Dynapac SD2500C Operation & Maintenance Manual
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Dynapac SD2500C Operation & Maintenance Manual

Paver finisher
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OPERATION & MAINTENANCE
Paver Finisher
Dynapac
SD2500C / SD2500CS
Typ 892 / 893
4812016236 (A5)
05-0814
Keep for later use in document compartment
Valid for:
_________________ - _________________
_________________ - _________________

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Do you have a question about the SD2500C and is the answer not in the manual?

Questions and answers

Sabri
January 20, 2025

اريد خطوات ضبط جهاز الاستشعار الفوق صوتي للمدة مع الابعاد وبداية التشغيل

0
1 comments:
Mr. Anderson
February 4, 2025

To set up the ultrasonic sensor on the Dynapac SD2500C for duration and dimensions:

1. Mount the Sensor:
- Secure the ultrasonic sensor to the side shield using a bracket.

2. Adjust the Sensor Angle:
- Loosen the clamps on the bracket.
- Swivel the bracket to achieve the desired angle.
- Retighten the clamps after adjustment.

3. Set the Sensor Height/Deactivation Point:
- Loosen the star handles.
- Adjust the linkage to the required length for the desired height or deactivation point.
- Retighten all mounting parts properly.

4. Connection:
- Connect the sensor cables to the relevant sockets on the remote control bracket.

5. Sensor Adjustment:
- Ensure the sensors are adjusted so that 2/3 of the augers are covered with paving material.
- The paving material must be conveyed over the full working width.

6. Limit Switch:
- During material distribution, adjust the limit switch positions as needed.

This answer is automatically generated

0

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Summary of Contents for Dynapac SD2500C

  • Page 1 OPERATION & MAINTENANCE Paver Finisher Dynapac SD2500C / SD2500CS Typ 892 / 893 4812016236 (A5) 05-0814 Keep for later use in document compartment Valid for: _________________ - _________________ _________________ - _________________...
  • Page 2 www.atlascopco.com...

  • Page 3: Table Of Contents

    Dimensions (all dimensions in mm) ............10 Allowed angle of rise and slope ............... 11 Permissible approach angle ..............11 Weights SD2500C (all weights in t) ............12 Weights SD2500CS (all weights in t) ............12 Performance data SD2500C ..............13 Performance data SD2500CS ..............
  • Page 4 Further warnings and operating instructions ..........29 Identification label for the paver finisher (41) ........31 EN standards ....................32 Continuous sound pressure SD2500C, Cummins QSB 6.7-C173 ...32 Operating conditions during measurement ..........32 Measuring point configuration ..............32 Continuous sound pressure SD2500CS, Cummins QSB 6.7-C200 ..33 Operating conditions during measurement ..........33...
  • Page 5 Operation ................. 1 Safety regulations ..................1 Controls ...................... 3 Operating panel ..................3 Special functions ..................50 Reversible conveyor ................50 Remote control ..................53 Operation ................. 1 Operation of the input and display terminal ..........1 Button layout on the display ..............1 Command symbols ................
  • Page 6 Operation .................1 Operating elements on the paver finisher ..........1 Control elements on the operator's control station ........1 Protective roof (o) ...................2 Ladder ....................4 Storage space ..................4 Control platform, moveable (o) ...............5 Control platform lock (o) .................6 Operating panel ..................7 Protective cabin (o) ................8 Windscreen wiper ...................9 .Emergency actuation control platform, movable .........10 Seat console ..................11...
  • Page 7 Fuelling pump (o) ................. 40 Illuminated balloon (o) ................. 41 Installation and operation ..............42 Maintenance ..................43 Replacing the lamp ................43 Operation ................. 1 Preparing for operation ................1 Required devices and aids ..............1 Before starting work (in the morning or when starting paving) ....3 Check list for the vehicle operator ............
  • Page 8 Set-up and modification ............1 Special notes on safety ................1 Distribution auger ..................2 Height adjustment ..................2 Grain sizes up to 16 mm ................2 Grain sizes > 16 mm ................2 Mechanical adjustment with ratchet (o) ............3 Hydraulic adjustment (o) ................3 Height adjustment for large working widths / with brace ......4 Auger extension ..................6 Mounting extension parts ................7 Mounting the material shaft and auger extension ........7...
  • Page 9 Connecting the sensor ................. 43 Automatic steering unit operating instructions ........44 Emergency stop during feeder operation ..........45 Limit switch ....................46 Auger limit switches (left and right) - mounting the PLC version ..... 46 Auger limit switches (left and right) - mounting the conventional version 47 Special accessories .................
  • Page 10 Maintenance - conveyor ............1 Maintenance - conveyor ................1 Maintenance intervals ................3 Points of maintenance ................4 Chain tension, conveyor (1) ..............4 Conveyor drive - drive chains (2) ............6 Conveyor deflectors / conveyor plates (3) ..........7 Maintenance - auger assembly ..........1 Maintenance - auger assembly ..............1 Maintenance intervals ................3 Points of maintenance ................5 Outer auger bearing (1) ................5...
  • Page 11 Maintenance - hydraulic system ..........1 Maintenance - hydraulic system ..............1 Maintenance intervals ................3 Points of maintenance ................5 Hydraulic oil tank (1) ................5 Suction/return flow hydraulic filter (2) ............ 7 Bleeding the filter ................... 8 Ventilation filter ..................8 High-pressure filter (3) ................
  • Page 12 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 ..............6 Preserving the paver finisher ..............7 Shutdowns for up to 6 months ..............7 Shutdowns lasting from 6 months to 1 year ..........7...

  • Page 13: Preface

    In the interest of continued development, the manufacturer reserves the right to make changes to the vehicle (which will not, however, change the essential features of the type of vehicle described) without updating the present operating instructions at the same time. Dynapac GmbH Wardenburg Ammerländer Strasse 93 D-26203 Wardenburg / Germany...

  • Page 14: General Safety Instructions

    Failure to observe this information, prohibitions and instructions can result in life- threatening injuries! The "Guidelines for the Correct Use and Application of Paver Finishers" compiled by Dynapac must also be observed!

  • 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

    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! Consult the Dynapac Service Department Fire!, naked flames and smoking are prohibited! Do not switch!

  • 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

    - damage occurrs through malfunctions caused by improper use and incorrect oper- ation. - repairs or manipulations are carried out by persons who are neither trained nor au- thorised accordingly. - accessories or spare parts are used that cause damage and which are not ap- proved by Dynapac. V 10...

  • 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.

  • Page 27: B Vehicle Description

    B Vehicle description Application The Dynapac SD2500C / SD2500CS paver finisher is a paver finisher with a caterpil- lar 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...

  • Page 28: Description Of Assemblies And Functions

    Description of assemblies and functions Item Designation Material compartment (hopper) Push roller crossbar for truck docking Push roller crossbar for truck docking, hydraulically extendable 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...

  • 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. The stage IV engine complies with the latest emissions standards and helps to re- duce diesel consumption and improve the working environment. The exhaust gas aftertreatment system consists e.g.
  • 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 to improve material transport, each of the lateral covers of the hopper can be hydraulically moved.
  • Page 32 Levelling/slope control system: The slope control system (o) can be used to reg- ulate the traction point on 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! - Never stand in the danger zone of the vehicle! - 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 Screed 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 if the control and safety devices are functioning perfectly and if the protective equipment is fitted correctly.

  • 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 15°...

  • Page 38: Weights Sd2500C (All Weights In T)

    Weights SD2500C (all weights in t) Paver finisher without screed Approx. 13.2 - 14.8 Paver finisher with screed: - V5100 Approx. 16.5 - 18.0 With extension parts for max. working width, additionally max.: With filled hopper Approx. 15.0 Additionally max.

  • Page 39: Performance Data Sd2500C

    Performance data SD2500C V5100TV(E) 2.55 2.05 5.10 8.80 V5100TV 2.55 2.05 5.10 8.80 V6000TV(E) 3.00 2.50 6.00 9.00 V6000TV 3.00 2.50 6.00 9.00 Transport speed 0 - 4 km/h Operating speed 0 - 28 m/min Paving height -150 - 320 Max.

  • Page 40: Performance Data Sd2500Cs

    Performance data SD2500CS V5100TV(E) 2.55 2.05 5.10 8.80 V5100TV 2.55 2.05 5.10 8.80 V6000TV(E) 3.00 2.50 6.00 9.70 V6000TV 3.00 2.50 6.00 9.70 R300TV(E) 3.00 10.00 R300TV 3.00 10.00 Transport speed 0 - 4 km/h Operating speed 0 - 28 m/min Paving height -150 - 320...

  • Page 41: Travel Drive/Traction Unit

    Two separately driven caterpillar drives with rub- Drive unit ber grouser chains Turning capacity Turning on the spot Speed See above Engine SD2500C Make/type Cummins QSB 6.7-C173 Version 6-cylinder diesel engine (water-cooled) Performance 129 kW / 175 hp (at 2200 rpm)

  • Page 42: Hydraulic System

    5.11 Hydraulic system Hydraulic pumps via distribution gear Pressure generation (directly flanged to the engine) Hydraulic circuits for: - Travel drive - Auger - Conveyor Pressure distribution - Tamper / vibration - Operating functions - Fan - Clutch - Separate hydraulic circuits for options Hydraulic oil reservoir - volume (See chapter F) 5.12...

  • Page 43: Screed Lifting Device

    5.15 Screed lifting device At standstill: - Screed stop - Screed stop with pretensioning (max. pressure 50 bar) Special functions During paving: - Screed charging - Screed relieving (max. pressure 50 bar) Mechanical grade control Levelling system Optional systems with and without Slope control system 5.16 Electrical system...

  • Page 44: Location Of Instruction Labels And Identification Plates

    Location of instruction labels and identification plates CAUTION Danger from 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 machine personnel must have read and understood the safety, operating and maintenance instructions for the ma- chine before the machine is put into op- eration! Failure to comply with the operating and warning instructions can cause severe or fatal injuries.
  • Page 48 Pictogram Meaning Warning - Danger of crushing fingers and hands with moving, accessible machine parts! Crushing points can cause severe inju- ries 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 res- ervoir 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 instruc- tions! Warning - Danger from tyres filled with water! Handling tyres filled with water incorrect-...

  • 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. Diesel fuel Position of the filling point.
  • 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. Gearbox oil Position of the filling and control 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 Pictogram Meaning Wear ear protection devices Do not enter the area! Do not spray the area or part 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 inflamma- tions. Avoid contact with the human body, also avoid inhaling the vapours and seek medical 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 screed lock only at crown adjustment "zero". Screed lock only for transportation! Do not enter or work under screed only secured with screed lock for transportation! - Caution - 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 func- tions are switched on. Always observe the operating instruc- tions! B 30...

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

    Identification label for the paver finisher (41) Item Designation Paver finisher type Year of construction Operating weight, incl. all extension parts, in kg Maximum permitted total weight in kg Max. permissible load on the front axle, in kg Max. permissible load on the rear axle, in kg Rated performance in kW Product identification number (PIN) Serial number (empty)

  • Page 58: Standards

    EN standards Continuous sound pressure SD2500C, 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 protection devices are used, hearing can be impaired.

  • Page 59: Continuous Sound Pressure Sd2500Cs, Cummins Qsb 6.7-C200

    Continuous sound pressure SD2500CS, Cummins QSB 6.7-C200 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 protection devices 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 60: Vibration Acting On The Entire Body

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

  • Page 61: C11 Transportation

    C 11 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 62: 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 63 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safe- guards. Lift the screed. Extend levelling cylinders completely. Retract the screed parts until the screed matches the basic width of the paver fin- isher.

  • Page 64: 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 65: 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 11 5...

  • Page 66: Lashing Equipment

    Lashing equipment Use the load securing equipment, lashing straps and chains belonging to the vehicle. Additional shackles, eyebolts, edge safeguards and non-slip mats may be needed, depending 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 handtight (100-150daN).

  • Page 67: 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 68: Preparing The Machine

    Preparing the machine After the machine has been positioned on the low-bed trailer, the following prepara- tions 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 69: Securing The Load

    Securing the load Securing at the sides Diagonal lashing secures the paver finisher at the side 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 70: 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 71: 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 72: Control Panel Transport Safeguard

    Control panel transport safeguard: - Release the latch (1) to move the control platform. The latch must be fixed when the control platform is set in the middle and during transport. To be able to set the lock, the platform must be positioned centrally above the vehicle frame..

  • Page 73: After Transportation

    After transportation - Remove the attachment devices. - Raise the protective roof : See section entitled "Protective roof" - Lift the screed to the transportation position. - Start the engine and drive from the trailer at a low engine/traction speed. - Park the paver finisher in a secure spot, lower the screed and switch off the engine.

  • Page 74: 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 in lowest...
  • Page 75 The protective roof can be raised and lowered with a manual hydraulic pump. The exhaust pipe is lowered or raised to- gether with the roof. "Screw lock" version (A) - Connect the pump lever (1) to the pump (2). - Lower the roof: The locks (3) on both sides of the roof must be released.

  • Page 76: 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 77 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safe- guards. Lift the screed. Extend levelling cylinders completely. Retract the screed parts until the screed matches the basic width of the paver fin- isher.

  • Page 78: Driving Mode

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

  • Page 79: Loading By Crane

    Loading by crane WARNING Danger from suspended loads Crane and/or raised vehicle can tilt when lifted and cause severe to fatal 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.
  • Page 80 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 the area of the drive unit's rear reversing roller (3).
  • Page 81 See section entitled "Protective roof" - Attach lifting gear to the four attachment points (1, 2). The max. permissible attachment point load 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 11 21...

  • Page 82: 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 83 Two high-pressure cartridges (6) are located on both of the travel drive pumps (5). The following activities must be carried out to activate the towing function: - Loosen lock nut (7) half a turn. - Screw in the bolt (8) until increased re- sistance occurs.

  • Page 84: 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 85: 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 86 C 11 26...

  • Page 87: D11 Operation

    D 11 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 be- neath the paver finisher or within its danger area! - Do not start the engine or do not actuate any controls when this is expressly forbid- den!
  • Page 88 DANGER Danger due to improper operation Improper operation of the vehicle can cause severe to fatal injuries! - The vehicle may only be used in the stipulated manner for its intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves familiar with the contents of the operating instructions.

  • Page 89: Controls

    Controls Operating panel All detent switch functions which may pose a risk on starting the diesel engine (auger and conveyor conveying function) are set to the STOP function in the case of EMER- GENCY STOP or restarting the control system. If settings are changed when the die- sel engine is stopped ("AUTO"...
  • Page 90 D 11 4...
  • Page 91 Item Designation Brief description In the case of an emergency (danger to persons, possible col- lision, etc.), press in the button! Pressing the emergency stop button switches the engine, the drives and the steering system off. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents! button...
  • Page 92 D 11 6...
  • Page 93 Item Designation Brief description For switching on the paver finisher functions and for continu- ously regulating the road speed – forward or reverse. Zero position: engine at idling speed; no travel drive; - To swivel the drive lever out, release by pulling the handle Depending on the position of the drive lever, the following func- tions can be activated: 1st position:...
  • Page 94 D 11 8...
  • Page 95 Item Designation Brief description For setting the maximum speed that can be reached when the drive lever is at its stop. The scale roughly matches the speed in m/min (during paving). Travel drive prese- The vehicle must not travel at max. transport speed lector when the hopper is full! The vehicle speed cannot be reduced to "0"...
  • Page 96 D 11 10...
  • Page 97 Item Designation Brief description Button with detent switch function and LED feedback: Working - For switching on the front working lights lights, front - Switch OFF by pressing the button again ON / OFF (o) Avoid dazzling other road users! Button with detent switch function and LED feedback: Working - For switching on the rear working lights...
  • Page 98 D 11 12...
  • Page 99 Item Designation Brief description Pushbutton function with LED feedback: - To move the control panel to the left The platform lock must be released before moving the Move control plat- control platform! form to the left On actuation, note danger zones of moving parts of the vehicle! Pushbutton function with LED feedback: - To move the control panel to the right...
  • Page 100 D 11 14...
  • Page 101 Item Designation Brief description Pushbutton function with LED feedback: - To hydraulically extend the screed lock. Extend screed l ock (o) Before retracting and extending, lift the crossbeams slightly over the locking bolts (lift screed)! Pushbutton function with LED feedback: - To hydraulically retract the screed lock.
  • Page 102 D 11 16...
  • Page 103 Item Designation Brief description Detent switch function and LED feedback: - for activating / manual trigger of particulate filter regeneration. Particulate filter Particulate filter regeneration does not start when the regeneration, soot level in the particulate filter is too low. manual (o) Particulate filter regeneration takes about 45 minutes.
  • Page 104 D 11 18...
  • Page 105 Item Designation Brief description Pushbutton function: - To close the left half of the hopper Separate actuation (o): Is required when paving in spaces where there is only Left hopper limited space at one side or when obstacles obstruct Close truck unloading.
  • Page 106 D 11 20...
  • Page 107 Item Designation Brief description Pushbutton function: - To extend the left half of the screed This function is not used in vehicle configurations with a Left screed screed which cannot be extended. Extend On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - To extend the right half of the screed...
  • Page 108 D 11 22...
  • Page 109 Item Designation Brief description Pushbutton function: - To manually trigger the conveying function for the left half of the auger, conveying direction outwards. Left auger "MANUAL" For manual triggering, the auger function must be conveying direction switched to "AUTO" or "MANUAL" outwards On manual triggering, the automatic function is overrid- den with reduced delivery capacity.
  • Page 110 D 11 24...
  • Page 111 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left conveyor is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switch- es in the material tunnel. - Switch OFF by pressing the button again Left conveyor The function is shut off by pressing the EMERGENCY...
  • Page 112 D 11 26...
  • Page 113 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left conveyor is switched on continuously with full delivery capacity, without material control via the limit switches in the material tunnel. - Switch OFF by pressing the button again. - Reverse conveyor: Keep button pressed for approx.
  • Page 114 D 11 28...
  • Page 115 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left half of the auger is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switch- - Switch OFF by pressing the button again Left auger The function is shut off by pressing the EMERGENCY...
  • Page 116 D 11 30...
  • Page 117 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left half of the auger is switched on continuously with full delivery capacity, without material control via the limit switches. - Switch OFF by pressing the button again Left auger The function is shut off by pressing the EMERGENCY "MANUAL"...
  • Page 118 D 11 32...
  • Page 119 Item Designation Brief description Button with detent switch function and LED feedback: - For manual actuation of the levelling cylinders when the automatic levelling system is switched off. - Switch OFF by pressing the button again The corresponding switch on the remote control must be switched to "Manual"...
  • Page 120 D 11 34...
  • Page 121 Item Designation Brief description Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction. Retract / lift on left On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction.
  • Page 122 D 11 36...
  • Page 123 Item Designation Brief description Pushbutton function with LED feedback: - For lifting the screed (LED ON) for switching off the "Screed floating position" function Check whether the screed transport safeguard is insert- Lift screed On actuation, note danger zones of moving parts of the vehicle! Button with detent switch function and LED feedback The main function switch must be set to the OFF posi-...
  • Page 124 D 11 38...
  • Page 125 Item Designation Brief description Detent switch function and LED feedback: Filling function for the paving process. The diesel engine's speed is increased to the preselect- ed nominal speed and all conveying functions set to "Au- tomatic" (conveyor and auger) are engaged. The main function switch must be set to the OFF po- sition.
  • Page 126 D 11 40...
  • Page 127 Item Designation Brief description Detent switch function and LED feedback: - To lock all functions relevant to paving. Despite "Au- to" settings in the individual functions, these are not activated when the drive lever is swivelled out. - Switch OFF by pressing the button again. Main function switch The preset vehicle can be relocated and released at the...
  • Page 128 D 11 42...
  • Page 129 Item Designation Brief description Button with detent switch function and LED feedback: - For relieving the screed to influence the traction force and compaction ratio. Screed relieving - Switch OFF by pressing the button again or switching between screed relieving and screed charging. To preset the hydraulic oil pressure, switch this button and the "Set-up mode"...
  • Page 130 D 11 44...
  • Page 131 Item Designation Brief description Buttons with detent switch function and LED feedback: - To preselect the speed level - Travel drive transport speed fast (hare) On restarting, the speed is set to operating speed (tortoise). Buttons with detent switch function and LED feedback: - To preselect the speed level - Travel drive operating speed.
  • Page 132 STOP D 11 46...
  • Page 133 - Indicator light goes off + indicator light "Engine malfunction" (78) is on all the time. Particulate filter regeneration is no longer possible. Operation must be stopped immediately. Consult the Dynapac Service Department. Indicator lamp Lights up when particulate filter regeneration is deactivated. particulate filter...
  • Page 134 STOP D 11 48...
  • Page 135 Item Designation Brief description Indicator lamp Lights up when the hydraulic filter needs replacing. hydraulic filter Replace filter element acc. to Maintenance Instructions! not used not used 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 The HEST lamp lights up when the exhaust gas temperature...

  • Page 136: Special Functions

    Special functions Reversible conveyor D 11 50...
  • Page 137 The conveyor's direction can be reversed in order to slightly reverse any paving ma- terial which may be positioned just in front of the auger. This enables e.g. material losses to be avoided during transportation. - Switch the main function switch (1) to the "off" position (LED off). - Keep one or both buttons (2) depressed for approx.
  • Page 138 D 11 52...

  • Page 139: Remote Control

    Remote control Depending on the side of the vehicle, the button blocks (A) and (B) are assigned to either the auger or the conveyor control system. The relevant element which is con- trolled is indicated by an illuminated symbol (C). Important! Do not disconnect remote controls during operation! This causes the paver finisher to be shut down! D 11 53...
  • Page 140 D 11 54...
  • Page 141 Item Designation Brief description In the case of an emergency (danger to persons, possible col- lision, etc.), press in the button! Pressing the emergency stop button switches the engine, the drives and the steering system off. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents! button...
  • Page 142 D 11 56...
  • Page 143 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the corresponding half of the auger is switched on continuously with full deliv- ery capacity, without material control via the limit switches. Auger - Switch OFF by pressing the button again "MANUAL"...
  • Page 144 D 11 58...
  • Page 145 Item Designation Brief description Pushbutton function: - Plus/minus buttons for adjusting the delivery capacity. - The delivery capacity is slowed down or speeded up Auger delivery depending on the length of time for which the button capacity is pressed. For adjustment purposes, the auger function must be switched to "AUTO"...
  • Page 146 D 11 60...
  • Page 147 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the corresponding half of the conveyor is switched on continuously with full de- livery capacity, without material control via the limit switches. Conveyor - Switch OFF by pressing the button again "MANUAL"...
  • Page 148 D 11 62...
  • Page 149 Item Designation Brief description Pushbutton function: - Plus/minus buttons for adjusting the delivery capaci- - The delivery capacity is slowed down or speeded up Conveyor depending on the length of time for which the button delivery capacity is pressed. For adjustment purposes, the conveyor function must be switched to "AUTO"...
  • Page 150 D 11 64...
  • Page 151 Item Designation Brief description Button with detent switch function and LED feedback: Operating mode - Operating mode "AUTO" (LED ON): levelling levelling engages automatically when the drive lever "AUTO" / is swivelled out for paving operation. "MANUAL" - Operating mode "MANUAL" (LED OFF): left levelling switched off.
  • Page 152 D 11 66...
  • Page 153 Item Designation Brief description Button with detent switch function and LED feedback: Operating mode - Operating mode "AUTO" (LED ON): levelling levelling engages automatically when the drive lever "AUTO" / is swivelled out for paving operation. "MANUAL" - Operating mode "MANUAL" (LED OFF): right levelling switched off.
  • Page 154 D 11 68...
  • Page 155 Item Designation Brief description Pushbutton function: - For manual actuation of the levelling cylinders on the corresponding side of the vehicle when the Levelling cylinder automatic levelling system is switched off (LED OFF). manual On adjustment, note the levelling display in the remote control display! Pushbutton function: - To retract and extend the screed half on the corre-...
  • Page 156 D 11 70...

  • Page 157: D21 Operation

    D 21 Operation Operation of the input and display terminal Button layout on the display - (A) Encoder (rotary actuation): - To scroll in the menu - To select various parameters within a menu - To change parameters - (B) - (G) Function buttons: - To trigger the commands assigned in the display area (H) - To select the menus assigned in the display area (H) D 21 1...

  • Page 158: Command Symbols

    Command symbols Command Symbol in the display Edit selected parameters. Adopt edited parameters. For error messages: confirms message and goes straight to the error list. Exit menu. Return to the previous menu. Edited parameters are not adopted. Cancel. Edited parameters are not adopted. Return to start menu.

  • Page 159: Menu Operation

    Menu operation D 21 3...
  • Page 160 Example: Screed heater menu - Turn the encoder (A) until the desired menu appears in the display area (H). - Press button (E) to call up the heater menu. - Turn the encoder (A) again until the selection field (red frame) is positioned over the desired parameter to be adjusted.

  • Page 161: Main Menu

    Main menu Display and function menu Displays: - (1) Speed: - paving operation (m/min) - driving mode (km/h) - (2) Actual temperature of the screen heater (°C) - (3) Fuel gauge - (4) Conveyor filling level left/right - (5) Distance travelled counter (m) - (6) Operating hours (h) - (7) Time of day (hh/mm) - (8) Used paving parameters from the parameter memory...
  • Page 162 Snow flake: hydraulic oil temperature too low! Bring vehicle up to tempera- ture with stationary acceleration! The engine speed cannot be increased when the hydraulic oil temperature is too low! Red cross: Emergency mode active. Hare with wheels: Trailer (o) connected. When the trailer (o) is connected, all screed, auger and levelling functions are locked, apart from lifting/lowering screed.
  • Page 163 Functions: Pressing encoder (A) calls up the available menus or func- tions in the start screen. The menus are called up by pressing the adjacent func- tion button. Pressing the adjacent func- tion button activates or deac- tivates the functions. If the relevant symbol is covered with a red cross, the function is deactivated.
  • Page 164 Functions: - (26) "Eco mode" function - The engine speed is constantly regulated to 1600 rpm. - (27) "Automatic steering unit" function - The vehicle is steered automatically via corresponding sensing along a reference (e.g. cable). When the automatic steering unit is activated, the steering potentiometer is deactivated.
  • Page 165 Active / inactive display function Pressing the adjacent func- tion button activates or deac- tivates the functions. If the relevant symbol is cov- ered with a red cross, the function is deactivated. D 21 9...

  • Page 166: Engine Speed" Menu

    "Engine speed" menu Menu for showing and adjust- ing the engine speed. Press the adjacent function button (B) to call up the menus. Set-up menu Engine speed - (1) Nominal speed display and adjustment parame- ters - (2) Actual speed display Press encoder (A) to start the editing menu.

  • Page 167: Measured Value Display Drive Engine

    Measured value display Drive engine Menu for querying various drive engine measured val- ues. - (1) On-board voltage (V) - (2) Engine coolant temperature (°C) - (3) Engine oil pressure (bar) - (4) Operating hours (h) - (5) Fuel consumption (l/h) D 21 11...

  • Page 168: Paving Parameters" Menu

    "Paving parameters" menu Menu for showing and adjust- ing the paving parameters. Press the adjacent function button (B) to call up the men- Set-up menu Paving parameters - (1) Left conveyor speed (%) display and adjustment parameters - (2) Right conveyor speed (%) display and adjustment parameters - (3) Left auger speed (%)

  • Page 169: Paving Parameters Load

    Paving parameters Save Menu for saving the personal vehicle settings. Preferred parameters or pa- rameters configured to the paving material can be saved in the memory for later use. Memory locations: Surface course: 1,2 Binder course: 3,4 Base course: 5 The memory locations may only be used for the intended type of course! The saved machine parameters are coordinated to the respective type of course! Press the corresponding function button to select the memory location.

  • Page 170: Actual Value Display Auger, Conveyor, Tamper, Vibration(O)

    Actual value display Auger, conveyor, tamper, vibration(o) Menu for checking the actual auger, conveyor, tamper and vibration speeds. - (1) Left conveyor (%) - (2) Right conveyor (%) - (3) Left auger (%) - (4) Right auger (%) - (5) Tamper (%)(o) - (6) Vibration (%)(o) Set-up menu Screed heater...

  • Page 171: Menu Paving Area / Automatic Steering Unit

    Menu Paving area / automatic steering unit Menu for retrieving and reset- ting the current paving area, for showing the steering mon- itoring resetting steering monitoring refer- ence. - (1) Current paving distance - Reset - set value to zero: button (C).

  • Page 172: Set-Up Menu - "Delayed Screed Start

    Menu "Machine settings memory" Menu for saving/retrieving the machine settings for the spe- cific construction site. The machine settings for - paving thickness - conveyor and auger speeds - tamper vibration speed - screed heater setting can be saved during work breaks / at the end of the working day and retrieved from the memory when starting up again.

  • Page 173: Menu "Camera Display

    Menu "Camera display" Machine parts partly con- cealed from view can be displayed by the cam- era system. When this function is called up, display camera 1 ap- pears. - Show camera 2 display: button (B). - Show camera 1+2 dis- play: button (C).

  • Page 174: Menu "Front Wheel Drive" (O)

    Menu "Front wheel drive" (o) Display of the power provided for the front wheel drive. - (1) Power display left front wheel drive. - (2) Power display right front wheel drive. D 21 18...

  • Page 175: Menu - "Error Memory

    Menu - "Error memory" Menu for retrieving existing error messages. - (1) Number of warning messages. - Warning messages re- trieval: button (C). - (2) Number of warning messages with engine stop. - Warning messages re- trieval: button (D). - (3) Number of warning messages drive engine. - Warning messages retrieval: button (E).

  • Page 176: Display "Engine Error Messages

    Display "Engine error messages" Display of existing error mes- sages in a table. This is shown separately from warning messages and error messages with engine stop. - (1) SPN code. - (2) FMI code. - (3) OC error frequency. All error messages can be identified in the section "Error codes drive engine".
  • Page 177 Menu "System information & basic settings" Display of the following infor- mation: - (1) Time (hh/mm/ss) - (2) Date (dd/mm/yyyy) - (3) Software version, travel drive computer - (4) Software version, terminal - (5) Operating hours (h) If consultation with Technical Support is required for your vehicle, always specify the software version! The following set-up menus can be called up directly: - (6) "Service"...

  • Page 178: Menu "Service

    Menu "Service" Password-protected menu for various service settings. D 21 22...

  • Page 179: Set-Up Menu "Levelling

    Set-up menu "Levelling" - (1) Left levelling display and adjustment parame- ters - (2) Right levelling display and adjustment parame- ters - Internal levelling: parameter 0 - External levelling: parameter 1 When "External levelling" is selected, the toggle switches of the system's own remote control remain active! Set-up menu "Screed type"...

  • Page 180: Set-Up Menu "Terminal Settings

    Set-up menu "Terminal settings" - (1) Button day time bright- ness (%) display and ad- justment parameters - (2) Button night time bright- ness (%) display and ad- justment parameters Setting range 0-100% When the working lights are switched on, the system au- tomatically switches to the night time operation settings.

  • Page 181: Terminal Error Messages

    Terminal error messages The following error messages appear directly in the display when corresponding er- rors occur. Press (B) to confirm and call up the corresponding error list. Error No. / meaning Display Error message "Stop" - Display for all error mes- sages with machine stop.

  • Page 182: Drive Engine Error Codes

    Drive engine error codes STOP If a fault has been detected on the drive engine, this is indicated by the corresponding warning lamp (1) / (2) and appears at the same time as a warning message in the display. The error message that can be called up in the display contains several numerical codes, which uniquely define the fault af- ter decoding.
  • Page 183 Example: STOP Explanation: Warning light and display signal a serious fault on the drive engine with automatic or necessary engine shut-down. Display: SPN: FMI: Cause: Cable break on sensor for rail pressure. Effect: Engine shut-down. Frequency: Fault occurs for the 1st time. Notify customer service of the error number displayed on your paver finisher;...

  • Page 184: Error Codes

    Error codes D 21 28...
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  • Page 191: Menu Structure Of The Setting And Display Menus

    Menu structure of the setting and display menus The following illustration shows the menu structure and serves to simplify operation and the procedure in the case of various settings and displays. D 21 35...
  • Page 192 D 21 36...
  • Page 193 D 30 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 the danger 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 194 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 in lowest...
  • Page 195 The protective roof can be raised and lowered with a manual hydraulic pump. The exhaust pipe is lowered or raised to- gether with the roof. "Screw lock" version (A) - Connect the pump lever (1) to the pump (2). - Lower the roof: The locks (3) on both sides of the roof must be released.
  • Page 196 Ladder The ladder is used to access the control platform. The ladder can be secured in the top po- sition: - 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 197 Control platform, moveable (o) D 30 5...
  • Page 198 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 transporters, the control platform must be secured in the central position! Actuating the platform shift function: see operating panel.
  • Page 199 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 200 Protective cabin (o) D 30 8...
  • Page 201 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 area. - 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 202 .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 203 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 neces- sary.
  • Page 204 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 205 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. - Weight setting (1): The relevant driv- er's weight should be set by turning the weight adjustment lever when the...
  • Page 206 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 207 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 must only be carried out according to the instructions (see section "Starting the paver finisher, ex- ternal starting (starting aid)".
  • Page 208 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 han- dle above the hopper cylinder's piston rod.
  • Page 209 Screed lock, hydraulic (o) The screed locks must additionally be extended on both sides of the vehicle prior to transportation with the screed lifted. Transportation with unsecured screed leads to a risk of accidents! - Lift the screed. - Activate the function on the operating panel.
  • Page 210 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 211 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...
  • Page 212 LED working light (o) There are two LED spotlights (1) at the front of the machine and also at the back. Always align the working lights to avoid dazzling the operating personnel or other road users! D 30 20...
  • Page 213 500 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 other road users! Danger of burning! The working lights get very hot! Do not touch working lights that are switched on or hot!
  • Page 214 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 au- ger. - Actuate the ratchet lever (2) - Set the desired height by alternatingly actuating the left and right ratchets.
  • Page 215 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 216 - 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 217 Manual separator fluid spray (o) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. - 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 218 Separator fluid spraying system (o) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. - Connect the spray hose (1) with quick- action coupling (2). Only switch on the spraying system when the diesel engine is running; other- wise, the battery will be discharged.
  • Page 219 Conveyor limit switches - PLC ver- sion The mechanical conveyor limit switches (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 materi- al has roughly reached the area below the auger tube.
  • Page 220 Conveyor limit switches - conven- tional version The mechanical conveyor limit switches (1) control the material flow on the rele- vant half of the conveyor. The conveyors should stop when the material has roughly reached the area below the au- ger tube.
  • Page 221 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 (3) and adjust the sensor's angle.
  • Page 222 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 223 24 volt / 12 volt sockets (o) A socket (1) is located behind the left/ right seat consoles. Additional working lights can be con- nected here, for example. - Right seat console: 12V socket - Left seat console: 24V socket Voltage is present when the main switch is switched on.
  • Page 224 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", "Op- eration"). - For pressure indication, see manome- ter (3). Pressure control valve for paving stop with relieving This is used to set the pressure for "Screed control with paver finisher stop - floating stop with relieving".
  • Page 225 Central lubrication system (o) The central lubrication system is activat- ed in automatic mode as soon as the drive engine is started. - Pumping time: 4 min - Pause time: It is prohibited to change the factory-set durations of pumping and break without consulting the technical customer serv- ice! Changing the duration of lubrication and...
  • Page 226 Lane clearer (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. Swivelling the lane clearers: - Swivel the lane clearer (1) up and se- cure in the uppermost position with a shackle (2).
  • Page 227 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 228 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 229 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 finish- On actuation, ensure that nobody is in...
  • Page 230 Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with fire extinguisher (2) oper- ation. Observe the inspection intervals 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 38...
  • Page 231 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 engage there - Slide the rotary beacon with tube (3) to...
  • Page 232 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 233 Illuminated balloon (o) 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 234 Danger due to electric shock. Voltage flashover poses the risk of severe or fatal injuries! Heed the following safety distances to high-voltage lines: < 125KV 5m > 125KV 15m The illuminated balloon must not be operated if the electric supply cables or connectors are damaged.
  • Page 235 When equipped with an electric screed, it is possible for the lamps to flicker irregularly during the heating-up phase with simultaneous 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. Maintenance Occasionally clean or replace the air filter (9) beneath the connection plate.
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  • Page 237 D 41 Operation Preparing for operation Required devices and aids To avoid delays on site, check before starting work whether or not the following devices 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 - Two filled propane gas bottles...
  • Page 238 CAUTION Danger due to restricted vision Restricted vision poses a risk of injury! - Before starting work, arrange the intended driver's seat so as to warrant 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 239 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 240 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 Screed covers and walkways and folded down accordingly. Check that the side shields and the cov- ers fit firmly.
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  • Page 242 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 hours counter to determine whether further maintenance work should be conducted.
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  • Page 244 External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24 V system - Additional 24 V battery - Start device that is suitable for external starting (24 V/90 A).
  • Page 245 - 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 (12) to start the engine. Do not let the starter run perma- nently for more than 30 seconds;...
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  • Page 247 After starting To increase the engine speed: - Press button (65) to increase engine speed. The engine speed is increased to the preset value. Let the paver finisher warm up for approx. 5 minutes if the engine is cold. D 41 11...
  • Page 248 STOP D 41 12...
  • Page 249 Observe indicator lamps The following indicator lamps must be observed under all circumstances: For further possible faults, see Engine operating instructions. Engine coolant temperature check (79) 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 250 STOP D 41 14...
  • Page 251 Oil pressure indicator lamp for the travel drive (87) - Must go out after starting. If the lamp does not go out: Do not switch on the travel drive! Otherwise, the entire hydraulic system could be damaged. When the hydraulic oil is cold: - Activate set-up mode function (65).
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  • Page 253 Preparation for transportation - Close the hopper with switch (36)/(37). - Engage both hopper transport safeguards. - Lift the screed completely using switch (62), set the crossbeam lock. - Turn the travel drive preselector (15) to zero. - Activate set-up mode function (65). - Fully extend the levelling cylinders with switch (56),(58)/(59).
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  • Page 255 Driving and stopping the paver finisher - Set the fast/slow switch (72) to "Hare". - Set the preselector (15) to mark 10. - For driving, carefully tilt the drive lever (13) forward or backward according to the drive direction desired. - Use the preselector (15) to regulate the speed.
  • Page 256 Preparations for paving Separator fluid Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator fluid. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). F0147_A1.TIF Screed heater system Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem- perature) before paving begins.
  • Page 257 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 accord- ingly.
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  • Page 259 Loading/conveying material - Button (68) has to be switched off. - Use switch (36)/(37) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (54)/(55) and the conveyor (50)/(51) to "Auto". - Activate function (64) to fill the vehicle for the paving process.
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  • Page 261 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 Tortoise-operating speed...
  • Page 262 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 - Uniform material transport and distribution or supply to the screed;...
  • Page 263 Paving with "screed control at paving stop" and "screed charging/relieving" General The screed hydraulics can be influenced in three different ways to attain optimum paving results: - Paving stop + 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.
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  • Page 265 Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Function (70) Relieving (screed "lighter") Function (71) Charging (screed "heavier") The "Screed charging and relieving" functions are only effective when the paver fin- isher moves. According to the activated function, the paver finisher is automatically switched to "paving stop + relief"...
  • Page 266 The pressure to be applied depends on the load-bearing capacity of the material. If necessary, the pressure must be readjusted or changed as required during the first stops until the lower edge of the screed no longer leaves any marks when the finisher moves on again.
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  • Page 269 Adjusting the pressure Pressure adjustments can only be made while the diesel engine is running. There- fore: - Start the diesel engine and turn the traction controller (15) back to zero (precaution against inadvertent advancing). - Activate the "floating position" using switch (63). For screed charging/relieving: - Set the drive lever (13) to the centre position.
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  • Page 271 Interrupting/terminating operation During breaks (e.g. the material supply truck is late) - 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.
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  • Page 273 When work is finished - Run the paver finisher empty and stop it. - Lift the screed using switch (62), set the crossbeam lock. - Retract the screed parts to the basic screed width and lift the auger. Where appli- cable, completely extend the levelling cylinders.
  • Page 274 Malfunctions Problems during paving Problem Reason - 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 275 Problem Reason - material temperature Cracks in the layer - cold screed (centre strip) - bottom plates are worn or warped - wrong crowning - material temperature - screed extendable parts are incorrectly installed Cracks in the layer - limit switch is not correctly set (outer strip) - cold screed - bottom plates are worn or warped...
  • Page 276 Malfunctions on the paver finisher or screed Malfunction Reason Remedy See operating instructions for the At the diesel engine Various engine See "External starting" (start Batteries empty Diesel engine does assistance) not start Various see "Towing" Tamper is obstructed by cold Properly heat the screed bitumen Hydraulic oil level in the tank...
  • Page 277 Malfunction Reason Remedy Control valve is defective Replace Hoppers lowers inad- Leaking seals of the hydrau- vertently Replace lic cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot be Screed relieving or charging Switch must be in the centre lifted is switched on position...
  • Page 278 Malfunction Reason 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 not Electro-hydraulic servo unit Replace the servo unit work of the pump defective Check and adjust if necessary...
  • Page 279 E 10 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, au- ger, 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...
  • Page 280 Distribution auger Height adjustment Depending on the mix of materials, the set height of the distribution auger (1) – measured from its bottom edge – should lie above the material layer height. Grain sizes up to 16 mm Example: Paving thickness 10 cm F0130_A1.TIF Min.
  • Page 281 Mechanical adjustment with ratchet (o) - Set the ratchet direction lever (1) to the clockwise or anti-clockwise direc- tion. Turning anti-clockwise lowers the auger, turning clockwise lifts the au- ger. - Set the desired height by alternatingly adjusting the right-hand and the left- hand side.
  • Page 282 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 283 - 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 284 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 Operating instruc- tions for the screed: – 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 285 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). - Insert the auger shaft extension into the auger shaft.
  • Page 286 Mounting the outer auger bearing - Dismantle the assembly parts (1) of the adjacent auger blade, remove plug (2). - Insert 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 287 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 288 Auger extension chart Symbol Meaning - Auger blade 160 mm - (160L) left - Auger blade 160 mm 160L 160R - (160R) right - Auger extension part 320 mm - (320L) left - Auger extension part 320 mm 320L 320R - (320R) right - Auger extension part 640 mm...
  • Page 289 Symbol Meaning Outer auger bearing Auger end bearing E 10 11...
  • Page 290 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 291 Auger upgrading, working width 5.06 m 960 L 320 R 320 L 960 R Auger upgrading, working width 5.70 m 640 L 960 L 960 R 640 R E 10 13...
  • Page 292 Auger upgrading, working width 6.34 m E 10 14...
  • Page 293 Auger upgrading, working width 6.98 m E 10 15...
  • Page 294 Auger upgrading, working width 7.62 m E 10 16...
  • Page 295 Auger upgrading, working width 8.26 m E 10 17...
  • Page 296 Auger upgrading, working width 8.90 m E 10 18...
  • Page 297 Mounting the auger brace E 10 19...
  • Page 298 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 299 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 300 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 retraction.
  • Page 301 Hopper scraper To reduce the gap between hopper and machine frame, the hopper scrapers (1) must be adjusted at both hopper halves. - Loosen the mounting screws (2). - Adjust a gap of 6 mm across the whole length of the scraper. - Retighten the mounting screws (2) properly.
  • Page 302 Crossbeam guide To warrant correct guidance of the crossbeams, the guide plates (1) at both sides of the vehicle must be adjusted to the prevailing paving conditions (e.g. positive or negative crowning, etc.). - Loosen screw (2) and remove screws (3). - Adjust guide plate to the required size (basic setting 25mm).
  • Page 303 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 304 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 retaining plate (3).
  • Page 305 Mounting the sensor arm - Position the sensor arm mounting (1) on the corresponding journal of the screed side board. - Tighten the pin (2) so that the sensor arm is just still able to swivel. The sensor arm can be secured on the side board with the lock (3).
  • Page 306 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 ref- erence.
  • Page 307 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 308 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 309 Mounting the big ski bracket on the crossbeam The entire big ski construction is mount- ed laterally on the crossbeams. To do so, the two crossbeam brackets must first be mounted. The crossbeam brack- et design differs slightly depending on the paver finisher which is used.
  • Page 310 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 311 Mounting the centre element MBS6b.bmp 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 312 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 313 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 it would be found during normal operation (approx.
  • Page 314 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 by loosening the 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 315 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 316 Connection diagram The three sensors are connected to the distributor box and the distributor to the machine according to the following scheme. - Sensors - Front (1) - Centre (2) - Rear (3) - Distributor box (4) - Machine interface (5) E 10 38...
  • Page 317 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 318 - 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 319 Automatic steering unit E 10 41...
  • Page 320 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 321 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 322 Automatic steering unit operating in- structions - 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 323 Emergency stop during feeder operation If the function is not in use, the bridge connector must be fitted to the corres- ponding socket, as otherwise the travel drive is blocked! E 10 45...
  • Page 324 Limit switch Auger limit switches (left and right) - mounting the 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 325 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, loosen the star handles (4) and adjust the linkage to the re- quired length.
  • Page 326 It is used to take larger volumes of material provided by a feeder. The material bucket may only be used in the following combinations: MH2500 - bucket, short (universal bucket): SD2500C, SD2500CS MH2550 - bucket, long: SD2550C, SD2550CS E 10 48...
  • Page 327 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 49...
  • Page 328 Technical data Dimensions, bucket MH2500 - (short version) 3700 3700 E 10 50...
  • Page 329 Dimensions, bucket MH2550 - (long version) 3690 3690 3000 E 10 51...
  • Page 330 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 52...
  • Page 331 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 332 10.1 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! 10.2 Warning signs Pictogram Meaning - Warning - hot surface - risk of burning! Hot surfaces can cause severe injuries! Keep your hands a safe distance away from the danger area! Use protective...
  • Page 333 10.4 Instructive symbols, prohibitive symbols, warning symbols No. Pictogram Meaning - Do not open - hazard! E 10 55...
  • Page 334 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 335 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 336 Lashing E 10 58...
  • Page 337 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 338 Loading with the crane - MH2500 E 10 60...
  • Page 339 Loading with the crane - MH2550 E 10 61...
  • Page 340 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 341 Lash the bucket in the paver E 10 63...
  • Page 342 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 343 Operation E 10 65...
  • Page 344 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 345 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 346 Screed The Operating instructions for the screed cover all work required for mounting, setting up and extending the screed. Electrical connections Establish the following connections on the rear of the remote control brackets (1) when the mechanical assemblies have been mounted and set up: PLC version: - Auger limit switches (2) - Remote control (3)
  • Page 347 12.1 Machine operation without remote control / side board The machine can only be driven without connected remote control corresponding bridge connectors have been fitted on both sides of the machine. Side board with mounted remote bracket: - Fit bridge connector (1) in the socket of the remote control and secure with cap.
  • Page 348 E 10 70...
  • Page 349 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 350 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 351 F 25 Maintenance review Maintenance review 90 100 F 25 1...
  • Page 352 Maintenance required after the following service hours Assembly Chapter Conveyor q q q q Auger Engine q q q q q q q q Hydraulics Drive units q q q q q q q q q q Electronics Lubrication points Checking/stopping F100 Maintenance required...
  • Page 353 F 31 Maintenance - conveyor Maintenance - conveyor F 31 1...
  • Page 354 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 355 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 356 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 357 - Conveyor deflectors - Conveyor plates - Deflector plates - Conveyor chain reversing rollers - Conveyor drive chain sprockets Your Dynapac customer service will be happy to provide support during maintenance, repair and the replacement of wearing parts! F 31 5...
  • Page 358 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 359 - Conveyor deflectors - Conveyor plates - Deflector plates - Conveyor chain reversing rollers - Conveyor drive chain sprockets Your Dynapac customer service will be happy to provide support during maintenance, repair and the replacement of wearing parts! F 31 7...
  • Page 360 F 31 8...
  • Page 361 F 40 Maintenance - auger assembly Maintenance - auger assembly F 40 1...
  • Page 362 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 363 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 364 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 365 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 366 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 367 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 368 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 369 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 370 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 371 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 372 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 373 F 54 Maintenance - engine assembly Tier 4F (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 54 1...
  • Page 374 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 375 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 376 Interval Maintenance point Note - Engine air filter Check air filter - Engine air filter Dust collector Emptying - Engine air filter Air filter cartridge Clean / 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 377 Interval Points of maintenance Note ® - AdBlue / DEF tank Check filling level ® - AdBlue / DEF tank ® Top up AdBlue / DEF ® - AdBlue / DEF tank Replace suction filter ® - AdBlue / DEF tank Check tank cover ®...
  • Page 378 Interval Maintenance point Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt - Crankshaft ventilation filter Replace filter element - Exhaust system / Inspect diesel oxidation catalytic converter Maintenance Maintenance during the running-in...
  • Page 379 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 380 For filling in the fuel: - Unscrew cap (A). - Fill in fuel through the filling port until the required fill lever is achieved. - Replace the cap (A). Clean the tank and system: - Unscrew the drain plug (B) at the bot- tom of the tank and drain into a collec- tion pan about 1 l fuel.
  • Page 381 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 382 - 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 383 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 384 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 385 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 386 Change extraction filter (o) The air outlet shaft (A) has to be disman- tled first in order to reach the filters. - Open engine hood, remove screws (B) underneath the shaft. - Loosen clips (C) on inside of frame and remove air outlet shaft (A). - After completing the maintenance work, fit the air outlet shaft again in re- verse order.
  • Page 387 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. - Open the collector housing (B) at the clips (C) and remove dust accumula- tions.
  • Page 388 Cleaning / replacing the air filter car- tridge Maintenance of the filter becomes nec- essary if: - Engine electronics service display or according to the maintenance interval. - Open the collector housing (B) at the clips (C). - Open the collector housing (D) at the clips (E).
  • Page 389 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 390 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 54 18...
  • Page 391 AdBlue ® / DEF tank (6) - Check the filling level using the dis- play on the operating panel. ® Top up with AdBlue / DEF if necessary. ® Storage and handling of AdBlue HINWEIS Diesel Exhaust Fluid (DEF) ® Incorrect handling of AdBlue / DEF can cause major dam- age to the vehicle:...
  • Page 392 WARNUNG ® Danger from AdBlue / Diesel Exhaust Fluid (DEF) ® Inadequate preparations for using AdBlue / DEF can result in severe injuries! ® AdBlue / DEF should never be in contact with the skin, ® eyes or clothing or be swallowed. Keep AdBlue / DEF out of reach of children.
  • Page 393 Risk from ammonia vapours, WARNUNG overpressure in the tank ® If you open the AdBlue / DEF tank cap at high tempera- tures, ammonia vapours can escape and cause injuries! ® - Only fill the AdBlue / DEF tank in well ventilated areas. ®...
  • Page 394 AdBlue ® / DEF tank - suction filter Replace filter element - To change the filter, the supply lines ® (B) at the AdBlue / DEF multi-head (A) must be dismantled and the elec- trical connection (plug) (C) discon- nected. Use a suitable container or cloth to take up any leaked residues.
  • Page 395 - Carefully lever the multi-head (A) from the tank surface by applying a suitable slotted screwdriver around the edge. Pull the head at the same time. Do not pull the connection cable or con- nection port! - Carefully pull the multi-head up until lower part beneath...
  • Page 396 Filter change < / = s/n 003055 - Loosen the fastening screw (F) of the filter. - Pull the used filter (G) from the suction pipe. - Fit the new filter onto the suction pipe and fasten with a new fastening screw (F).
  • Page 397 - Lightly grease the O-ring (H) of the multi-head. - Fold the filter element (G) in the mid- dle towards the underside of the lower part. - Tilt the lower part at an angle of about 45°. - Place the filter side and the tip of the lower part in the tank opening as shown.
  • Page 398 - Place the retaining ring (E) over the fil- ter head. - Tighten the screws (D) properly. - Then mount the supply lines (B) and connect up to the power supply (plug) (C). After installation, check correct sealing during a trial run. F 54 26...
  • Page 399 Filter change > / = s/n 003056 - Loosen the fastening screw (F) of the filter. - Pull the used filter (G) from the suction pipe. - Fit the new filter onto the suction pipe and fasten with a new fastening screw (F).
  • Page 400 - Introduce the filter side into the tank opening as shown. - Gradually introduce the whole unit I into the tank opening, using due caution. Do not push the parts with force directly into the tank opening. This will cause damage! - Position the head in the required align- ment.
  • Page 401 - Tighten the screws (D) properly. - Then mount the supply lines (B) and connect up to the power supply (plug) (C). After installation, check correct sealing during a trial run. F 54 29...
  • Page 402 AdBlue ® / DEF tank - tank cover Clean tank cover Impurities or crystals of AdBlue / DEF ® on the outside and inside of the tank cov- er can considerably interfere with the system! If the tank cover is visibly soiled, it must be cleaned as follows.
  • Page 403 - Wipe the gasket with a damp cloth to remove any remaining DEF crystals or dirt. - Then connect the tank cover with the previously loosened retaining tab and screw onto the tank. F 54 31...
  • Page 404 AdBlue ® / DEF dosing unit Do not disconnect the vehicle batteries until the dosing system has finished the rinsing cycle. Wait for at least 5 minutes after the ignition has been switched off before starting work dosing unit. Replace filter element - Place a suitable container under the ®...
  • Page 405 Engine drive belt (7) 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 406 Crankshaft ventilation filter (8) Change filter element - Take the cover off (A) and remove the filter cover (B) - Remove the depleted filter. Check the cover and cover seal for any signs of damage and replace if neces- sary! - Clean the contact surface (D) of the fil- ter and the sealing surfaces of the O-rings with a cloth and light solvent...
  • Page 407 Exhaust system - diesel oxidation catalytic converter (9) Inspect the exhaust system Basically the exhaust system does not need any maintenance. Inspection consists of a visual check: - damaged parts? - loose screwed connections, plugs or lines? WARNUNG Risk from hot surfaces! During system cleaning, the exhaust temperature and the surface temperature of the exhaust system is very hot and can cause severe injuries! The exhaust and exhaust com-...
  • Page 408 F 54 36...
  • Page 409 F 60 Maintenance - hydraulic system Maintenance - hydraulic system F 60 1...
  • Page 410 WARNING Danger from 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 411 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 - Intake / return hydraulic filter;...
  • Page 412 Interval Maintenance point Note - Pump distribution gear - Check oil level q - Pump distribution gear - Top up oil - Pump distribution gear - Change oil - Pump distribution gear - Check bleeder q - Pump distribution gear - Clean bleeder - Hydraulic hoses - Visual inspection...
  • Page 413 Points of maintenance Hydraulic oil tank (1) - Check oil level on sight glass (A). The oil level must be up to the centre of the sight glass when the cylinders are re- tracted. If all the cylinders are extended, the level can fall below the sight glass.
  • Page 414 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 returning the screw, make sure to use a new seal. When using the drainage hose (o): - Unscrew seal cap (E).
  • Page 415 Suction/return flow hydraulic filter (2) Carry out filter replacement according to the interval or the indicator lamp in the operating panel! - Remove cover mounting screws (A) and lift off cover. - Disassemble the removed unit into: - Cover (B) - Separating plate (C) - Filter (D) - Dirt trap (E)
  • Page 416 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.
  • Page 417 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 hous- ing.
  • Page 418 Pump distribution gear (4) - Oil level check on dipstick (A). The oil level must lie between the upper and lower marks. For filling in the oil: - Pull out the dipstick (A) completely. - Add new oil through the dipstick open- ing (B).
  • Page 419 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 11...
  • Page 420 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 421 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 422 Marking hydraulic hoses / storage pe- riod, period of use A number stamped onto the threaded connection provides information about the date of manufacture (A) (month / year)and the maximum pressure permit- ted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.
  • Page 423 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 neces- sary! 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 424 F 60 16...
  • Page 425 F 73 Maintenance – drive units Maintenance – drive units F 73 1...
  • Page 426 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 427 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 428 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 - Screw connections Check - Planetary gear - Screw connections Tighten Maintenance...
  • Page 429 Repairing the spring elements involves significant safety measures and should only be carried out by a specialist workshop! Your Dynapac customer service will be happy to provide support during maintenance, repair and the replacement of wearing parts! F 73 5...
  • Page 430 Points of maintenance 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 431 - 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. - Insert a measuring rule between the sliding piece (C) and (D) of the track to determine the maximum slack: - the distance (E) between bottom plate and measuring rule must be 10-20 mm.
  • Page 432 If a different level of slack is detected during the measurement process, proceed as follows: - Screw head section for flat nipple (tool box) onto the grease gun. - Refill the chain tensioner with grease at the filler connection (A), then remove the grease gun.
  • Page 433 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 434 Rollers (3) Rollers with damaged surfaces or which are leaking should be replaced immedi- ately! - Relieving the caterpillar chain: - Raise the 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 435 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 436 Alternatively, the oil level can be checked and the oil changed at the rear of the gear- box: - 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 437 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 tightening torque for the connecting screws for the gearbox - drive unit frame (B) is: 500Nm +/-50Nm...
  • Page 438 F 73 14...
  • Page 439 F 81 Maintenance - electrical system Maintenance - electrical system F 81 1...
  • Page 440 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 441 Maintenance intervals Interval Maintenance point Note Filling level of battery electrolyte - check q Top up with distilled water Apply grease to battery terminals - Generator Electrical system insulation monitoring Check function - Alternator Visual check for pollution or damage - Check the cooling air openings for pollution or clogging, clean if nec- essary.
  • Page 442 Points of maintenance 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 clips must be free of oxide and protected with a special termi- nal grease.
  • Page 443 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 444 Alternator (2) Electrical system insulation monitoring 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 in- sulation error has occurred on the heat- ing sections or consumers.
  • Page 445 Insulation faults If an insulation fault occurs during operation, and the indicator lamp displays an insu- lation fault, the operator may proceed as follows: - Switch the switches of all external equipment and the heating system to OFF and press the reset button for at least 3 seconds to delete the fault. - If the indicator lamp does not go out, the fault lies in the generator.
  • Page 446 Cleaning the generator generator 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 81 8...
  • Page 447 Electrical fuses / relays (3) Main fuses Fuses in terminal box Relays in terminal box Main fuses (A) F1.1 Main fuse F1.2 Main fuse F 81 9...
  • Page 448 Fuses in terminal box (B) F 81 10...
  • Page 449 Screed Screed Levelling Engine start / emergency stop not used not used not used Emergency stop / remote steering Emulsion spraying system Travel drive sensors Electric heating Conveyor sensors 12V socket not used not used 24V socket Display voltage supply Keyboard voltage supply Engine compartment lighting Rotary beacon...
  • Page 450 Relays in terminal box (C) F 81 12...
  • Page 451 Engine start Ignition Travel drive computer voltage supply Travel drive computer voltage supply Engine start Travel drive computer control voltage Keyboard / display Front working lights Rear working lights Horn Start inhibit, emergency stop Start inhibit Rotary beacon Seat heating Windscreen wiper Windscreen washer system Reverse buzzer...
  • Page 452 Relays in the engine compartment (E) Engine start F 81 14...
  • Page 453 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 454 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 455 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 456 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 457 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 458 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 459 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 460 F 90 8...
  • Page 461 F 100 Tests, stopping ... Tests, checks, cleaning, stopping F 100 1...
  • Page 462 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 - Preserving the paver finisher Maintenance Maintenance during the running-in period F 100 2...
  • Page 463 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 464 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 465 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 466 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 467 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 468 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 469 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 470 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 471 F 114 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 472 F 114 2...
  • Page 473 Capacities Substance Volume Fuel tank Diesel fuel litres Diesel engine Engine oil litres (with oil filter change) Engine cooling system Cooling liquid 32.0 litres Hydraulic oil reservoir Hydraulic oil litres Pump distribution gear Gearbox oil litres Planetary gear Gearbox oil litres drive unit Planetary gear...
  • Page 474 Mobil Shell Exxon Paroil E Emission Green (*) = recommended Observe the instructions for lubricant recommendations and the specification in the maintenance instructions of the engine manufacturer! Cooling system Dynapac Petronas AGIP Chevron Caltex Delo Coolant Frost -Antifreeze Extended Extended...
  • Page 475 Mobil Shell Hydraulic Rando Rando -Tellus Oil HDZ 46 HDZ 46 S2 V46 (*) = recommended Pump distribution gear Esso / Dynapac Aral Fuchs Mobil Shell Exxon -Spirax S4 -Titan ATF ATF HDX 6000 SL (*) -Spirax S4 ATF VM...
  • Page 476 Auger box Esso / Dynapac Aral Fuchs Mobil Shell Exxon -Omala S4WE460 (*) = recommended Grease Esso / Dynapac Aral Fuchs Mobil Shell Chevron Exxon Paver -High -Gadus S5 Grease Temp T460 1.5 Premium2 (*) = recommended F 114 6...
  • Page 477 2.10 Drive engine - AdBlue ® / DEF ® For correct operation of the exhaust gas treatment system, the use of AdBlue DEF fluid is prescribed pursuant to ISO 22241-1 respectively DIN 70070! For vehicles operating in North America, the use of a DEF fluid with API approval is urgently recommended! ®...
  • Page 478 2.11 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Atlas Copco Hydraulic 120 (*) Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 (*) = recommended...
  • Page 479 Parts & Service Training We offer our customers training courses on DYNAPAC equipment in our dedicated factory training centre. We hold regular training courses in this training centre as well as courses outside the scheduled hours. Service Please contact one of our responsible service outlets if you encounter any operational problems or have enquiries about spare parts.
  • Page 480 www.atlascopco.com...

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