre position, switch (5) to the top position and switch (6) to lifting.

  • Page 216: Malfunctions

    Malfunctions Error code query for engine D 40 36...
  • Page 217 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). Output of the flash code is performed by the other warning lamp: if a fault is displayed by warning lamp (1), output is carried out via warning lamp (2) and vice-versa.

  • Page 218: Output Of Numerical Code

    Output of numerical code - Press switch (3) into display position until the three-digit code has been output via the warning lamp. While the switch for error queries is being actuated, the warning lamp which first signalled the fault which occurred goes out. Example: PAUSE PAUSE...
  • Page 219 Flash sequence: 4-Pause-2-Pause-5. Fault code: 425 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. This continues until the corresponding error or malfunction has been rectified.

  • Page 220: Error Codes

    Error codes Scan QR-Code to access failure code chart… D 40 40...

  • Page 221: 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 222 Problem Cause - material temperature Cracks in the - cold screed layer(centre strip) - bottom plates are worn or warped - wrong crowning - material temperature - screed extendable parts are incorrectly installed Cracks in the - limit switch is not correctly set layer(outer strip) - cold screed - bottom plates are worn or warped...

  • Page 223: Malfunctions On The Paver Finisher Or Screed

    Malfunctions on the paver finisher or screed Malfunction Cause Remedy See operating instructions At the diesel engine Various for the engine See "External starting" Batteries empty Diesel engine does (start assistance) not start Various see "Towing" Tamper is obstructed by Properly heat the screed cold bitumen Hydraulic oil level in the...
  • Page 224 Engine speed is too low Increase the speed Hydraulic oil level is too low Top up oil Leak in the suction line Tighten the connections Flow rate regulator Replace Hopper cannot be defective swung open Leaking seals of the Replace hydraulic cylinder Control valve is defective Replace...
  • Page 225 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 Screed relieving or charg- Switch must be in the centre be lifted ing is switched on position...
  • Page 226 Malfunction Cause Remedy Replace (fuse strip on the oper- Travel drive fuse defective ating panel) Check potentiometer, cables, Power supply interrupted connectors; replace if necessary Travel drive monitoring Replace (type-specific) defective Traction does Electro-hydraulic servo unit Replace the servo unit not work of the pump defective Check and adjust if necessary...

  • Page 227: E10 Set-Up And Modification

    E 10 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, auger, screed or screed lifting devices. Unless otherwise specified, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Move drive lever into centre position and turn preselector controller to zero, remove ignition key and battery main switch.

  • Page 228: Distribution Auger

    Distribution auger Height adjustment Depending on the mix of materials, the set height of the distribution auger (1) – measured from its bottom edge – should above material layer height. Grain sizes up to 16 mm Example: F0130_A1.TIF Paving thickness 10 cm Min.

  • Page 229: Mechanical Adjustment With Ratchet (O)

    Mechanical adjustment with ratchet (o) - Set the ratchet direction lever (1) to the clockwise or anti-clockwise di- rection. Turning anti-clockwise lowers the auger, turning clockwise lifts the auger. - Set the desired height by alternately adjusting the right-hand and the left- hand side.

  • Page 230: Height Adjustment For Large Working Widths / With Brace

    Height adjustment for large working widths / with brace Auger height adjustment for large working widths can be carried out with a hinged brace: Only adjust the height of the auger with the slewing bracket retaining pins removed! - Remove the slewing bracket (3) split pin (1) and retaining pin (2) on both sides of the vehicle.
  • Page 231 - Extend or shorten the braces by rotating the adjustment rods (5) until the retaining pins can be inserted. - Retighten the lock nuts (4). - Install the split pin (1) and retaining pin (2). Each time the height is adjusted, the auger must be realigned via the braces! See section "Aligning the auger"! E 10 5...

  • Page 232: Auger Extension

    Auger extension Auger_DEM.bmp Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. Refer to the appropriate chapter "Set-up and modification" in the screed operating instructions: – screed extension chart To attain the desired working width, the respective screed extensions, side plates, au- gers, tunnel plates or cut-off shoes must be mounted.

  • Page 233: Mounting Extension Parts

    Mounting extension parts Mounting the material shaft and auger extension - Secure the additional material shaft (1) to the basic unit or the adjacent material shaft with the relevant assembly parts (2) (bolts, washers, nuts). - Dismantle the assembly parts (3) of the adjacent auger blade, remove plug (4). - Guide the auger shaft extension into the auger shaft.

  • Page 234: Mounting The Outer Auger Bearing

    Mounting the outer auger bearing - Dismantle the assembly parts (1) of the adjacent auger blade, remove plug (2). - Guide the outer auger bearing (3) into the auger extension. - Secure the outer auger bearing to the brace shaft with the relevant assembly parts (4) (bolts, washers, pins).

  • Page 235: Mounting The Auger End Bearing

    Mounting the auger end bearing - The auger end bearing must first be pre-assembled: - Mount the auger end bearing (1) together with the fitted plate (2) on the interme- diate plate (4) with the relevant assembly parts (3) (bolt, washer). - Dismantle the assembly parts (5) of the adjacent auger blade, remove plug (6).

  • Page 236: Auger Extension Chart

    Auger extension chart Symbol Meaning - (160L) - Auger blade 160mm left - (160R) - Auger blade 160mm right 160L 160R - Auger extension part 320 mm - (320L) left - Auger extension part 320 mm 320L 320R - (320R) right - Auger extension part 640mm - (640L)
  • Page 237 Symbol Meaning Outer auger bearing Auger end bearing E 10 11...

  • Page 238: Auger Upgrading, Working Width 3.14 M

    Auger upgrading, working width 3.14 m 320 L 320 R Auger upgrading, working width 3.78 m 640 L 640 R Auger upgrading, working width 4.42 m 640 L 320 R 320 L 640 R E 10 12...

  • Page 239: Auger Upgrading, Working Width 5.06 M

    Auger upgrading, working width 5.06 m 320 L 960 L 320 R 960 R Auger upgrading, working width 5.70 m 640 L 960 L 960 R 640 R E 10 13...

  • Page 240: Auger Upgrading, Working Width 6.34 M

    Auger upgrading, working width 6.34 m E 10 14...

  • Page 241: Auger Upgrading, Working Width 6.98 M

    Auger upgrading, working width 6.98 m E 10 15...

  • Page 242: Auger Upgrading, Working Width 7.62 M

    Auger upgrading, working width 7.62 m E 10 16...

  • Page 243: Auger Upgrading, Working Width 8.26 M

    Auger upgrading, working width 8.26 m E 10 17...

  • Page 244: Auger Upgrading, Working Width 8.90 M

    Auger upgrading, working width 8.90 m E 10 18...

  • Page 245: Mounting The Auger Brace

    Mounting the auger brace E 10 19...
  • Page 246 Before mounting the auger brace, the required auger height should already have been set on the basic auger! Note the section "Height adjustment for large operating widths / with brace"! - Mount the left/right guide plates (1) on the vehicle frame shackles with the relevant assembly parts (2).

  • Page 247: Aligning The Auger

    Aligning the auger - Loosen lock nuts (26). Note the left-hand thread (L) and right-hand thread (R) mark on the brace! - Extend or shorten the braces (17) by rotating both adjustment rods (21) until all mounted material shafts align with the auger. The adjustment rod (21) is equipped with a bore (27) on the left and right.

  • Page 248: Material Shaft, Hinged

    Material shaft, hinged To close the gap between auger box and side board of the screen, hinged material shafts can be fitted to both sides of the auger. The hinged material shafts swivel up due to the material pressure which is exerted and swivel in due to screed re- traction.

  • Page 249: Hopper Scraper

    Hopper scraper To reduce the gap between hopper and vehicle frame, the hopper scrapers (1) must be adjusted on both hopper lids. - Loosen the mounting screws (2). - Set a gap of 6 mm across the whole length of the scraper. - Retighten the mounting screws (2) properly.

  • Page 250: Crossbeam Guide

    Crossbeam guide To warrant correct guidance of the crossbeams, the guide plates (1) at both sides of the vehicle must be adjusted to prevailing paving conditions (e.g. positive or negative crowning, etc.). - Loosen screw remove screws (3). - Adjust guide plate to the required size (basic setting 25mm).
  • Page 251 Offsetting the screed Depending on the paving condition re- quirements, the crossbeam can be moved backwards or forwards. This adjustment enlarges the material space between the auger and screed. - Loosen the four mounting screws (1). - Remove the screws and move the ve- hicle forwards.
  • Page 252 Levelling Slope controller During operation, no work may be car- ried out on the slope control linkage or the slope controller! - Mount the slope control linkage (1) in the intended position between the two crossbeams. - Mount the slope controller (2) on the slope control linkage's...
  • Page 253 Fitting the height sensing device Fit the sensor arm to the required side of the machine. - Place the holder (1) on the corre- sponding journal (2) of the side shield and fasten with the pin (3), bush (4) and spring washers (5). - Tighten the pin (3) so that the sensor arm is just still able to swivel.
  • Page 254 Setting up the sensor arm Before starting paving, the sensor arm must be set, with the grade control sys- tem, to its reference (cable, kerb, etc.). Sensing should be carried out in the area of the auger. - Swivel the sensor arm (2) over the reference.
  • Page 255 Big ski 9 m, big ski 13 m MBS6.bmp The big ski is used for contactless sensing over a particularly large reference length. A total max. ski length of approx. 9.30 m can be achieved with the combination of 1 centre element and 2 module elements together with the sensor arm extensions. A total max.
  • Page 256 Assembly of the short version is described in the following, as the longer variant is achieved simply by adding further module elements. MBS11.bmp The distances between the sensors are ideally identical (X1 = X2). The centre sensor is mounted in the usual individual sensor position so that, if nec- essary, work can be carried out with just one sensor by switching over on the MOBA- matic (e.g.
  • Page 257 Mounting the big ski bracket on the crossbeam The entire big ski construction is mounted laterally on the crossbeams. To do so, the two crossbeam brackets must first be mounted. The crossbeam bracket design dif- fers slightly depending on the paver finisher which is used. During assembly, it is possible either to bolt the brackets directly at the existing bores (A) or to secure them to the crossbeam using clamping plates (B).
  • Page 258 Mounting the swivel arms - Slide a fixing ring (1) over the tube of the big ski bracket (2). The fixing ring's 45° chamfer must point upwards. - Then slide the two swivel arms (3) onto the tube of the big ski bracket. The rear swivel arm is positioned, rotat- ed by 180°, on the big ski bracket.
  • Page 259 Mounting the centre element During assembly, it must be ensured that the round lug (1) for attaching the subse- quent modules points upwards. The centre element (2) is already fitted in the factory with 2 pre-assembled sliding parts (3) / (4), which are pushed over the two round mounting journals of the swivel arms.
  • Page 260 Extending the big ski The big ski can be extended to both the 9 m and 13 m versions. Structure of the 9 m version: Extension part at the front/rear each. Structure of the 13 m version: Two extension parts at the front/rear each.
  • Page 261 Mounting the sensor bracket A sensing system with 3 sensors is pro- vided over the entire length of the big ski. One sensor each on the centre element, and the front and rear end elements. The centre sensor should be mounted on the ski in precisely the location in which would...
  • Page 262 Mounting and aligning the sensors - Insert the sensor mounting (1) into the bracket (2). - Align the sensor and secure with the relevant star handle bolts. - The sensing height can be adjusted loosening star handle bolts (3). At the two outer sensor brackets, the sensor can also be mounted on the swiv- elling sensor extension arm (4).
  • Page 263 Mounting the distributor box The distributor box should be mounted in such a way that simple wiring to the controller and the sensors is possible. The connections for the sensors should always point down to prevent water from entering the distributor box. Inlets which are not required must be sealed with dust caps.
  • Page 264 Connection diagram The three sensors are connected to the distributor box and the distributor to the ma- chine according to the following scheme. - Sensors - Front (1) - Centre (2) - Rear (3) - Distributor box (4) - Machine interface (5) E 10 38...
  • Page 265 Levelling shoe 6m, 9m The levelling shoe includes a shoe that moves at several joints and runs on the ref- erence surface, together with a rotary sensor that scans a reference wire on the shoe. The levelling shoe is ideal for compensating for long bumps in the ground. It is used on roadworks sections without tight bends.
  • Page 266 - Align the shoe to be parallel to the paver across the whole length and not tilted to the side. - Fix with bolts (9) at the front. - Set the spring cotter pin (10) at the back. - Insert the sensor (11) in the height sensing unit (12).
  • Page 267 Automatic steering unit E 10 41...
  • Page 268 Mounting the automatic steering unit on the paver finisher During operation, no work may be carried out on the automatic steering unit! Depending on the desired sensing side on the vehicle, the sensor rod tube may have to be removed and re-inserted on the other side of the vehicle! - Pull the sensor rod tube (1) at the front of the vehicle out to the desired length and secure with the clamping bolts (2).
  • Page 269 Mounting and aligning the sensor - Insert the sensor mounting (13) into the bracket (14) and secure with a wing nut (15). - Align the angle between the sensor and reference and secure with the relevant clamping bolt (16). The sensor and reference must be at right angles to each other! - The sensing height can be set by loosening the fixing screw (17).
  • Page 270 Automatic steering unit operating instructions - When the automatic steering unit is activated, the steering potentiometer is deactivated. Steering is carried out automatically via ski cable sensing. - Activate the function on the operating panel as necessary. - The automatic steering unit can be overridden by actuating the steering potentiometer.
  • Page 271 Emergency stop during feeder operation If the function is not in use, the bridge connector must be fitted to the corre- sponding socket, as otherwise the travel drive is blocked! E 10 45...
  • Page 272 Auger temperature measurement (O) A sensor can be installed to detect the material temperature in the auger area. - Fasten the sensor (1) above the basic auger width on the machine frame with the related magnetic holder (2) as shown. - Connect the connection cable (3) of the sensor to the centre socket (TEMP) of the signal converter (4).
  • Page 273 MATTRACKER (O) The MatTracker is an edge tracking system that automatically controls the working width of the screed. It tracks a finished asphalt edge, kerb edge or planed edge. This warrants a uniform overlap and uniform quality of an edge or joint. The MatTracker is available for one-sided or two-sided use.
  • Page 274 Limit switch 10.1 Auger limit switches (left and right) - mount PLC version The auger's ultrasonic limit switch is mounted on both sides on the side board's handrail. - Place the sensor bracket (1) onto the handrail, align it and tighten with a wing bolt (2).
  • Page 275 10.2 Auger limit switches (left and right) - mounting the conventional version The ultrasonic sensor (1) is secured to the side shield via a bracket (2). - To adjust the sensor angle, loosen the clamps (3) and swivel the bracket. - To set the sensor height / the deacti- vation point,...
  • Page 276 Special accessories 11.1 Material bucket Application The additional bucket is placed in the open hopper and secured in position. It is used to take larger volumes of material provided by a feeder. NOTE Caution! Possible material damage The material bucket may only be used in the following combinations: - MH2500 - bucket, short (universal bucket): SD2500C, SD2500CS...
  • Page 277 Description of assemblies and functions Item Designation Swivelling front flap Swivelling side flaps Maintenance door Reflector plate for feeder clearance sensor Reflector plate extension pipe - for operation on the side Fixture for paver option "extraction system" Tie-down rings Lashing points for loading by crane E 10 51...
  • Page 278 Technical data Dimensions, bucket MH2500 - short version 3700 3700 E 10 52...
  • Page 279 Dimensions, bucket MH2550 - long version 3690 3690 3000 E 10 53...
  • Page 280 Weights Bucket MH2500 - short version approx. 1.2t Bucket MH2550 - long version approx. 1.7t Volume approx. 10.9 m / 24.0t Bucket MH2500 - short version approx. 10.0m / 22.0t (OFFSET) Bucket MH2550 - long version approx. 12.7 m / 28.0t E 10 54...
  • Page 281 Identification points CAUTION Danger due to missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries! - Never remove any warnings or information signs from the vehicle. - Damaged or lost warning or information signs must be replaced immediately.
  • Page 282 12.1 Information signs Pictogram Meaning - Lifting point Lifting the machine is only permitted at these lifting points! - Lashing point Lashing the machine is only permitted at these points! 12.2 Warning signs Pictogram Meaning - Warning - Hot surface - Risk of burning! Hot surfaces can cause severe injuries! Keep your hands at a safe distance from...
  • Page 283 12.4 Instructive symbols, prohibitive symbols, warning symbols No. Pictogram Meaning - Do not open - hazard! E 10 57...
  • Page 284 Load securing - bucket The following instructions for securing the bucket for transport on the low-bed trailer consist merely in examples of how to secure the load correctly. Always comply with the local regulations for securing the load and for correct use of load securing equipment.
  • Page 285 Lashing equipment Use the load securing equipment, lashing straps and chains belonging to the vehicle. Additional shackles, eyebolts, edge guards and non-slip mats may be needed de- pending on the type of load securing equipment. Always comply with the stated values for permitted lashing force and load rating! Always tighten the lashing chains as stated by the manufacturer.
  • Page 286 Lashing E 10 60...
  • Page 287 When securing the bucket, make sure that the sensor plate is dismantled and the front flap properly closed. Diagonal lashing secures the bucket at the front and rear, using the lashing points on the bucket and on the low-load trailer. Fasten the lashing straps as shown.
  • Page 288 Loading with the crane - MH2500 E 10 62...
  • Page 289 Loading with the crane - MH2550 E 10 63...
  • Page 290 WARNING Danger from suspended loads Crane and/or lifted load can tip when lifted and cause injuries! - The load may only be raised at the marked lifting points. - Do not enter the danger zone. - Use only lifting gear that can bear the load. - Do not leave any material residues or loose parts in the bucket.
  • Page 291 Lash the bucket in the paver E 10 65...
  • Page 292 The following explanations for securing the bucket in the paver act as examples for correct usage in a Dynapac paver finisher. When combining different brands, the bucket must be secured according to the avail- able possibilities. Dynapac does not assume any warranty for damage caused by the bucket being in- correctly secured! The paver finisher must have the necessary number of lashing points with a lashing strength of LC 5,000 daN.
  • Page 293 Mode of operation E 10 67...
  • Page 294 Depending on the specific use, the reflector plate (1) can be fitted in front of the buck- et in the middle or to the side of the bucket on the left/right. - Reflector plate in the middle: fixed with the corresponding clamping levers (2). - Reflector plate on the side: dismantle reflector plate (1), mount additional retaining rod (3) and support holder (4) to the required side.
  • Page 295 Cleaning the bucket Clean the bucket regularly and remove adhering asphalt residues. Only clean the hopper after it has cooled down. If the bucket is inserted in a paver during cleaning, the paver must be switched off and secured to prevent it being switched on again. Spray all surfaces coming into contact with asphalt material with separator fluid.
  • Page 296 Screed All work required for mounting, setting up and extending the screed are described in the screed operating instructions. 13.1 Electrical connections side board - screed - Conventional version Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control to holder (1).
  • Page 297 Other connection possibilities: - Auger limit switches (5) - Grade control system (6) - External levelling system (7) - 24 volt consumers, e.g. additional lighting (8). When using an external levelling system, this must be logged in using the remote con- trol menu.
  • Page 298 13.2 Electrical connections side board - screed PLC version Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control on holder (1), tighten knurled screw (1a). - Connect the plug of the lead (2) with the socket (2a) on the remote control. If the remote control is not mounted, the plug has to be set on the bridge socket (3).
  • Page 299 If the side board is not connected, the socket (5) has to be connected with the bridge plug (5a). Other connection possibilities: - Auger limit switches (6) - Grade control system (7) - External levelling system (8) - 24 volt consumers, e.g. additional lighting (9). When using an external levelling system, this must be logged in using the remote con- trol menu.
  • Page 300 E 10 74...
  • Page 301 F 10 Maintenance Notes regarding safety DANGER Danger due to changes at the vehicle Structural chances to the vehicle make the operating licence null and void and can cause severe to fatal injuries! - Only use original spare parts and approved accessories. - After maintenance and repair work, ensure that any dis- mantled protective and safety devices are all completely fitted again.
  • Page 302 CAUTION Hot surfaces! Surfaces including those behind covering parts, together with combustion fuels from the engine or screed heater can be very hot and cause injuries! - Wear your personal safety gear. - Do not touch hot parts of the vehicle. - Only perform maintenance and repair work after the vehicle has cooled down.
  • Page 303 F 20 Maintenance review Maintenance review 90 100 F 20 1...
  • Page 304 Maintenance required after the following service hours Assembly Chapter Conveyor Auger q q q q q q q q Engine q q q Hydraulics Drive units q q q q q q Electronics Lubrication points Checking/stopping F100 Maintenance required In this overview, you will find the maintenance intervals for optional machine equip- ment! F 20 2...
  • Page 305 F 30 Maintenance - conveyor Maintenance - conveyor F 30 1...
  • Page 306 Danger of being pulled in by rotating or conveying WARNING vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 307 Maintenance intervals Interval Maintenance point Note - Conveyor chain - Check tightness - Conveyor chain - Adjust tension - Conveyor chain - Replace chain - Conveyor drive - drive chains - Check chain tightness - Conveyor drive - drive chains - Adjust chain tightness - Replace conveyor deflectors / conveyor plates...
  • Page 308 Points of maintenance Chain tension, conveyor (1) Check chain tension: When the conveyor chain is correctly tensioned, the lower edge of the chain is approx. 20-25mm over the lower edge of the chassis. The conveyor chains should not be too tight or too slack.
  • Page 309 Check / replace chain: At the latest, the conveyor chains (A) must be replaced when their elongation has progressed so far that they can no longer be re-tensioned. Chain links must not be removed to shorten the chain! Incorrectly dividing the chains would lead to the destruction of the drive wheels! If components have to be replaced as a...
  • Page 310 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 lock nut (B) slightly.
  • Page 311 Conveyor deflectors / conveyor plates (3) At the latest, the conveyor deflectors (A) must be replaced when their lower edg- es are worn or reveal holes. The conveyor chain is not offered pro- tection by worn conveyor deflectors! - Remove conveyor deflector bolts. - Remove the conveyor deflectors from the material tunnel.
  • Page 312 F 30 8...
  • Page 313 F 40 Maintenance - auger assembly Maintenance - auger assembly F 40 1...
  • Page 314 Danger of being pulled in by rotating or conveying WARNING vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 315 Maintenance intervals Interval Maintenance point Note Outer auger bearing - Lubricate Auger planetary gear - Check oil level Auger planetary gear - Top up oil Auger planetary gear - Change oil Auger drive chains - Check tension Auger drive chains - Adjust tension Auger box - Check oil level...
  • Page 316 Interval Maintenance point Note Gearbox bolts - Check tightening Gearbox bolts - Tighten to correct torque Outer bearing bolts - Check tightening Outer bearing bolts - Tighten to correct torque Auger blade - Check wear Auger blade - Replace auger blade Maintenance Maintenance during the running-in period...
  • Page 317 Points of maintenance Outer auger bearing (1) The grease nipples are located on each side at the top of the outer auger bear- ings. These nipples must be lubricated at the end of work to force out any bitumen res- idues which may have entered and to supply the bearings with fresh grease when warm.
  • Page 318 Auger 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 319 Drive chains of the augers (3) To check the chain tension: - Manually turn both augers to the right and left. In this case, movement clearance (C) at the augers' outer circumference should be 10 mm. Risk of injury due to sharp-edged parts! To re-tension the chains - Release the mounting screws (A).
  • Page 320 Auger box (4) Check oil level In case of correct oil level, the oil is between the two notches of the dipstick (A). For filling in the oil: - Unscrew screws (B) from the top cov- er of the auger box. - Take off the cover (C).
  • Page 321 Seals and sealing rings (5) After reaching operating temperature, check the gearbox for leaks. In case of visible leaks, e.g. between the flange surfaces (A) of the gearbox, re- placement of the seals and sealing rings is necessary. F 40 9...
  • Page 322 Gearbox bolts Check tightening (6) Following the running-in period, the tightening torques of the outer gearbox bolts must be checked. Please check which gear version is used in your vehicle. - Tighten to the following torques if nec- essary: - (A): 86 Nm - (B): 83 Nm - (C): 49 Nm - (D): 49 Nm...
  • Page 323 Mounting screws - Outer auger bearing Check tightening (7) Following the running-in period, the tightening torques of the outer auger bearing mounting screws must be checked. - Tighten to the following torques if nec- essary: - (F): 210 Nm If the auger's working width is changed, the tightening check must be repeated after the running-in period! F 40 11...
  • Page 324 Auger blade (8) If the surface of the auger blade (A) be- comes sharp-edged, the diameter of the auger is reduced and the blades (B) have to be replaced. - Remove the bolts (C), washers (D), nuts (E) and auger blade (B). Risk of injury due to sharp-edged parts! Auger blades must be installed play- free;...
  • Page 325 F 50 Maintenance - engine assembly Tier 3 (o) Maintenance - engine assembly In addition to these maintenance instructions, the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances. All mainte- nance work and service intervals itemised here are binding in nature. F 50 1...
  • Page 326 Danger of being pulled in by rotating or conveying WARNING vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 327 Maintenance intervals Interval Maintenance point Note - 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 328 Interval Maintenance point Note - Engine air filter Check air filter - Engine air filter Dust collector Emptying - Engine air filter Air filter cartridge Replace - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system...
  • Page 329 Interval Maintenance point Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt Maintenance Maintenance during the running-in period F 50 5...
  • Page 330 Points of maintenance Engine fuel tank (1) - Check the filling level on the gauge on the operating panel. Fill the fuel tank each time before start- ing work so that the fuel system cannot "run dry" and time-consuming venting (bleeding) can therefore be avoided.
  • Page 331 Engine lube oil system (2) Check oil level In case of correct oil level, the oil is between the two notches of the dipstick (A). Only check the oil level when the finisher is in a horizontal position! Too much oil in engine damages gas- kets;...
  • Page 332 - Position a collecting container be- neath the oil pan oil drain screw (E). - Remove the oil drain screw (E) and al- low the oil to drain completely. - Reinstall the oil drain screw (E) with a new seal and tighten properly. - Fill in the specified quality of oil through the filler opening (B) on the engine until the oil level rises to the...
  • Page 333 The new filter is inserted during an oil change once the used oil has been drained out. - Loosen the filter (H) with a filter wrench or filter strap and unscrew it. Clean the contact surface. - Apply light coating of oil to the gasket on the new filter and fill filter with oil before installing it.
  • Page 334 Engine fuel system (3) All filters are accessed via the service flap (A) on the vehicle's centre wall: - Remove the screws (B) from the inner side of the frame and remove the serv- ice flap (A). - After completing the maintenance work, reinstall the service flap (A) properly.
  • Page 335 Changing the prefilter: - Drain off separated water at the cock (E) and collect, then close the cock again. - Pull off the water sensor (F) connector. - Loosen the filter cartridge (C) using a filter wrench or filter strap and unscrew. - Clean sealing surface of filter bracket.
  • Page 336 Engine air filter (4) Empty dust collector - Empty the dust removal valve (A) on the air filter housing by compressing the discharge slot. - Remove any baked on dust by press- ing together the upper valve section. Clean the dust removal valve from time to time.
  • Page 337 Replace air filter insert Maintenance of the filter becomes nec- essary if: - Engine electronics service indicator - Open the air filter housing (B) at the clips (C). - Move filter element (D) to the side a lit- tle and then pull it out of the housing. - Pull out the safety element (E) and check for signs of damage.
  • Page 338 Engine cooling system (5) Checking / topping up coolant The cooling water level must be checked when the system is cold. Make sure that the anti-freeze and anti-corrosive liquid is sufficient (-25°C). When hot, the system is under pressure. When it is opened, there is danger of scalding! - If necessary fill in a sufficient amount of coolant through the open port (A) of...
  • Page 339 Checking and cleaning the radiator fins - If necessary, remove leaves, dust or sand from the radiator. Observe engine's operating instructions Checking coolant concentration - Check the concentration using a suitable tester (hydrometer). - Adjust the concentration if necessary. Observe engine's operating instructions F 50 15...
  • Page 340 Engine drive belt (6) Check drive belts - Check the drive belt for damage. Small transverse cracks in the belt are acceptable. In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces, belt re- placement is necessary. Observe engine's operating instructions Replace drive belt Observe engine's operating instructions...
  • Page 341 F 60 Maintenance - hydraulic system Maintenance - hydraulic system F 60 1...
  • Page 342 WARNING Danger due to hydraulic oil Hydraulic oil under high pressure can cause severe to fatal injuries! - Only competent staff should work on the hydraulic system! - Any hydraulic hoses that are cracked or soaked through must be replaced immediately. - Depressurise the hydraulic system.
  • Page 343 WARNING Danger from residual pressure in hydraulic lines Residual pressure in the hydraulic system can cause severe or fatal injuries! - Proceed as follows before working on the hydraulic system: 1. Place the machine on a level surface, secure it against accidentally rolling away and activate the parking brake if necessary.
  • Page 344 Maintenance intervals Interval Maintenance point Note - Hydraulic oil tank - Check fill level - Hydraulic oil tank - Top up with oil - Hydraulic oil tank - Change oil and clean - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank - Change and vent the suction/re- turn flow hydraulic filter...
  • Page 345 Interval Maintenance point Note - Pump distribution gear - Check oil level - Pump distribution gear - Top up oil - Pump distribution gear - Change oil - Pump distribution gear - Check bleeder - Pump distribution gear - Clean bleeder - Hydraulic hoses - Visual inspection - Hydraulic system...
  • Page 346 Points of maintenance Hydraulic oil tank (1) - Check oil level on sight glass (A). The hydraulic oil should have reached a temperature of at least 50°C for the check. The oil level must be up to the centre of the sight glass when the cylinders are retracted.
  • Page 347 To change oil: - To drain the hydraulic oil unscrew the drain plug (D) at the bottom of the tank. - Collect the oil in a container using a funnel. - When fastening the screw again after draining, make sure to use a new seal. When using the drainage hose (o): - Unscrew seal cap (E).
  • Page 348 Suction/return flow hydraulic filter (2) Carry out filter replacement according to the interval or the indicator lamp in the operating panel! - Remove cover securing screws (A) and lift off cover. - Disassemble the removed unit into: - Cover (B) - Separating plate (C) - Filter (D) - Dirt trap (E)
  • Page 349 Bleeding the filter - Fill the opened filter housing with hy- draulic oil up to approx. 2 cm below the top edge. - If the oil level drops, replenish oil again. Slow oil level reduction of approx. 1 cm / min. is normal! - If the oil level remains stable, slowly insert the assembled unit with new fil- ter element into the housing and tight-...
  • Page 350 High-pressure filter (3) The filter elements must be replaced when the maintenance indicator (A) turns red. The vehicle's hydraulic system contains 3 high-pressure filters. - Unscrew filter housing (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge. - Replace the seal ring of the filter housing.
  • Page 351 Pump distribution gear (4) - Check oil level check on sensor rod (A). The oil level must lie between the upper and lower marks. For filling in the oil: - Pull out the dipstick (A) completely. - Replenish new oil through the dipstick opening (B).
  • Page 352 Bleeder The bleeder (A) can be found on the rear of the pump distribution gear housing. - The functioning of the bleeder must be ensured. If soiling has occurred, the bleeder should be cleaned. F 60 12...
  • Page 353 Hydraulic hoses (5) - Specifically check the condition of the hydraulic hoses. - Immediately replace any damaged hoses. Replace hydraulic hoses if the following criteria are found on inspection: - damage of the outer layer to the inlay (e.g. chafing, cuts, cracks). - brittleness of the outer layer (cracking of the hose material).
  • Page 354 Always comply with the following instructions when installing and removing hydraulic hoses: - Always only use original Dynapac hydraulic hoses! - Always observe high standards of cleanliness! - Hydraulic hoses must always be fitted to ensure that in all operating statuses, - there is no tensile load apart from dead weight.
  • Page 355 Marking hydraulic hoses / storage period, period of use A number stamped onto the screwed connection provides information about the date of manufacture (A) (month / year) and the maximum pressure per- mitted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.
  • Page 356 Auxiliary flow filter (6) The hydraulic oil change is omitted on use of an auxiliary flow filter! The quality of the oil must be checked regularly. The oil level must be topped up if necessary! Replacing filter element: - Release the threaded cover connection (A) then open the non-return valve briefly to lower the oil level in the filter, then close the non-return valve again.
  • Page 357 F 73 Maintenance - drive units Maintenance - drive units F 73 1...
  • Page 358 Danger of being pulled in by rotating WARNING or conveying vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 359 Maintenance intervals Interval Maintenance point Note - Chain tension - Check - Chain tension - Adjust - Chains - Relieve - Bottom plates - Check wear - Bottom plates - Replace - Rollers - Check for leaks - Rollers - Check wear - Rollers - Replace...
  • Page 360 Interval Maintenance point Note - Planetary gear - Check oil level - Planetary gear - Top up oil - Planetary gear - Change oil - Planetary gear - Check oil quality - Planetary gear - Check screw connections q - Planetary gear - Tighten screw connections Maintenance Maintenance during the running-in period...
  • Page 361 WARNING Danger from pretensioned springs Incorrectly performed maintenance and repair work can cause severe or fatal injuries! - Always observe the maintenance instructions. - Do not perform any unauthorised maintenance or repair work to pretensioned springs. - Comply with all further information in these instructions and in the safety manual.
  • Page 362 Maintenance points Chain tension (1) If the chains are not tensioned sufficient- ly, they can slip out of their guide formed by rollers, drive gear and idler wheel, thereby increasing wear levels. If the chains are tensioned too tightly, this increases wear on the idler wheel and drive unit mounting, and also increases wear on track bolts and bushes.
  • Page 363 - Before checking/adjusting the chain tension, ensure that the position of the chain to the idler wheel is as shown in diagram (A). Correct if necessary by moving the vehicle a little. - The correct setting has been adjusted when the pressure gauge (C) shows a value between 65-85 bar.
  • Page 364 If a different pressure is detected during the measurement process, proceed as follows: - Screw head section for flat nipple (toolbox) onto the grease gun. - Top up the grease in the chain tighten- er at the filling connection (A) until the correct pressure appears at the pres- sure gauge (B).
  • Page 365 Bottom plates (2) Always use new bolts and nuts when in- stalling new bottom plates! - After removing the worn bottom plates, the adhesions must be cleaned from the contact surfaces of the chain links and the nut seats. - Place the bottom plate with the front edge (A) over the chain links' bolt eye (B).
  • Page 366 Rollers (3) Rollers with damaged surfaces or which are leaking should be replaced immediately! - Relieving the caterpillar chain: - Raise track chassis using suitable lifting equipment and remove adhering dirt. Observe the safety measures when rais- ing and securing loads! - Remove the defective roller.
  • Page 367 Planetary gear (4) - Turn the conveyor chain sprocket so that the drain plug (B) is located at the bottom. - 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 368 Alternatively, the oil level can be checked and the oil changed at the rear of the gearbox: - Remove protective cover (A) - The following are located at the rear of the gearbox: - Oil inlet (B) - Oil level check (C) - Oil drain (D) Carry out the oil level check and oil change as per the description above.
  • Page 369 Screw connections After approx. 250 hours of operation at full load, check that all gearbox mount- ing screws are firmly seated. Improperly tightened screws may lead to increased wear and to the destruction of components! - The correct torque for the gear/track chassis connecting screws (B) is: 500Nm +/-50Nm - The correct torque for the hydraulic...
  • Page 370 F 73 14...
  • Page 371 F 80 Maintenance - electrical system Maintenance - electrical system F 80 1...
  • Page 372 Danger of being pulled in by rotating WARNING or conveying vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 373 Maintenance intervals Interval Maintenance point Note Check fill level of battery acid q Top up with distilled water Apply grease to battery terminals - Alternator Insulation monitoring, check elec- tric system is functioning - Alternator Visual check for pollution or damage - Check the cooling air openings for pollution or clogging, clean if necessary.
  • Page 374 Maintenance points Batteries (1) Maintenance of batteries The batteries are factory-filled with the correct quantity of acid. The fluid level should come up to the top mark. If re- quired, top up the battery, but only use distilled water to do so! The battery terminal clamps must be free of oxide and protected with a special terminal grease.
  • Page 375 Recharging the batteries Both batteries must be recharged individually and must be dismantled from the vehi- cle for this purpose. Always keep batteries upright during transport! Before and after recharging a battery, always check the electrolyte level in every cell; if this needs to be topped up, only use distilled water.
  • Page 376 Alternator (2) Electrical system insulation monitoring 3 SEC The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an insula- tion error has occurred on the heating sections or consumers. - Start the paver finisher's drive engine.
  • Page 377 Cleaning the alternator alternator must regularly checked for excessive dirt and must be cleaned if necessary. - The air intake (1) and fan shroud (2) must be kept free of dirt. Cleaning with a high-pressure cleaner is not permissible! F 80 7...
  • Page 378 Electrical fuses / relays (3) Fuses The fuses installed may differ depending on equipment. Function F1.1 Main fuse 1 F1.2 Main fuse 2 F1.3 Raise / lower roof Screed Screed Hopper Motor start Tamper / vibration Extend/retract screed F 80 8...
  • Page 379 Function Spare Hydraulic temperature / pressure sensor Emulsion spraying system (o) Caterpillar paver: steering sensor, transport gear, "turning on the spot" function Wheeled paver: transport gear, differential lock Screed heater system Conveyor Connector 12V Levelling Not used Connector 24V Indicator displays Auger Screed Rotary beacon (o)
  • Page 380 Function Travel drive computer Not used Not used Rear working lights Front working lights Diagnostic interface engine Diagnostic interface control unit Control voltage raise / lower roof * Raise roof * Lower roof * * The fuses are under the control platform. Move the platform out to the left for access! F 80 10...
  • Page 381 Relays in the engine compartment Function Engine start F 80 11...
  • Page 382 Relays in terminal box Function Ignition Travel drive computer voltage supply Not used Engine start Travel drive computer outputs Release operating functions Front working lights Rear working lights Horn Start inhibit, emergency stop F 80 12...
  • Page 383 Function Start inhibit Rotary beacon (o) Not used Not used Not used Reverse buzzer (o) Not used Not used Not used Not used Not used Not used Not used Auto conveyor left Auto conveyor right Auto auger, left Auto auger, right Levelling F 80 13...
  • Page 384 Relays in operating panel Function Floating position Screed start (auto) Screed hazard warning flashers, left-hand Screed hazard warning flashers, right-hand Latch for extending/retracting screed, left Latch for extending/retracting screed, right Operating hour meter F 80 14...
  • Page 385 Relay in connection box under the operating platform Function Raise roof Lower roof F 80 15...
  • Page 386 F 80 16...
  • Page 387 F 90 Maintenance - lubricating points Maintenance - lubricating points The information on the lubricating points for the various assemblies is assigned to the specific maintenance descriptions and must be read there! F 90 1...
  • Page 388 Due to the use of a central lubrication system (o), the number of lubricating points may deviate from the description. Maintenance intervals Interval Maintenance point Note Check lubricant tank fill level Top up lubricant tank Bleed central lubrication system Check pressure limiting valve Check flow of lubricant at the consumer Bearing points...
  • Page 389 Points of maintenance Central lubrication system (1) Danger of injuries! Do not reach into the tank when the pump is running! The central lubrication system must only be operated with the safety valve in- stalled! Handverl.jpg/Gefahr.jpg Do not undertake any work on the pres- sure relief valve during operation! Risk of injury due to escaping lubricant, as the system operates at high pressures! Ensure that the diesel engine cannot be started when working on the system!
  • Page 390 Central lubrication system Check filling level The lubricant tank should always be filled sufficiently to ensure that the sys- tem does not "run dry", that adequate lu- bricating point supply is ensured and that time-consuming bleeding does not become necessary. - Always maintain a fill level above the "MIN"...
  • Page 391 Bleed central lubrication system Bleeding the lubrication system is nec- essary if the central lubrication system has been operated with an empty lubri- cant tank. - Release the main lubrication line (a) at the distributor (b). - Start up the central lubrication sys- tem with the filled lubricant tank (c).
  • Page 392 Check the flow of lubricant at the con- sumers Each lubrication channel at the consum- ers must be checked as regards clear- ance. - Remove the lubrication line (a) and install a normal lubricating nipple (b). - Connect the grease gun (c) en- closed on delivery to the lubricating nipple (b).
  • Page 393 Bearing points (2) One lubricating nipple (A) is located at each hydraulic cylinder bearing point (top and bottom). One lubricating nipple (B) is located at each push roller bearing point. F 90 7...
  • Page 394 F 90 8...
  • Page 395 F 100 Tests, stopping ... Tests, checks, cleaning, stopping F 100 1...
  • Page 396 Maintenance intervals Interval Maintenance point Note - General visual inspection - Check that the bolts and regularly nuts fit firmly q - Inspection by an expert q - Cleaning q - Cleaning sensors q - Preserving the paver finisher Maintenance Maintenance during the running-in period F 100 2...
  • Page 397 General visual inspection The daily routine should comprise a visual inspection around the entire paver finisher. The following items must be checked: - Are components or controls damaged? - Are there leaks on the engine, the hydraulics, the gearbox, etc.? - Are all fastening points (conveyor, auger, screed, etc.) in order? - Are the warnings affixed to the vehicle complete and legible? - Are the non-slip surfaces at ladders, steps, etc.
  • Page 398 Inspection by an expert Have finisher, screed and optional gas or electric system checked by a trained spe- cialist - when required (according to the operating conditions and the nature of application), - however, at least once a year, check that they are all in good operational condition. F 100 4...
  • Page 399 Cleaning - Clean all parts coming into contact with paving material. - Spray contaminated parts with the separator fluid spraying system (o). Before cleaning work with the high pressure cleaner, grease all lube points acc. to specification. - Clean the vehicle with water after laying mineral aggregates, lean-mixed concrete, etc.
  • Page 400 Danger of being pulled in by rotating or conveying WARNING vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 401 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions. Daily cleaning with a dry, lint-free cloth. F 100 7...
  • Page 402 Preserving the paver finisher Shutdowns for up to 6 months - Park the vehicle in a place where it is protected from great exposure to direct sun- light, wind, humidity and frost. - Grease all lube points in accordance with specifications. Allow optional central lu- bricating unit to run if necessary.
  • Page 403 Operating the vehicle in special climatic conditions or environments. Salty air in coastal regions, high UV radiation, sand, soil or changing conditions may cause permanent damage to vehicle parts and surfaces. There may be visible corrosion or changes to the surfaces. This has a negative impact on preserving the value of the machine! NOTE Caution! Possible damage to or destruction of parts!
  • Page 404 Environmental protection, disposal Environmental protection Packaging materials, used operating substances, cleaning agents and machine ac- cessories must be correctly recycled. Always observe the local regulations! Disposal Correctly sorted disposal must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service (scrapped). The materials must be sorted correctly according to metal, plastic, electronic scrap, various operating substances etc.
  • Page 405 Bolts - torques Standard metric threads - strength class 8.8 / 10.9 / 12.9 dry/lightly oiled Molykote ® 10.9 10.9 12.9 12.9 10.9 10.9 12.9 12.9 1020 1206 1410 1067 1281 1200 1622 1948 1049 1475 1770 1581 2224 2669 1400 1969 2362...
  • Page 406 Fine metric threads - strength class 8.8 / 10.9 / 12.9 dry/lightly oiled Molykote ® 10.9 10.9 12.9 12.9 10.9 10.9 12.9 12.9 M3x0,35 M4x0,5 M5x0,5 M6x0,75 12,9 15,5 11,6 13,9 M8x1 21,7 30,6 36,7 19,5 27,4 32,8 M10x1,25 42,1 10,5 59,2 17,8...
  • Page 407 F 110 Lubricants and operating substances Lubricants and operating substances Use only the lubricants listed below or comparable qualities of well-known brands. Only use containers which are clean on inside and outside for filling oil or fuel. Note capacities (see section "Capacities"). Incorrect oil or lubricant levels promote rapid wear and paver finisher failure.
  • Page 408 F 110 2...
  • Page 409 Capacities Substance Volume Diesel engine Engine oil litres (with oil filter change) Engine cooling system Cooling liquid 32,0 litres Fuel tank Diesel fuel litres Hydraulic oil reservoir Hydraulic oil litres Pump distribution gear Gearbox oil litres Planetary gear Gearbox oil litres drive unit Planetary gear...
  • Page 410 Lubricant specifications Engine Esso / Dynapac Aral Fuchs Mobil Shell Exxon Engine Oil (*) = recommended Cooling system Dynapac Petronas Finke AGIP Chevron Caltex Delo Coolant Aviaticon -Antifreeze Extended Antifreeze Finkofreeze Special Life Coolant P12+ (*) = recommended Hydraulic system Dynapac AGIP Chevron...
  • Page 411 Drive unit planetary gear Esso / Dynapac Aral Fuchs Mobil Shell Exxon Gear Oil -Omala S2 GX 220 (*) = recommended Auger drive planetary gear Esso / Dynapac Aral Fuchs Mobil Shell Exxon Gear Oil -Omala S2 GX 220 (*) = recommended Auger box Esso / Dynapac...
  • Page 412 Separator emulsion Dynapac Dynapac Dynapac Belt Guard Belt Guard Belt Guard 208L 1000L 4812215842 4812215846 4812216094 (*) = recommended Caution! Possible subsequent damage NOTE from not approved separator emulsion Considerable damage can be caused to the vehicle by using separator emulsions and other cleaning agents not approved by the factory without prior consultation.
  • Page 413 2.10 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 (*) Shell Natural HF-E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 (*) = recommended...
  • Page 414 F 110 8...
  • Page 416 www.dynapac.com...

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