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Fayat DYNAPAC F1000T T4f Operation & Maintenance Manual

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OPERATION & MAINTENANCE
Paver Finisher
F1000T T4f
Edit.2
April 2016
EN
Keep for later use in document compartment
Valid for:
4812243646 (A4) ; 4812247168 (A5)
-
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Summary of Contents for Fayat DYNAPAC F1000T T4f

  • Page 1 OPERATION & MAINTENANCE Paver Finisher F1000T T4f Edit.2 April 2016 4812243646 (A4) ; 4812247168 (A5) Keep for later use in document compartment Valid for:...
  • Page 2 www. .com...

  • Page 3: Table Of Contents

    Table of contents V Perface............................V1 ......................V3 1 General safety instructions ................. V3 1.1 Acts, directives, accident prevention regulations ........................ V3 1.2 Warning instructions ........................V6 1.3 Prohibitive signs ........................V7 1.4 Protective gear ......................V8 1.5 Environmental protection ........................
  • Page 4 .................... B11 4.13 Permissible temperature ranges ..............B12 5 Location of instruction labels and identification plates ....................B16 5.1 Identification label for the paver .......................... B18 6 EN standards 6.1 Continuous sound pressure level on the F1000T Track Paver, ..................B18 Cummins QSB 6.7 Tier IV Final Engine ................
  • Page 5 ......................D64 1.2 Engine Error messages ..........................D47 D 3.0 Operation ..................... D105 1 Operation elements on the paver ..........................D113 D 4.0 Operation ......................D113 1 Preparation of operation ........................ D117 1.1 Starting the paver ......................D123 1.2 Transport Operation ......................
  • Page 6 ....................E9 4.5 Left hand auger sensor control ........................... E10 4.6 Auger chart ..........................F1 F 1.0 Maintenance ......................... F1 1 Note regarding safety ....................... F2 F 2.0 Maintenance overview ........................ F2 1 Maintenance overview ..................F4 F 3.0 Maintenance – Conveyor and Hopper ..................

  • Page 7: Environmental Protection

    ......................F50 3.1 Lubrications and fuels ........................F50 3.2 Filling volumes ....................F51 F 8.0 Maintenance – Electric system ....................F51 1 Maintenance – Electric system ......................F52 1.1 Maintenance intervals ......................F54 1.2 Points of maintenance .................... F58 F 9.0 Maintenance – Lubricating Points ....................

  • Page 8: A Correct Use And Application

    A Correct use and application The “Guidelines for the Correct Use and Application of Paver” complied 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 followed. Federal, state and local regulations are fully applicable.

  • Page 9: B Vehicle Description

    B Vehicle description 1. Application The Dynapac F1000T is a rubber track paver that is used for laying bituminous mixed material, roll-down or lean-mixed concrete, track-laying ballast and unbound mineral aggregates for paving foundations.

  • Page 10: Description Of Assemblies And Functions

    2. Description of assemblies and functions Item Standard or Optional Description Standard Material hopper Standard Conveyor Standard Truck push rollers Optional Truck hitch Standard Mounting tube for alignment indicator Standard Rubber track Standard Track drive wheel Standard Leveling cylinder (for paving thickness) Standard Leveling arm guide Standard...

  • Page 11: Vehicle

    2.1 Vehicle Construction (Please read and conform the red chapters) The Dynapac F1000T is a rubber track propelled paver built with a welded steel frame on which the power pack, augers, conveyors, hopper and operator positions are mounted. The track suspension compensates for uneven areas on the ground. The suspension of the attached screed helps to attain high paving precision.
  • Page 12 Engine: The paver is powered by a 6-cylinder, water cooled diesel engine with direct injection and a turbo charger. Electric starting and belt driven alternator battery charging is standard. The engine power / rpm is controlled by the engine speed control on either of the consoles. The engine is shut down either by removing the key “ON/OFF”...
  • Page 13 filling height during the paving procedure, the transfer amount or speed regulation is completely automatic. Augers: The augers are driven and controlled independently from the conveyors. The auger hydraulics consist of two high pressure, variable displacement, closed loop pumps driving two fixed volume motors.

  • Page 14: Danger Zones

    3. Danger zones In the working areas around the machine (marked in red), there may be a risk of drawing in or crushing during normal operation caused by rotating and conveying elements, or by components in motion.

  • Page 15: Technical Data, Standard Configuration

    4 Technical data, standard configuration 4.1 Dimensions For screed technical data, refer to the screed operating instructions.

  • Page 16: Allowed Angle Of Rise And Slope

    4.2 Allowed angle of rise and slope Before operating your machine in an inclined position (gradient, slope, lateral inclination) which is above the specified limit value, please consult the customer service department for your machine! 4.3 Permissible approach angle * with truck hitch...

  • Page 17: Weights, F1000T

    4.4 Weights, F1000T Paver without screed approx. 35,300 lbs. (16012 kg) Paver with screed: - Carlsson EZ IV 1019 (7000 lbs) approx. 42300 lbs. (19187 kg) - Carlsson EZ III 10 (6000 lbs) approx. 41300 lbs. (18598 kg) - Carlsson EZR 10 (8250 lbs) approx.

  • Page 18: Engine

    4.6 Engine Make/type Cummins QSB-6.7 Tier IV Final Version 6-cylinder diesel engine (water-cooled) 222 hp @ 1800rpm Performance 225 hp @ 2000rpm Fuel tank capacity 2 tanks, 49 Gal (185 lt) each. 4.7 Hydraulic system Hydraulic pumps via distribution gear Hydraulic pressure supply source (directly flanged to the engine) Hydraulic circuits for:...

  • Page 19: Auger

    4.12 Auger Dual independent proportional augers Auger control 4.13 Permissible temperature ranges Maximum Ambient Operating +120°F (+48.9°C) Temperature For the capacities for the various lubricants and operating substances, see chapter F. B 11...

  • Page 20: Location Of Instruction Labels And Identification Plates

    5 Location of instruction labels and identification plates B 12...
  • Page 21 Item Decal Description Warning! Crush area! Keep a safe distance when machine is running or moving. Do not work in this area when the machine turns or machine parts move! Crushing can cause severe injury or death! Warning! Do not work on this machine unless you have read and fully understand the warnings and instructions in the Operation/Maintenance and Safety Manual! Failure to follow the instructions or heed the...
  • Page 22 Item Decal Description Main battery switch location! NOTE: Follow instructions for using battery main switch! ON/OFF positions for battery main switch. ON - battery connected OFF - battery disconnected Warning! Hot parts or components can cause burns! Keep a safe distance! Hot surface can cause burns or personal injury.
  • Page 23 Item Decal Description Ultra-low sulfur diesel only. Warning! Crush area! Keep a safe distance when machine is running or moving. Do not work in this area when the machine turns or machine parts move! Crushing can cause severe injury or death! B 15...
  • Page 24 Identification plate for the paver finisher Item Designation Paver Paver type Mass of the base machine with all standard equipment kg Paver rated power kW Year of manufacturing Product identification number (PIN) The stamped vehicle identification number on the paver must match the product iden- tification number.

  • Page 25: Standards

    6 EN standards 6.1 Continuous sound pressure level on the F1000T Track Paver, Cummins QSB 6.7 Tier IV Final Engine. The operator always must use ear protection. The noise level at the operator’s ear varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protection devices are used, hearing can be impaired.

  • Page 26: Measuring Point Configuration

    6.3 Measuring point configuration Hemispherical measuring surface with a radius of 52.5 ft. (16 m). The machine was at the center. The measuring points had been assigned the following coordinates: Measuring points 2, 4, 6, 8 Measuring points 10, 12 Co-ordinates - 0.27 +0.65...
  • Page 27 B 19...

  • Page 28: C Transport

    Transport 1 Safety regulation for transportation Accidents can happen when the paver and the screed are not properly prepared for transportation or when transportation is carried out improperly! Reduce both the paver and the screed to their basic widths. Remove all protruding parts (such as the automatic leveling system, auger limit switches, aprons, etc.).
  • Page 29 The operator must be in the possession of a valid permit for vehicles of this type. The operating panel must be moved to the side of the oncoming traffic and secured in this position. The driving lights must be properly adjusted. Only attachments and extension parts may be transported in the hopper, no material! If necessary, the operator must be assisted by a second person when driving on public roads –...

  • Page 30: Transportation On Low-Bed Trailers

    2 Transportation on low-bed trailers Reduce the paver and the screed to their basic widths; also remove any attached side plates. The maximum approach angle is indicated in the section entitled “Technical Data”! Check the fill level of the operating fluids so that these do not escape when driving on an incline. Attachment and loading equipment must meet the federal, state and local safety regulations! The weight of the paver must be taken into consideration when selecting the attachment and loading equipment!
  • Page 32 Step Operation - Select the master console. - Close the hopper lids. - Engage both hopper transport safeguards. - Lift the screed. - Retract the screed to the basic width of the paver. - Engage both screed transport safeguards. - Lift the auger. - Turn the ranage shift selector to zero.

  • Page 33: Driving Onto The Low-Bed Trailer

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

  • Page 34: After Transportation

    2.4 After transportation Remove the chains, hooks and all other transport tie-down tools. Swing the exhaust extension pipe up and secure it. Lift the screed to the transport position Start the engine and drive from the trailer at a low speed. Park the paver in a secure spot, lower the screed and switch the engine off.

  • Page 35: Transportation

    3 Transportation Reduce the paver and the screed to their basic widths; also remove any attached side plates. 3.1 Preparations Prepare the paver for transportation (see chapter D) Remove all overlaying or loose parts from the paver and screed (see also Operating Instructions for the screed).
  • Page 37 Step Operation - Select the master console. - Close the hopper lids. - Engage both hopper transport safeguards. - Lift the screed. - Retract the screed to the basic width of the paver. - Engage both screed transport safeguards. - Lift the auger. - Turn the ranage shift selector to zero.

  • Page 38: Driving Mode

    3.2 Driving mode C 11...
  • Page 39 Step Operation - Turn the selector to position 3. - Turn the pre-selecting regulator to its maximum point. - Use the drive lever to regulate the speed. Press the emergency stop button when an emergency situation arises! C 12...

  • Page 40: Loading By Crane

    4 Loading by crane Use only lifting gear that can bear the load. (See chapter B for weights and dimensions). Attachment and loading equipment must meet the conditions of the applicable accident prevention regulations! The vehicle’s center of gravity is dependent on the mounted screed. Four lifting eyes (1,2) are provided for loading the vehicle with a crane.
  • Page 41 Depending on the type of screed used, the paver’s center of gravity, with the screed mounted, is located in the area of the drive unit’s rear reversing roller. Secure vehicle wherever it is parked. Engage the transport safeguards. Remove any attachments and extension parts from the paver and the screed until the basic width has been attained.

  • Page 42: Towing

    5 Towing Follow all regulations and apply all safety measures applicable for towing heavy construction machines. The towing vehicle must be capable of securing the paver, even on slopes. Use only approved tow bars! If necessary, remove any attachments and accessories from the paver and the screed until the basic width has been attained.

  • Page 43: Safety Parking The Vehicle

    Always tow the machine the shortest distance to the means of transport or the next parking opportunity. After towing, return the Pump Pressure Lock and Release Handle (2) to the UP position. This will release pressure in the Hand Pump and will allow the braking system to engage. The track drive system brakes are now reactivated and the machine is secured against rolling 6 Safety parking the vehicle When the paver is parked at a location accessible to the public, it must be secured in such a way...

  • Page 44: D 1.0 Operation

    D 1.0 Operation 1 Safety regulations Starting the engine, the traction drive, the conveyor, the auger, the screed or the lifting devices can cause severe injury or death. Make sure, before starting any of these devices, that no-one is working on, in or beneath the paver or within its danger area! Do not start the engine or actuate any controls when this is expressly forbidden! Unless otherwise specified, the controls may only be actuated when the engine is running!

  • Page 45: Controls

    2 Controls 2.1 Operating panel Left Hand Operator’s Panel Right Hand Operator’s Panel...
  • Page 46 Item Designation Brief description - Steering is regulated by the speed of two drive units. NOTE: Steering wheel - Use the turn signals when turning! - For precise adjustment, see “straight-ahead travel trimming". Illuminates the instrument panels when the work lights Console lights are switched on.
  • Page 47 PANEL A Left Hand Operator’s Panel Right Hand Operator’s Panel...
  • Page 48 Item Designation Brief description Key position - 1: Ignition OFF - 2: Ignition ON Ignition lock - 3: Starting position NOTE: The key can only be removed in position 1. Press in the case of emergencies and to indicate when the machine starts to move! Horn NOTE:...
  • Page 49 PANEL B Left Hand Operator’s Panel Right Hand Operator’s Panel...
  • Page 50 Item Designation Brief description For switch on the paver functions and for regulating the road speed - forward or reverse. Zero position: starting is possible; engine at idle speed; no track drive; protected against inadvertent start. To move the lever, lift the ring (20a) to release it. Depending on the position of the drive lever, the following functions can be activated: - 1 st position: Engine runs at preselected speed...
  • Page 51 PANEL B Left Hand Operator’s Panel Right Hand Operator’s Panel...
  • Page 52 Item Designation Brief description Use the push button to activate the parking brake. The parking brake must be activated anytime the vehicle is stationary. Push button parking brake - Parking brake activated - push button illuminated - Parking brake de-activated - push button not illuminated not used Switches the regeneration function on and off: Toggle switch function:...
  • Page 53 PANEL B Left Hand Operator’s Panel Right Hand Operator’s Panel D 10...
  • Page 54 Item Designation Brief description Switches screed vibration on and off. Toggle function: - Toggle the switch to setting 0: Vibration OFF. Vibration ON / OFF - Toggle the switch to setting 1: Vibration ON. NOTE: Speed control (see "Operating instructions for screed") Switches the screed tamper function on and off.
  • Page 55 PANEL C D 12...
  • Page 56 Item Designation Brief description In case of an emergency (danger to persons, possible collision, etc.), press the Emergency stop button! - Pressing the Emergency stop button switches the engine, the drives and the steering system off. Emergency stop button Paving, lifting the screed or other functions are no longer possible! Do not reset the Emergency stop button until the danger is no longer present! - To restart the engine, the button must be pulled out again.
  • Page 57 PANEL C D 14...
  • Page 58 Item Designation Brief description Toggle the conveyor and auger (automatic or manual mode) on and off. Toggle switch function: - Toggle the switch forward (away from the operator): Auger + conveyor are ready for operation (LED ON) Conveyor + auger ON + - Toggle the switch back (forward the operator): Auger + activation LED / OFF conveyor OFF.
  • Page 59 PANEL C D 16...
  • Page 60 Item Designation Brief description Hydraulically adjusts the height of the left auger. Toggle switch function: - Toggle the switch forward (away from the operator): Raise auger. - Toggle the switch back (forward the operator): Lower auger. Raise / lower left auger Toggle both switches (raise / lower left + right auger) at the same time to keep the auger crossbeam level! Do not raise or lower the auger until all equipment and persons are...
  • Page 61 PANEL D D 18...
  • Page 62 Item Designation Brief description Hydraulically retracts and extends the left extendable part of the screed. Toggle switch function: - Toggle the switch left: Extend screed extension. Extend / retract left screed - Toggle the switch right: Retract screed extension. extension Do not extend or retract the screed until all equipment and persons are clear of the machine.
  • Page 63 PANEL D D 20...
  • Page 64 Item Designation Brief description Switches between floating screed functions and screed stop. Toggle switch function: - Toggle the switch forward (away from the operator): Screed stop. - "Screed stop" is used to lock the screed hydraulics to prevent the screed from sinking into the paved material when the paver is stationary (intermediate stop).
  • Page 65 PANEL D D 22...
  • Page 66 Item Designation Brief description Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system. Toggle switch function: - Toggle the switch forward (away from the screed): Retract or raise the leveling cylinder to raise the screed. Left leveling cylinder - Toggle the switch back (toward the screed): Extend or lower the leveling cylinder to lower the screed.
  • Page 67 PANEL E D 24...
  • Page 68 Item Designation Brief description Lit LED indicates that the diesel particulate filter is becoming filled and a regeneration is needed. The operator could either increase the engine speed and allow the engine to operate until an automatic regeneration is complete or the operator could initiate a manual regeneration. Regeneration is an extremely hot process.
  • Page 69 PANEL E D 26...
  • Page 70 Item Designation Brief description Lit LED indicates that the regeneration system temperature is elevated. During a manual regeneration, the LED turns on during automatic regeneration or when the filter temperature reaches 1247°F. The LED stays on during the regeneration and will then turn off when the Regeneration system temperature temperature falls below 1157°F Regeneration is an extremely hot process.
  • Page 71 PANEL E D 28...
  • Page 72 H53 (DEF Indicator) Symbol and title Symbol description Additional information Diesel exhaust fluid (DEF) To identify the fluid used to reduce Included in New Work Item emissions from operation of the Proposal for amendment of ISO diesel engine by means of a 6405-1 by ISO/TC 127.

  • Page 73: Auxiliary Functions

    3 Auxiliary functions D 30...
  • Page 74 Item Designation Brief description Press and release to reverse the direction of the cooling fan for 15 Cooling fan reverse seconds. Fan automatically returns to the normal direction after 15 seconds. Controls the working lights. - Toggle the switch up: Turns on the lights - Toggle the switch down: Turns off the lights.

  • Page 75: Left / Right Remote Controls And Handsets

    4 Left / right remote controls and handsets Item Designation Brief description - Control certain functions on the left-hand side of the LEFT remote control vehicle and various overall functions. - Control certain functions on the right-hand side of the RIGHT remote control vehicle and various overall functions.
  • Page 76 Left / right remote control left remote controls the left auger and conveyor right remote controls right auger and conveyor D 33...
  • Page 77 Item Designation Brief description In case of an emergency (danger to persons, possible collision, etc.), press the Emergency Stop button! - Pressing the Emergency Stop button switches the engine, the drives and the steering system off. Emergency stop button Paving, lifting the screed or other functions are no longer possible! Do not reset the Emergency Stop Button until the danger is no longer present! - To restart the engine, the button must be pulled out again.
  • Page 78 left remote controls the left auger and conveyor right remote controls right auger and conveyor D 35...
  • Page 79 Item Designation Brief description Overrides the auger and conveyor function automatic mode. Toggle switch function: - Toggle the switch away from the operator (upward) to run the auger and conveyor only using the pile height knobs. The Right speed manual / max. material sensor will not be used.
  • Page 80 left remote controls the left auger and conveyor right remote controls right auger and conveyor D 37...
  • Page 81 Item Designation Brief description Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system. Toggle switch function: - Toggle the switch forward (away from the screed): Retract or raise the leveling cylinder to raise the screed. Left leveling cylinder - Toggle the switch back (toward the screed): Extend or lower the leveling cylinder to lower the screed.
  • Page 82 left remote controls the left auger and conveyor right remote controls right auger and conveyor D 39...
  • Page 83 Item Designation Brief description Hydraulically raises or lowers the Berm. Toggle switch function: - Toggle the switch forward (away from the operator): Raises Berm. Berm raise / lower - Toggle the switch back (toward from the operator): lower (Option) Berm. Before operating the toggle switch, ensure that equipment and persons are clear of the machine! Locks and unlocks the Berm.
  • Page 84 left remote controls the left auger and conveyor right remote controls right auger and conveyor D 41...
  • Page 85 Item Designation Brief description Hydraulically retracts and extends the left extendable part of the screed. Toggle switch function: Extend / retract left screed - Toggle the switch left: Extend screed extension. extension - Toggle the switch right: Retract screed extension. Before operating the toggle switch, ensure that equipment and persons are clear of the machine! To hydraulically retract and extend the right extendable part of...
  • Page 86 Left / right handset D 43...
  • Page 87 Item Designation Brief description Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system. Toggle switch function: - Toggle the switch forward (away from the operator): Raises the left screed side arm. Left leveling cylinder - Toggle the switch back (toward the operator): Lowers the screed side arm.
  • Page 88 D 45...
  • Page 89 Item Designation Brief description Hydraulically retracts and extends the right extendable part of the screed. Push button function: - Toggle switch left: Retract screed. Extend / retract right screed - Toggle switch right: Extend screed. Before operating the toggle switch, ensure that equipment and per- sons are clear of the machine! Handset connection cable - Connects to the left remote control.

  • Page 90: D 2.0 Operation

    D 2.0 Operation 1 Operation of the graphical terminal Item Designation Brief description - Display for engine information, diagnostic information and Display configuration. - Terminal is controlled by navigation through a set of four soft keys. The keys are context dependent. Soft key selection Soft keys options are displayed above each key and are dependent on the current navigation location within the engine monitor...

  • Page 91: Navigation Using Soft Keys

    1.1 Navigation using Soft keys Item Designation Brief description Brightness/Contrast - Press to access brightness and contrast settings. Navigate Up - Press up to move up through menu items. Navigate Down - Press up to move down through menu items. Main Menu - Press to go to Main Menu screen.
  • Page 92 Brightness / Contrast Adjustment Adjust brightness and contrast levels by pressing the far left soft key. This will display brightness and contrast soft key bar. The bar will disappear after 3 seconds of inactivity. Main Menu – Start Menu The Main Menu screen is the starting point for configuring the termianl.
  • Page 93 Main Menu – Basic Setup Use the Basic setup screen to set time, language and display units for the terminal. - Use Time/Date set date and display style for time and date Time / Date information. Language - Use Language to set the system language. - Use Units to set speed, distance, pressure, volume, Units temperature and fuel rates and economy settings.
  • Page 94 Main Menu – Basic Setup Use Time/Date screen to set Time, Date, calendar style and time style. Use up, down select and next soft keys to navigate. Main Menu – Basic Setup - Language Use Language screen to select program language.
  • Page 95 Main Menu – Basic Setup - Units Use the up, down, select and next soft keys to define unit measurements Speed - km/h, mph Distance - km, mi Pressure - kPa, bar, lbs/sq in Volume - l, gal, imp, gal Temperature - °C, °F Fuel Economy...
  • Page 96 Main Menu – Diagnostics Use the Diagnostics screen to display current system in- formation, view and monitor fault logs and display all J1939 devices connected to the graphical terminal. D 53...
  • Page 97 Main Menu – Diagnostics – System Info The system info screen dis- plays the hardware system serial number, current soft- ware version, current system version node number. Only information is displayed in the System Info window. No changes can be made. Main Menu –...
  • Page 98 Main Menu – Diagnostics – Fault Log Active and Previous Faults Selecting Active Faults in the Fault Menu will display all active faults on the CAN network. Selecting Previous Faults in the Fault Menu will display all previously active faults on the CAN network. D 55...
  • Page 99 Main Menu – Diagnostics – Fault Pop – Up Alarms When a fault is detected on the CAN network, a flashing red warning alarm will be activated and a fault information pop-up window will be displayed listing current fault information. Warning lights will flash when a popup alarm occurs and will stay flashing until acknowledged.
  • Page 100 Main Menu – Diagnostics – Device List The Device list page will list all J1939 devices and addresses that are currently being monitored on the network D 57...
  • Page 101 Main Menu – Diagnostics – Quick Data The Quick Data function allows selected signals to be monitored in a scrollable single view display. To select signals for display, press the far right soft key Quick Data soft key Scroll through signal list using the up down arrow soft...
  • Page 102 Start Display Appears at system start. Model Select Use the scroll buttons to select the appropriate paver model. Once the check mark is on the correct model, press “OK”. D 59...
  • Page 103 Display 01 Display menu Vehicle Speed (1) in fpm Engine RPM (2) In rpm – with bar chart Diesel tank filling (3) in % - with bar chart Engine Coolant Temperature (4) in °C Display 02 Display menu Hydraulic Oil Temperature (1) in °C Engine Operation Hours (2) in hours Engine Coolant Level (3) in % - with bar chart...
  • Page 104 Active Faults Display Appears when a fault occurs. To see a list with active faults, first use button 2 or 3 from the current screed and go to Active Fault Screen, then press button 4 to get into the Active Fault Screen. After entering Active...
  • Page 105 Warning Display Appears due to faulty machine operation. Line (1): Actual displayed Warning of (x) active Warnings. Code number is displayed. Scroll between the active warnings by using buttons 2 or 3. Leave Warning display by using button Warning Codes Situation Code Display Message...
  • Page 106 Situation Code Display Message Open: 19 UltrasConvLH_Open, LH conveyor ultrasonic sensor open/short Short: 18 UltrasConvLH_Short Open: 21 UltrasConvRH_Open, RH conveyor ultrasonic sensor open/short Short: 20 UltrasConvRH_Short Open: 23 UltrasAugerLH_Open, LH auger ultrasonic sensor open/short Short: 22 UltrasAugerLH_Short Open: 25 UltrasAugerRH_Open, RH auger ultrasonic sensor open/short Short: 24 UltrasAugerRH_Short Open: 27 Conv_PotLH_Open,...

  • Page 107: Engine Error Messages

    1.2 Engine Error messages D 64...
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  • Page 148: D 3.0 Operation

    D 3.0 Operation 1 Operating elements on the paver Operator’s platform Seat console The seat console can pivot beyond the outer edge of the vehicle, providing the driver with a better view of the paving area in this position Release the platform lock (1). Swing the seat console to the desired position.
  • Page 149 Dust cover To avoid injury, the individual seat settings should be checked and adjusted before starting the vehicle. After the adjustments are set, check the seat to ensure it does not move out of adjustment. Seat forward and back adjustment (1): The seat can be moved forward or it can be moved back to adjust the seat;...
  • Page 150 Battery main switch The main switch interrupting the circuit between the battery and the main fuse is located above the battery pack. See chapter F for fuse locations and fuse order. To switch the ignition off, turn the key (1) to the left and pull it out Do not lose the key.
  • Page 151 Transport safeguards for the hopper Before parking or transporting the paver, the hop- per halves must be pivoted upwards and the trans- port safeguards for the hopper must be inserted. Before parking or transporting the paver, the hopper halves must be pivoted upwards and the trans- port safeguards for the hopper must be inserted.
  • Page 152 Paving thickness indicator The Paving Thickness Indicator scales are located on the left and right sides of the vehicle. The Paving Thickness Indicator (1) shows the setting on the Scale (2). In normal paving situations, the same paving thickness should be set on both sides of the vehicle! Avoid different settings on the scales as this will produce un-even pavement D 109...
  • Page 153 Release Agent System Used to spray the parts coming into contact with asphalt with a separator emulsion. NOTE: Check local regulations concerning use of cleaners and use of solvents Pull hose (1) out of the guide until there is an audible click.
  • Page 154 On/Off switch of working lights (1) Toggle switch (1) to switch on all installed working lights. On/Off switch hazard flasher (2) Activate switch (2) to switch on installed flasher Warning Beacon NOTE: The function of the warning beacon must be checked daily before starting work.
  • Page 155 Conveyor limit sensors The ultrasonic conveyor limit sensors control the material flow at the respective conveyor half. The conveyors should stop when the material has roughly reached the area below the auger tube NOTE: This requires that the auger height has been adjusted correctly (see chapter E).

  • Page 156: D 4.0 Operation

    D 4.0 Operation 1 Preparation of operation Required equipment and tools To avoid delays on site, check before starting work whether or not the following equipment and tools are present Wheel loader for transporting heavy extendable parts. Diesel fuel. Engine oil and hydraulic oil, lubricants. Separating agents (emulsion) and manual injector.
  • Page 157 Before starting work (In the morning or when starting paving). Follow the safety instructions. Check personal protective equipment Take an inspection walk around the paver and check for leaks and damages. Install parts removed for transportation or for the night. Perform the check according to the “Checklist for the machine operator”...
  • Page 158 Check! How? For larger working widths, the walkway plates must Auger covers be extended and the auger tunnels must be covered. For larger working widths, the walkway plates must be extended. Hinged walkway plates must be swung Screed covers and walkways down.
  • Page 159 D 116...

  • Page 160: Starting The Paver

    1.1 Starting the paver Before starting the paver Before starting the diesel engine and beginning operation, the following steps must be performed. Daily maintenance of the paver (see chapter F) Check the operating hours counter to determine whether or not additional maintenance work (such as monthly or yearly maintenance) must be performed.
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  • Page 162 Jump starting The engine can be started with the help of an external power source if the batteries are low 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 jump starting (24V / 90A). Standard 12V chargers or quick chargers cannot be used for jump starting.
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  • Page 164 After starting To increase the engine speed: Set selector (21) for traction drive / engine to position 2. Let the paver warm up for about 5 minutes if the engine is cold. Read and follow Chapter D2 of this manual for possible warnings on the graphical terminal! D 121...
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  • Page 166: Transport Operation

    1.2 Transport Operation Lifting and securing the screed Raise the screed using switch (52). Center the leveling cylinders using the switches (54) / (55). The remote control must be connected and this function must be set to “Manual“. Raise the auger crossbeam using switches (47) / (48). Engage both screed transport safeguards to secure the screed in the raised position.

  • Page 167: Preparation For Paving

    1.3 Preparation for paving Releasing agent Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator emulsion. Do not use diesel fuel as it dissolves the bitumen. Screed heater Switch the screed heater “On” for about 15–30 minutes (depending on the ambient temperature before paving begins.
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  • Page 169 Loading / distributing material Open the hopper with switch (15). Have the truck back short of the paver and pull the paver against the truck tires. Guide the truck driver when dumping the material mix Set the switch (45) of the auger and conveyor to the “ON” position. Set both switches (46) of the auger and conveyor to “AUTO “position.
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  • Page 171: Starting For Paving

    1.4 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 Switch Position Selector position 1 Preselector approx.

  • Page 172: Checking During Paving

    1.5 Checking during paving The following points must be constantly observed during paving: Paving function Screed heater Vibration and / or tamper 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;...
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  • Page 174: Interrupting / Terminating Operation

    1.6 Interrupting / terminating operation During breaks (i.e. the material supply truck is late) Determine the approximate duration. When the material’s temperature drops below the minimum paving temperature, run the paver empty and create an edge like the end of a layer. Set the drive lever (20) to the center position.
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  • Page 176 When work is finished Run the paver empty, then bring it to a stop. Turn drive lever (20) to the center position. Move the preselector (12) and selector (21) to minimum position. Switch off conveyor + auger (45), vibration (27), and lights (25). Lift the screed by using switch (52).

  • Page 177: Malfunctions

    2 Malfunctions 2.1 Problems during paving Problem Cause: - change in the material temperature, segregation - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long idle standing 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 ("short waves")
  • Page 178 Problem Cause: - material temperature is too low - change in the material temperature - moisture on the foundation - segregation Cracks in the layer (cover the - wrong material composition entire width) - wrong layer height for the maximum grain size - cold screed - bottom plates of the screed are worn or warped - paver speed is too high...
  • Page 179 Problem Cause: - truck hits against the paver too much while aligning to the paver Marks in the surface - too much play in the mechanical screed link/suspension - truck parking brake is applied - vibration is too high while standing in one spot - temperature of the material - change in the material temperature - wrong layer height for maximum grain size...

  • Page 180: Malfunctions On The Paver Or Screed

    2.2 Malfunctions on the paver or screed Malfunction Cause: Remedy At the diesel engine Diverse See operating instructions for the engine Diesel engine does Batteries drained See ”External starting" (start assistance) not start Other see ”Towing” Tamper is obstructed by cold Properly heat the screed bitumen Hydraulic oil level in the tank...
  • Page 181 Malfunction Cause: Remedy Control valve is defective Replace Hoppers lowers Leaking seals in the hydraulic inadvertently Replace cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot be Screed relieving or charging is Switch must be in the center position lifted switched on Check fuse and cables;...
  • Page 182 Malfunction Cause: Remedy Replace Traction drive fuse defective (Fuse holder is on the operating panel) Check potentiometer, cables, connectors; Power supply is interrupted replace if necessary Traction drive monitoring Replace defective Traction does not Electro-hydraulic servo unit of work Replace the servo unit the pump is defective Check and adjust if necessary Insufficient supply pressure...

  • Page 183: Set-Up And Modification

    E 01 Set-up and modification 1 Special note on safety Inadvertently starting the engine, the traction drive, the conveyor, the auger, the screed or the lifting units can be dangerous. Unless specified otherwise, work may only be performed when the engine is not running! To protect the paver against inadvertent starting: Set the drive lever to the center position and set the preselector to zero;...

  • Page 184: Auger

    2 Auger 2.1 Height adjustment Depending on the mix of materials, when working with layer thicknesses of up to 10 in. (25.4 cm), the height of the distribution auger (1). –measured from its bottom edge – should be around 5 cm (2 inches) above the material layer thickness (depending on its mix of materials).

  • Page 185: Auger Extension

    2.3 Auger extension Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. See the operating instructions for the appropriate screed, chapter “Set-up and modification”, especially: Screed extension chart Auger extension chart To attain the desired working width, the respective screed extensions, side plates, augers, tunnel plates or cut-off shoes must be mounted For widths of more than 11.5 ft.

  • Page 186: Mounting Extension Parts

    2.4 Mounting extension parts Loosen the clamping screws (6) on the support tube. Then turn in the center expanding screw (5) to expand the clamping. Pull the telescopic tube out of the support tube (7). Mount the required extension parts. NOTE: Observe the guide groove of the spline! Make sure that the shaft end is clean!

  • Page 187: Mounting Support Tube Extensions

    2.5 Mounting support tube extensions If the working width exceeds 23 ft. (7.01 m.) an auger crossbeam extension must be mounted. The support tube extension of the auger cross- beam consists of two halves (8) and is attached to the existing support tube by using a total of 5 screws.

  • Page 188: Installing Tunnel Plates

    2.6 Installing tunnel plates To ensure an optimum material flow - especially in the case of large paving widths – so-called tunnel plates (11) must be installed. They are located directly in front of the auger distributor and – in conjunction with the auger – is an ideal system for conveying the material.

  • Page 189: Installation Additional Braces

    2.7 Installation additional braces When operating with width of more than 25 ft. (7.62 m.) the augers must be provided with an additional support. To do so, attach two braces on both the left-hand and the right-hand side, between the tunnel plate support and the bracket provided on the paver.

  • Page 190: Screed

    3 Screed The operating instructions for the screed explains what is required for mounting, setting up and extending the screed 4 Electrical connections Ensure the following connections have been made once the screed has been mounted and set up. 4.1 Remotes from screed to paver The screed plugs into the back of the paver socket (15).

  • Page 191: Left Hand Conveyor Sensor Control

    4.4 Left hand conveyor sensor control The conveyor sensor connects to the DC control box. The control box is connected to the right re- mote by a cable through the rear bulkhead. The remote then sends the signal from the sensor to the paver thru the cable shown.

  • Page 192: Auger Chart

    4.6 Auger Chart Auger ext. parts per side Guide Auger plate 11.4 in. (289.6 mm) 17.0 in. (431.8 mm) 22.8 in. (579.1 mm) 28.4 in. (721.4 mm) 34.1 in. (866.1 mm) 45.5 in. (1155.7 E 10...
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  • Page 194: F 1.0 Maintenance

    F 1.0 Maintenance 1 Notes regarding safety Maintenance work: Maintenance work may only be carried out when the engine is not running. Secure the paver and the attachments against inadvertent starting before beginning any maintenance work. Set the drive lever to the center position and the speed preselector to zero. Remove the ignition key and the battery main switch,.

  • Page 195: F 2.0 Maintenance Overview

    F 2.0 Maintenance overview Maintenance overview...
  • Page 196 Maintenance required after the following service hours Assembly Chapter Conveyor and Hopper F3.0 Auger F4.0 Engine F5.0 Hydraulics F6.0 Track F7.0 Electronics F8.0 Lubrication points F9.0 Checking/decommissioning F10.0 Maintenance required...

  • Page 197: F 3.0 Maintenance - Conveyor And Hopper

    F 3.0 Maintenance – Conveyor and Hopper Maintenance – Conveyor and hopper...

  • Page 198: Maintenance Intervals

    1.1 Maintenance intervals Interval Points of maintenance Remark Checking the tension of the conveyor chain Adjusting the tension of the conveyor chain Conveyor chain - Check chain Conveyor chain - Replace chain Clean Conveyor chain supports Conveyor tensioning sprocket - Lubricate grease zert Conveyor bearing - Lubricate grease zert...

  • Page 199: Points Of Maintenance

    1.2 Points of maintenance Chain tension of the conveyor (1) Checking the track tension: For daily inspection look straight through under the bumper. The chain must not hang below the bottom edge of the bumper. Should readjustment be necessary, measure the slack unloaded from the bottom edge of the floor plate to the bottom edge of the chain (see the figure).
  • Page 200 Check / replace chain: When the conveyor chains (A) have stretched so far that they can no longer be adjusted, they must be replaced. Chain links must not be removed to shorten the chain! Shortening the chains would lead to the destruction of the drive sprockets! Adjust the tensioning instead! If components have to be replaced as a result of wear, the following components should always be...
  • Page 201 Conveyor tensioning sprocket bearings The tensioning sprocket bearings for the conveyors are lubricated at the grease zerts (A) located behind the crossbeam. The center bearings are lubricated at the outer lubricating grease zerts. Pump 5 strokes of grease with a grease gun! Conveyor bearing block (1) center conveyor...
  • Page 202 Conveyor drive – (5) drive chains Checking for chain tension: In normal conditions, the chain has to have approximately .4 to .6 inch (10 – 15 mm) of play. To set the chain tension: Loosen the locking bolts (A) and the lock-nut (B).
  • Page 203 Conveyor drive – (6) planetary drive (Left/right) To check the oil level, unscrew the inspection plug (A). NOTE: For proper oil level, the oil must be at the lower edge of the inspection port or a little oil flows from the hole. To add oil: Check oil at oil level site glass (A).
  • Page 204 Conveyor chain guards / conveyor plates (7) NOTE: When the lower edges of the conveyor chain guards (A) are worn or reveal holes, they must be replaced. The conveyor chain is not protected when the conveyor chain guards are worn! Remove conveyor chain guard bolts.

  • Page 205: F 4.0 Maintenance - Auger

    F 4.0 Maintenance – Auger Maintenance – Auger F 12...

  • Page 206: Maintenance Intervals

    1.1 Maintenance intervals Interval Points of maintenance Remark Auger - outer bearing Lubrication Auger central bearing Lubrication Auger drive neck bearing Lubrication Auger bevel gear oil level check Auger bevel gear topping up the oil Auger bevel gear oil change Auger wear plates (auger segments) Check wear...

  • Page 207: Points Of Maintenance

    1.2 Points of maintenance Auger – outer bearing (1) The grease zerts (A) are located on each side on the top of outer bearing. These zerts must be lubricated each time work is finished. The outer bearings of the auger must be lubricated when hot, so that the eventual bitumen residue is expelled.
  • Page 208 Auger – drive gear neck bearing (3) Remove the hexagonal plug (A) in the neck of the drive. Replace the plug under it with an extended grease zert 10 x 1. Use a grease gun to pump about 10 strokes of grease.
  • Page 209 Auger bevel gear (on the RH and LH sides) (4) To check the oil level: unscrew the inspection / filling plug (A). NOTE: The oil level is full when the oil is at the lower edge of the inspection port or a little oil flows from the hole.
  • Page 210 Auger blade (5) If the surface of the auger blade (A) becomes sharp-edged, the diameter of the auger is reduced and the blades (B) have to be replaced. Remove the bolts (C), nuts (E) and auger blade (B). Sharp-edged parts can cause personal injury! Auger blades must be installed without any play and the contact surfaces must be dirt-free! Install the new auger blade (B);...

  • Page 211: F 5.0 Maintenance - Engine

    F 5.0 Maintenance – Engine Maintenance – engine sub-unit F 18...

  • Page 212: Maintenance Intervals

    In addition to these Maintenance Instructions, the Maintenance Instructions of the engine manufacturer must always also be observed. All other maintenance work and intervals noted in these instructions are also binding. 1.1 Maintenance intervals Interval Points of maintenance Remark Fuel tank Check the filling level Fuel tank Refill with fuel...
  • Page 213 Interval Points of maintenance Remark Engine air filter Check the air filter Engine air filter Empty the dust collecting bin Engine air filter Clean / Replace the filter cartridge Engine cooling system Inspection the radiator fins Engine cooling system Clean the radiator fins Engine cooling system Check the level of the coolant.

  • Page 214: Points Of Maintenance

    1.2 Points of maintenance Engine fuel tank (1) NOTE: There is one fuel tank on each side of the machine. Check the fuel level on the operating panel (check display). Fill the fuel tank before each work shift to prevent the fuel system of running dry. If the tank is ran dry, the system will have to be bled causing work delay To add fuel: Unscrew cap (A) (under tank covers, r.
  • Page 215 Engine lube-oil system (2) Check oil level Check that the oil level is between the maximum and minimum lines on the dipstick (A). NOTE: Check the oil level with the paver parked on a flat surface! Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity.
  • Page 216 Oil change: Do not drain the oil when the engine is cold. As the oil cools, suspended waste particals settle on the bottom of the oil pan. The waste particles are not removed with the draining cold oil. Drain the crankcase with the engine stopped.
  • Page 217 Engine fuel system (3) The fuel system consists of two filters: Pre-filter (A) with water separator (located in the engine compartment). Main filters (B). Pre-filter – drain the water Empty the condensation prior to every engine start or when the engine electronics indicate a fault.
  • Page 218 Main filter replacement: Loosen the filter (A) and clean the surface where the new filter will mount. Apply a thin coat of oil to the gasket of the new filter. Tighten the filter by hand. NOTE: After mounting the filter, check it for proper tightness.
  • Page 219 Engine air cleaner (4): The function of the engine air cleaner is to filter the air taken into the engine through the engine’s air intake. The engine air cleaner is the dry type with two elements: a primary element that is cleanable and replaceable, and a safety element that should only be replaced and not cleaned.
  • Page 220 To remove the filter cartridges: Open the latches to remove the cover. Remove the primary filter and then the filter cartridge (B). NOTE: Clean the filter cartridge and replace at least once per year. Blow out with dry pressure air (max. 30 psi / 2.07 bar) from inside blowing out. In case of urgency, tap the cartridge to remove dust.
  • Page 221 Engine Coolant system (5): Fully formulated antifreeze must be mixed with quality water at a 50/50 ratio. A 50/50 mixture of water and ethylene glycol or propylene glycol antifreeze to fill the cooling system. The 50/50 mix gives protection to the cooling system at a range of --34_F (--36_C) freezing point and a 228_F.
  • Page 222 Once drained, dispose of the coolant fluid in an appropriate manner. Coolant is toxic. Keep away from children and pets. Dispose of in accordance with federal, state and local environmental regulations. Close the drain valve. Fill the radiator with a 50 / 50 mix of water and ethylene glycol or propylene glycol antifreeze. Install the radiator cap.
  • Page 223 Engine drive belt (6): Check drive belt / replacement. Under normal operating conditions, the engine drive belt(s) should be inspected daily. Belt dam- age can be caused by incorrect size or length, pulley misalignment, incorrect installation, severe operating environment and oil or grease on the belt(s).
  • Page 224 Maintenance – DEF tank Clean the DEF tank Drain the tank. Remove the Multifunction Head Unit from the tank. Inspect the debris saturation of the DEF suction filter to determine if the filter needs to be replaced. If the filter is damaged or dirty, replace the filter. Rinse out the interior of the DEF tank using an ordinary hose or pressure washer.
  • Page 225 mounting base until it is completely seated in the tank bore. Position the retaining ring on Head unit and install the retention screws using the T25 Torx wrench. Recommended torque on screws is 20-30 in-lbs (2.26-3.38Nm) DEF suction filter DEF Suction Filter is located at the bottom of the Multifunction Head Unit assembly thus requiring the head unit to be removed from the DEF reservoir.

  • Page 226: F 6.0 Maintenance - Hydraulic System

    F 6.0 Maintenance – Hydraulic System Maintenance – hydraulic system F 31...

  • Page 227: Maintenance Intervals

    1.1 Maintenance intervals Interval Points of maintenance Remark Hydraulic oil tank Check the oil level Hydraulic oil tank Fill with oil Hydraulic oil tank Oil change and cleaning Hydraulic oil tank Check the maintenance indicator Hydraulic oil tank Intake / return Change the hydraulic filter High pressure filter Check the maintenance...

  • Page 228: Hydraulic System

    1.2 Hydraulic System A paving machine has many components and implements that are controlled by a hydraulic system, either directly or indirectly. Before working on or inspecting any part of a paving machine, it is important that the individual knows how the components move and are controlled by the hydraulic system components including the respective control circuits Before working on or inspecting any component, it must be physically constrained from any movement that could cause injury to the worker.

  • Page 229: Points Of Maintenance

    1.3 Points of maintenance Hydraulic oil tank (1) Oil level check at the sight level gauge (A) on the side of the tank. NOTE: View the sight level gauge by the opening tank flap on the L.H. side of the machine. With the cylinders fully retracted, the oil level should at the upper mark.
  • Page 230 To change the oil: To drain the hydraulic oil unscrew the drain plug (C) at the bottom of the tank. Collect the oil in an appropriate container using a funnel. After draining, add a new seal ring and then screw the plug back into place. Hot oil or components can burn.
  • Page 231 Suction / return flow hydraulic filter (2) Change the filter at the intervals specified or when the maintenance indicator (A) is at the red mark or when changing hydraulic oil. When inspecting the maintenance indicator, the hydraulic oil must be at least 175°F (80° When changing the hydraulic oil also change the filter.
  • Page 232 Venting the filter Fill the open filter case with hydraulic oil to just below the upper rim. Should the oil level drop, fill with oil. The oil level slowly lowering by about 1/4 in. /min. (1 cm/min) is normal! When the oil level remains steady, mount the assembled unit with the new filter cartridge, carefully into the housing and tighten the locking screws of the lid (B).
  • Page 233 High pressure filters (3) Replace the auger charge filter (A) cartridge and conveyor pump / work system filter (B) when the maintenance indicator on top of the filter cartridge head turns “red”. Unscrew filter housing. Remove the filter cartridge. Clean the filter housing. Insert the new filter cartridge.
  • Page 234 Pump distribution gear (4) Check the oil level at the sight glass (A) (at the side of the distribution box). NOTE: The oil level must be up to the center of the sight glass. To add oil: Unscrew the plug (B). Add oil until the sight glass (A) shows the correct fluid level.
  • Page 235 Change the oil when the engine is at operating temperature. Place the end of the hose in an appropriate container and catch the oil. Open the shut-off valve and let the oil drain completely. Shut off the valve, remove the hose and return the cover cap.
  • Page 236 Hydraulic hoses (5) Frayed or damaged hoses can break instantly causing hot hydraulic fluid to spray causing severe burns. Always replace worn or damage hoses immediately Hot oil or components can burn. Oil must be at normal operation temperature when draining. Avoid con- tact with hot oil or components.

  • Page 237: F 7.0 Maintenance - Track

    F 7.0 Maintenance – Track Maintenance – running gear F 42...

  • Page 238: Maintenance Intervals

    1.1 Maintenance intervals Interval Points of maintenance Remark Idlers, guide rollers, drive wheels - Check the torque at the bolts Idlers, guide rollers, drive wheels - En- sure proper torque for bolts Guide rollers - check straight running Guide rollers - straight running, setting Guide rollers - ensure the adjusting bolts are tight...

  • Page 239: Instructions For Undercarriage Maintenances

    1.2 Instructions for undercarriage maintenance In order to avoid a disclaimer of responsibility by the manufacturer or dealer and to extend the life of the rubber parts, the directives below should be strictly adhered to. Check and maintain the track and undercarriage as specified. Although the rubber itself needs little daily maintenance, the metal parts of the undercarriage are very sophisticated, therefore they require frequent checking.

  • Page 240: Long-Term Effect Of Parked Machines

    2.1 Long-term effect of parked machines If the machine is not used for a long period, observe the following directives. Avoid exposing the machine to direct sunlight. Over a period of time, the direct UV radiation may cause the drive wheels, idlers or guide rollers to become porous.

  • Page 241: Maintenance

    2.2 Maintenance Idlers, guide rollers, drive (1) Check / tighten the mounting bolts Mounting bolts for all idlers, guide rollers and drives should be checked and tightened if necessary! The mounting bolts should be tightened to the following torque values: Guide rollers (A) - (12 rollers): 105 ft.
  • Page 242 Guide rollers – straight running secure the adjustment bolts (2) The adjustment bolts are located in the front part of the drives and at the regulator links of the guide rollers. If the wheels and rollers run outwards or inwards or are not centered on the two guide rollers, side ward tilt of the guide rollers should be adjusted.
  • Page 243 Planetary gear (3) Care must be taken to ensure fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the paver. Be pre- pared to collect the fluid with suitable containers before opening compartment disassembling any component containing fluids. Dispose of fluids according to local regulations and mandate To check the oil level in the Planetary...
  • Page 244 Idler rollers, front (4) Tracks that are not adjusted properly can cause rapid wear at the idler bearings and can put extra stress on the undercarriage while wasting horsepower and causing higher fuel consumption. Check the drive idler bearing (A) for wear and ensure they are filled with grease.

  • Page 245: Gear - Lubrication Materials

    3 Gear – lubrication materials (5) 3.1 Lubrications and fuels NOTE: Use only lubricants listed or the equivalent quality lubricants. Use only clean containers for adding oil or fuel. Take into account the filling volumes (see the section “Filling volumes”) Low quality oil or lubricant causes faster wear and the failure of the machine.

  • Page 246: F 8.0 Maintenance - Electric System

    F 8.0 Maintenance – Electronic System Maintenance – Electronic system F 51...

  • Page 247: Maintenance Intervals

    1.1 Maintenance intervals Interval Maintenance point Note Check the charge level of the batteries, replace if necessary Apply grease to battery terminals Electric fuses Maintenance Maintenance during the running-in period F 52...

  • Page 248: Points Of Maintenance

    1.2 Points of maintenance Batteries (1) Maintenance of batteries NOTE: The batteries equipped with the paver are “Maintenance Free” batteries. When batteries can no longer hold a charge, they must be replaced. The battery terminal clips must be free of corrosion (oxide) and protected with grease.
  • Page 249 Electric fuses / relays (3) Main fuses (A) Fuse Description Rating (A) Main Battery Alternator Switch Power From Key Air Heater Power Supply ECM Power Supply F 54...
  • Page 250 Fuses in terminal box (B) Fuse No. Description Rating (A) Proper Controller Emergency Stop ECM Key Switch Signal Key Switch Power DP2000 Display Power Horn Power Supply Start Prevention Relay, Hour Meter Proper Devices Console Select Switch and Parking Brake Auger Conveyor On / Off and Auto / Manual Switch Auger Raise / Lower, Ext / Ret...
  • Page 251 Fuse No. Description Rating (A) Flasher 2 Roading Lights Truch Hitch and Wash Down Screed Power Supply Screed Power Supply Front Wheel Assist Auger / Conveyor Controller Power Supply Auger / Conveyor Cleaning / Fast Fill Switch Auger / Conveyor Ultrasonic Sensor Auger / Conveyor Override Switch Power F 56...
  • Page 252 Relays in terminal box (C) Relay No. Description Starter Anti Start Circuit Emergency Stop Circuit Intake Air Heater Auger / Conveyor ON / OFF Auto Mode Enable (Screed Float, Vibration, Leveling) Left Conveyor OFF Right Conveyor OFF Starter Lock Out Screed Float / Lock Console Select Indication Left Auger OFF...

  • Page 253: F 9.0 Maintenance - Lubricating Points

    F 9.0 Maintenance – Lubricating Points Maintenance – Lubricating points NOTE: The information on the lubrication points for the various assemblies is assigned to the specific maintenance descriptions (I.E. grease points for the auger are in the auger section and grease points for the undercarriage are in the section on undercarriages)! F 58...

  • Page 254: Maintenance Intervals

    1.1 Maintenance intervals Interval Maintenance point Note - Bearing points Maintenance Maintenance during the break-in period F 59...

  • Page 255: Points Of Maintenance

    1.2 Points of maintenance Bearing points (1) One grease zert (A) is located at each hydraulic cylinder bearing point (top and bottom). F 60...

  • Page 256: Test, Check-Up, Cleaning, Stopping

    F 10.0 Checks, Decommissioning Tests, check-up, cleaning, stopping F 61...

  • Page 257: Maintenance Intervals

    1.1 Maintenance intervals Interval Points of maintenance Remark General observation Checked by a specialist Cleaning Preservation for storage of paver Maintenance Maintenance during run-in period F 62...

  • Page 258: General Observation

    2 General observation The daily check includes a walk around the machine while checking the following items: Are any of the parts or controls damaged? Are there leaks at the engine, the hydraulics, the gearbox, etc? Are all the locking points secure (conveyor, auger, screed)? Repair the damages and clean any spills immediately to avoid risks of accidents and environmental pollution! 3 Check performed by a specialist...

  • Page 259: Cleaning

    4 Cleaning Clean all parts that come into contact with the material to be laid. Spray these parts with the release agent spray equipment. Before cleaning with high pressure jet, lubricate all the bearings with grease as specified. Clean the machine with after laying material mixes, lean concrete etc. Remove all residue of the material laid.

  • Page 260: Preservation For Storage Of Paver

    Preservation for storage of paver Downtime up to 6 months - Stop the machine in a place protected from intensive sunshine, wind, moisture and frost. Lubricate all the lubrication points with grease as specified. Change the oil in the Diesel engine Seal the muffler of the exhaust pipe.

  • Page 261: Environmental Protection, Disposal

    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 262: F 11.0 Lubricants And Operating Substances

    F 11.0 Lubricants and Operating Substances Lubricants and operating substances Use only the lubricants listed below or their equivalents. Only use clean containers for filling oil or fuel. Follow to the correct filling volumes (see the section “Capacities“). Incorrect oil or lubricant levels increase the wear and cause the paver to fail. Never mix synthetic oils with mineral oils! F 67...

  • Page 263: Capacities

    1.1 Capacities Lubrication Substance Volume 1630047100 5L 18.5 qts (17.5 L) 1630047200 20L Engine Sump+Oil Filter, Cummins PAROIL E GREEN 1630047300 209L 9106230321 20L Hydraulic Oil Hydraulic 100 66 gal (250 L) 9106230320 209L 4812008274 5L Fluid Gearbox 100 Conveyor Gearbox - Left 1.58 qt.

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