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Fayat Group DYNAPAC SD2550C Operating Instructions Manual

Paver finisher
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Operating Instructions
Paver Finisher
SD2550C / SD2550CS
Type 894 / 895
10-0118
4812202131

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Summary of Contents for Fayat Group DYNAPAC SD2550C

  • Page 1 Operating Instructions Paver Finisher SD2550C / SD2550CS Type 894 / 895 10-0118 4812202131...
  • Page 2 www.dynapac.com...

  • Page 3: Table Of Contents

    Table of contents Preface ..................1 General safety instructions ................ 2 Laws, guidelines, accident prevention regulations ........2 Safety signs, signal words ................. 3 "Danger"! ....................3 "Warning" ! ..................... 3 "Caution" ! ....................3 "Note" ! ....................3 Other supplementary information ............... 3 Warnings ....................
  • Page 4 5.16 Material compartment (hopper) ..............19 5.17 Material transfer ..................19 5.18 Material distribution SD2550C ..............20 5.19 Material distribution SD2550CS ...............20 5.20 Screed lifting device .................21 5.21 Electrical system ..................21 5.22 Permissible temperature ranges ..............21 Identification points ...................22 Warning signs ...................25 Information signs ..................28 CE marking ....................30 Instructive symbols, prohibitive symbols, warning symbols .....31 Danger symbols ..................32...
  • Page 5 ......................14 Transportation ..................16 Preparations ..................... 16 Driving mode .................... 18 Loading by crane ..................19 Towing ..................... 22 Safely parking the vehicle ................ 25 Lifting the vehicle with hydraulic lifts, lifting points ........26 Operation ................. 1 Safety regulations ..................1 Controls ......................
  • Page 6 "Display" set-up menu ................38 "Camera / display" set-up menu ............39 "Licence text" display ................40 Terminal error messages .................41 Status, warning and error messages symbols ........41 Drive engine error codes ................48 Error codes ....................52 Menu structure of the setting and display menus ........53 Mode of operation ..............1 Operating elements on the paver finisher ..........1 Control elements on the operator's control station ........1...
  • Page 7 Central lubricating system (o): ............. 33 Lane clearer (o) ................... 34 Screed eccentric adjustment ............... 35 Push roller crossbar, adjustable ............36 Push roller crossbar, hydraulically extendable (o) ....... 37 Push roller damping, hydraulic (o) ............37 Fire extinguisher (o) ................38 First-aid kit (o) ..................
  • Page 8 Adjusting the pressure .................33 Setting pressure for screed control with paving stop + relieving: ..33 Interrupting/terminating operation ............35 During breaks in paving (e.g. delay due to material trucks) ....35 During longer breaks (e.g. lunch break) ..........35 When work is finished ................37 Malfunctions .....................38 Problems during paving ................38 Malfunctions on the paver finisher or screed ..........40...
  • Page 9 Mounting the sensor arm ................. 34 Mounting the grade control system ............34 Setting up the sensor arm ................ 35 Big ski 9 m, big ski 13 m ................. 36 Mounting the big ski bracket on the crossbeam ........38 Mounting the swivel arms ..............
  • Page 10 Maintenance ................1 Notes regarding safety ................1 Maintenance review ..............1 Maintenance review ...................1 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 ..........
  • Page 11 Maintenance - engine assembly Tier 4i (o) ......1 Maintenance - engine assembly ..............1 Maintenance intervals ................3 Points of maintenance ................6 Engine fuel tank (1) ................6 Engine lube oil system (2) ..............7 Engine fuel system (3) ................ 10 Engine air filter (4) ................
  • Page 12 Maintenance – drive units ............1 Maintenance – drive units ................1 Maintenance intervals ................3 Points of maintenance ................6 Chain tension (1) ..................6 Bottom plates (2) ..................9 Rollers (3) .....................10 Planetary gear (4) ................11 Screw connections ................13 Maintenance - electrical system ..........1 Maintenance - electrical system ..............1 Maintenance intervals ................3 Points of maintenance ................4...
  • Page 13 Environmental protection ................. 10 Disposal ....................10 Bolts - torques ..................11 Standard metric threads - strength class 8.8 / 10.9 / 12.9 ....... 11 Fine metric threads - strength class 8.8 / 10.9 / 12.9 ....... 12 F114 Lubricants and operating substances ........1 Lubricants and operating substances ............

  • Page 15: Preface

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

  • Page 16: General Safety Instructions

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

  • Page 17: 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 18: 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 19 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 20: Prohibitive Symbols

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

  • Page 21: 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 22: 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 23: 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 24: Ce Identification And Declaration Of Conformity

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

  • Page 25: 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 26: 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 27: A Correct Use And Application

    A Correct use and application The "Guidelines for the Correct Use and Application of Paver Finishers" compiled by Dynapac are included in the scope of delivery for the present machine. The guidelines are part of the present operating instructions and must always be heeded. National regulations are fully applicable.

  • Page 29: B Vehicle Description

    B Vehicle description Application The Dynapac SD2550C / SD2550CS paver finisher is a paver finisher with a caterpillar drive which is used for paving bituminous mixed material, roll-down or lean-mixed con- crete, track-laying ballast and unbound mineral aggregates for foundations for paving.

  • Page 30: Description Of Assemblies And Functions

    Description of assemblies and functions Item Description 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 31: 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 32 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. Various engine variants in different emission classes are available as options. Stage IIIa / Tier 3 (o): There is no separate exhaust aftertreatment for this engine type when used in countries without specific regulations.
  • Page 33 Steering system/operator's platform: The independent hydrostatic travel drives al- low the paver finisher to be turned on the spot. Electronic synchronous control ensures precise straight-ahead travel. The operating panel 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. The entire operating panel can be swivelled for operation beyond the outer edge of the vehicle, and can be additionally be locked in several positions along the control platform.
  • Page 34 Augers: The augers are driven and actuated independently from the conveyors. The left-hand and the right-hand half of the auger can be controlled separately. The drive system is fully hydraulic. The conveying direction can be changed towards the centre or towards the outside. This ensures that there is always a sufficient supply of material even if an excessive amount of material is required at one side.
  • Page 35 Crossbeams / screed lifting device: The screed lifting device is used to lift the screed during transportation. The screed's approach angle can be changed using the eccentric adjustment facility on the crossbeam. Depending on the paving condition requirements, the crossbeam can be moved backwards or forwards.

  • Page 36: Danger Zones

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

  • Page 37: Safety Devices

    Safety devices 4 5 6 7...
  • Page 38 Item Description 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 when all operating and control elements are function- ing correctly and when all safety devices are in position.

  • Page 39: Technical Data, Standard Configuration

    Technical data, standard configuration Dimensions (all dimensions in mm) 2605 3360 6625 6880 1995 2550 3290 3470 For screed technical data, refer to the screed operating instructions. B 11...

  • Page 40: Allowed Angle Of Rise And Slope

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

  • Page 41: Weights Sd2550C (All Weights In T)

    Weights SD2550C (all weights in t) Paver finisher without screed approx. 15.5 Paver finisher with screed: - V5100 approx. 19.2 With extension parts for max. approx. xxx working width, additionally max.: With filled hopper approx. 17.5 Additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.

  • Page 42: Performance Data Sd2550C

    Performance data SD2550C V5100TV(E) 2.55 2.00 5.10 8.80 V5100TV 2.55 2.00 5.10 8.80 V6000TV(E) 3.00 2.45 6.00 9.70 V6000TV 3.00 2.45 6.00 9.70 R300TV(E) 3.00 12.00 R300TV 3.00 12.00 Transport speed 0 - 4 km/h Operating speed 0 - 28 m/min Paving height -150 - 350...

  • Page 43: Performance Data Sd2550Cs

    Performance data SD2550CS V5100TV(E) 2.55 2.00 5.10 8.80 V5100TV 2.55 2.00 5.10 8.80 V6000TV(E) 3.00 2.45 6.00 9.70 V6000TV 3.00 2.45 6.00 9.70 R300TV(E) 3.00 14.00 R300TV 3.00 14.00 Transport speed 0 - 4 km/h Operating speed 0 - 28 m/min Paving height -150 - 350...

  • Page 44: Travel Drive/Traction Unit

    Travel drive/traction unit Drive Hydrostatic drive, continuously controllable Two separately driven caterpillar drives with rub- Drive unit ber grouser chains Turning capacity Turning on the spot Speed See above SD2550C - Engine EU IIIa / Tier 3 (o) Make/type Cummins QSB 6.7-C220 Version 6-cylinder diesel engine (water-cooled) Performance...

  • Page 45: Sd2550C - Engine Eu Iiib / Tier 4I (O)

    5.11 SD2550C - Engine EU IIIb / Tier 4i (o) Make/type Cummins QSB 6.7-C260 Version 6-cylinder diesel engine (water-cooled) Performance 170 kW / 231 hp (at 2200 rpm) Pollutant emissions Stage IIIb / Tier 4i in accordance with: Fuel consumption, full load 44.0 l/h Fuel consumption, 2/3 load 29.4 l/h...

  • Page 46: Sd2550C - Engine Engine Eu Iv / Tier 4Final (O)

    5.13 SD2550C - Engine Engine EU IV / Tier 4final (o) Make/type Cummins QSB 6.7-C225 Version 6-cylinder diesel engine (water-cooled) Performance 168 KW / 228PS (at 2200 rpm) Pollutant emissions Stage IV / Tier 4final in accordance with: Fuel consumption, full load 42.1 l/h Fuel consumption, 2/3 load 28.1 l/h...

  • Page 47: Hydraulic System

    5.15 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) 5.16...

  • Page 48: Material Distribution Sd2550C

    5.18 Material distribution SD2550C Auger diameter 430 mm Hydrostatic external drive, fully variable regardless of conveyor Drive Auger halves can be switched to opposite directions Reversible direction of rotation Conveying volume controller Fully automatic via configurable switching points Auger height adjustment - Mechanically Auger extension With extension parts (see auger extension chart)

  • Page 49: Screed Lifting Device

    5.20 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 5.21 Electrical system On-board voltage...

  • Page 50: Identification Points

    Identification points CAUTION Danger due to missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries! - Never remove any warnings or information signs from the vehicle. - Damaged or lost warning or information signs must be replaced immediately.
  • Page 51 B 23...
  • Page 52 xxxxxxxxxxxxxxxxx B 24...

  • Page 53: Warning Signs

    Warning signs Pictogram Meaning - Warning - operating instructions! Danger due to improper operation. The vehicle personnel must have read and understood the safety, operating and maintenance instructions for the ve- hicle before the vehicle is put into opera- tion! Failure to comply with the operating and warning instructions can cause se- vere or fatal injuries.
  • Page 54 Pictogram Meaning - Warning - danger of crushing fingers and hands due to moving, accessible vehicle 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 55 Pictogram Meaning - Warning - hazard from hydraulic reser- voir and from hydraulic oil under pressure! Escaping hydraulic oil under pressure can pierce the skin and enter into the body, causing severe or fatal injuries. Always observe the operating instructions! - Warning - danger from tyres filled with water! Handling tyres filled with water incorrect-...

  • Page 56: Information Signs

    Information signs Pictogram Meaning - Operating Instructions Position of the storage compartment. - Lifting point Lifting the machine is only permitted at these lifting points! - Lashing point Lashing the machine is only permitted at these points! - Main battery switch Position of the main battery switch.
  • Page 57 Pictogram Meaning - Engine oil Position of the filling and control point. - Engine coolant Position of the filling and control point. - Hydraulic oil Position of the filling point. - Hydraulic oil level Position of the control point. - Engine oil drainage point Position of the drainage point.

  • Page 58: Ce Marking

    Pictogram Meaning - Tamper speed adjuster Position of the speed adjuster. - Vibration, speed adjuster Position of the speed adjuster. CE marking Pictogram Meaning - CE, sound output level B 30...

  • Page 59: Instructive Symbols, Prohibitive Symbols, Warning Symbols

    Instructive symbols, prohibitive symbols, warning symbols No. Pictogram Meaning - Wear ear protectors - Do not enter the area! - Do not spray the area or component with water! - Warning on dangers posed by batteries! - First aid kit B 31...

  • Page 60: Danger Symbols

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

  • Page 61: Further Warnings And Operating Instructions

    Further warnings and operating instructions Pictogram Meaning - Warning - hazard from unsupported screed! If the screed sags, this can cause severe or fatal injuries! Insert crossbeam lock only at crown adjustment "zero". Cross- beam lock only for transportation! Do not enter or work under screed only secured with screed lock for transportation! - Attention - danger of high voltage in...
  • Page 62 Pictogram Meaning - Overview "Tyre pressure / working width / speed preselection" - Overview "Tyre pressure / working width / speed preselection" - Engine start - all switches in neutral! The engine cannot be started when functions are switched on. Always observe the operating instructions! B 34...

  • Page 63: Identification Label For The Paver Finisher (41)

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

  • Page 64: Explanation Of 17-Digit Pin Serial Number

    Explanation of 17-digit PIN serial number >10002014JHG002076< - Manufacturer - Family/Model - Code letter - Serial number B 36...

  • Page 65: Engine Type Plate

    Engine type plate The engine type plate (1) is affixed on top of the engine. The type plate states the engine type, serial number and engine data. Please state the engine number of the engine when ordering spare parts. See also operating instructions for the engine. B 37...

  • Page 66: Standards

    EN standards Continuous sound pressure SD2550C 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 67: Continuous Sound Pressure Sd2550Cs

    Continuous sound pressure SD2550CS 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 68: Vibration Acting On The Entire Body

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

  • Page 69: 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 70: 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 71 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Fully extend the levelling cylinder. Retract the screed parts until the screed matches the basic width of the paver finisher. Deactivate set-up mode.

  • Page 72: 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 73: 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 74: Lashing Equipment

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

  • Page 75: 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 76: Preparing The Vehicle

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

  • Page 77: Securing The Load

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

  • Page 78: 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 79: 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 80: Control Panel Transport Safeguard

    Control panel transport safeguard: - Release the latch (1) to move the con- trol 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 81: After Transportation

    After transportation - Remove the attachment devices. - Raise protective roof: See section entitled "Protective roof" - Lift the screed to the transportation position. - Start the engine and drive 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. - Remove the key and/or cover the operating panel with the protective hood and secure it.

  • Page 82: 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...
  • Page 83 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. - Connect the pump lever (1) to the pump (2). - Tighten bolts (3) on both sides of the roof.
  • Page 84 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 Screed op- erating instructions).
  • Page 85 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Fully extend the levelling cylinder. Retract the screed parts until the screed matches the basic width of the paver finisher. Extend crossbeam lock.

  • Page 86: Driving Mode

    Driving mode Operation Buttons Set the fast/slow switch to "Hare" if necessary. Turn the preselector to "zero". Swivel the drive lever to maximum. The vehicle already advances slightly on deflecting the drive lever! Adjust required vehicle speed with the preselector. To stop the vehicle, swivel the drive lever to the middle setting and set the preselec- tor to "zero".

  • Page 87: Loading By Crane

    Loading by crane WARNING Danger from suspended loads Crane and/or lifted vehicle can tip when lifted and cause injuries! - The vehicle may only be raised at the marked lifting points. - Heed the operating weight of the vehicle. - Do not enter the danger zone. - Use only lifting gear that can bear the load.
  • Page 88 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). - Secure vehicle wherever it is parked up.
  • Page 89 See section entitled "Protective roof" - Attach lifting gear to the four attachment points (1, 2). The max. permissible attachment point load at the attachment points is 73.5 kN. The permissible load applies in the vertical direction! Make sure that the paver finisher remains in a horizontal position during transportation! C 11 21...

  • Page 90: 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 91 A hand pump (1) is located in the engine compartment (left side); it must be actuated to be able to tow the machine. Pressure for releasing the traction system brakes is built up with the hand pump. - Release lock nut (2), screw threaded dowel (3) into pump as far as possible and secure with lock nut.
  • Page 92 Two high-pressure cartridges (6) are lo- cated 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 93: 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 94: 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 95: 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 forbidden!
  • Page 96 DANGER Danger due to improper operation Improper operation of the vehicles can cause severe to fatal injuries! - The vehicle may only be used in the proper manner for its intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves famil- iar with the contents of the operating instructions.

  • Page 97: 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 98 D 11 4...
  • Page 99 Item Description Brief description Press in an emergency (danger to persons, impending colli- sion, etc.)! Pressing the emergency stop button switches off the en- gine, the drives and the steering system. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accident! button...
  • Page 100 D 11 6...
  • Page 101 Item Description Brief description For switching on the paver finisher functions and for continu- ously regulating the road speed – forward or reverse. Centre position: Engine in neutral; no travel drive; - To swivel the drive lever out, release by pulling the handle up.
  • Page 102 D 11 8...
  • Page 103 Item Description 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 The vehicle must not travel at max. transport speed preselector when the hopper is full! The vehicle speed cannot be reduced to "0"...
  • Page 104 D 11 10...
  • Page 105 Item Description Brief description Button with detent switch function and LED feedback: Front working - For switching on the front working lights lights - Switch OFF by pressing the button again ON / OFF (o) Avoid dazzling other road users! Button with detent switch function and LED feedback: - For switching on the rear working lights Rear working lights...
  • Page 106 D 11 12...
  • Page 107 Item Description Brief description Detent switch function and LED feedback: Windscreen wip- - For switching on the windscreen wipers ers ON / OFF (o) - Switch OFF by pressing the button again Detent switch function and LED feedback: Windscreen wash- - For engaging the windscreen washer system + wind- er system + wind- screen wipers...
  • Page 108 D 11 14...
  • Page 109 Item Description Brief description Button with detent switch function and LED feedback: Filling pump - For switching on the filling pump Fuel tank ON / OFF (o) - Switch OFF by pressing the button again Button with detent switch function and LED feedback: Seat heating - For switching on the seat heating ON / OFF (o)
  • Page 110 D 11 16...
  • Page 111 Item Description Brief description Pushbutton function with LED feedback: - To hydraulically extend the push roller crossbar. Extend push roller (o) On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function with LED feedback: - To hydraulically retract the push roller crossbar. Retract push roller (o) On actuation, heed danger zones of moving parts of...
  • Page 112 D 11 18...
  • Page 113 Item Description Brief description Button with detent switch function and LED feedback: - The vehicle turns on the spot (the caterpillar chains run in opposite directions) when the steering is set to "10". - Steering turned to the left = vehicle turns to the left - Steering turned to the right = vehicle turns to the right The function can only be activated in the working gear ("travel drive slow") speed.
  • Page 114 D 11 20...
  • Page 115 Item Description 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 Close hopper left limited space at one side or when obstacles obstruct truck unloading.
  • Page 116 D 11 22...
  • Page 117 The Truck Assist system is used for communication between the driver of the paver and the driver of the material truck. The corresponding signal system shows the truck driver which action to perform (reversing / stop / tip material / depart). Caution! Possible material damage through insuffi- NOTE cient instruction...
  • Page 118 D 11 24...
  • Page 119 Item Description Brief description LED display Pushbutton function with LED feedback: - To change over to the "Start Tipping" signal. (YELLOW SIGNAL, running light as- cending) - Press button again to change signal over to "Pause". Tell truck "Start (YELLOW SIGNAL, flashing). Tipping"(raise truck hopper) The button LED + button LED (41) flash-...
  • Page 120 D 11 26...
  • Page 121 Item Description Brief description LED display Pushbutton function with LED feedback: - The "Truck Assist" function runs automatically. - Switch OFF by pressing the button again - Press button (38) to request a truck with material / Release for truck to approach (GREEN SIGNAL) The truck is detected by a laser sensor at...
  • Page 122 D 11 28...
  • Page 123 Item Description Brief description Pushbutton function: - To extend the left half of the screed This function is not used in vehicle configurations with a Extend left screed screed which cannot be extended. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - To extend the right half of the screed...
  • Page 124 D 11 30...
  • Page 125 Item Description 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 126 D 11 32...
  • Page 127 Item Description 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. To avoid excessive conveying, the system is shut off at Left conveyor a defined material height!
  • Page 128 D 11 34...
  • Page 129 Item Description Brief description Pushbutton function: - The conveying direction of the conveyor can be re- versed in order to slightly reverse paving material for example which may be present in the material tunnel. The function can be triggered in all modes of the con- veyor.
  • Page 130 D 11 36...
  • Page 131 Item Description 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 switches. - Switch OFF by pressing the button again Left auger The function is shut off by pressing the EMERGENCY...
  • Page 132 D 11 38...
  • Page 133 Item Description 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 134 D 11 40...
  • Page 135 Item Description Brief description Pushbutton function: - To manually trigger the conveying function for the left half of the auger, conveying direction inwards. Left auger "MANUAL" For manual triggering, the auger function must be Conveying direc- switched to "AUTO" or "MANUAL" tion inwards On manual triggering, the automatic function is overrid- den with reduced delivery capacity.
  • Page 136 D 11 42...
  • Page 137 Item Description Brief description Detent switch function and LED feedback: - To lock all functions relevant to paving. Despite "Auto" 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 138 D 11 44...
  • Page 139 Item Description 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 Adjustment be switched to "Manual"...
  • Page 140 D 11 46...
  • Page 141 Item Description Brief description Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction. Retract / lift on left On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction.
  • Page 142 D 11 48...
  • Page 143 Item Description Brief description Detent switch function and LED feedback: Filling function for the paving process. The diesel engine's speed is increased to the preselected nominal speed and all conveying functions set to "Auto- matic" (conveyor and auger) are engaged. The main function switch must be set to the OFF position.
  • Page 144 D 11 50...
  • Page 145 Item Description Brief description Pushbutton function with LED feedback: - For lifting the screed (LED ON) and for switching off the "Screed floating position" function Lift screed Check whether the screed transport safeguard is inserted! On actuation, heed 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 position.
  • Page 146 D 11 52...
  • Page 147 Item Description Brief description Button with detent switch function and LED feedback: - Tamper ON and OFF function. - Activation is carried out by swivelling the drive lever out. - Switch OFF by pressing the button again. Tamper (screed-specific) The main function switch must be set to the OFF position.
  • Page 148 D 11 54...
  • Page 149 Item Description 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 150 D 11 56...
  • Page 151 Item Description Brief description Pushbutton function with LED feedback: - To hydraulically extend the crossbeam lock. Extend cross- Before retracting and extending the lock, raise the beam lock (o) crossbeams slightly over the locking bolts (raise the screed)! Pushbutton function with LED feedback: - To hydraulically retract the screed lock.
  • Page 152 D 11 58...
  • Page 153 The "Set Assist" function prepares the paver to relocate to another section of road- works or for transportation. When the function is activated, previously selected vehicle functions are carried out to make the vehicle ready for transport. The function can be reset after relocating the paver. This restores the corresponding elements to the previously saved working condition /position.

  • Page 154: Remote Control

    Remote control D 11 60...
  • Page 155 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 61...
  • Page 156 D 11 62...
  • Page 157 Item Description Brief description Press in an emergency (danger to persons, impending colli- sion, etc.)! Pressing the emergency stop button switches off the en- gine, the drives and the steering system. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accident! button...
  • Page 158 D 11 64...
  • Page 159 Item Description 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 160 D 11 66...
  • Page 161 Item Description 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. The auger function must be switched to "AUTO" or "MANUAL"...
  • Page 162 D 11 68...
  • Page 163 Item Description 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 164 D 11 70...
  • Page 165 Item Description Brief description Pushbutton function: - Plus/minus buttons for adjusting the delivery capacity. - The delivery capacity is slowed down or speeded up Conveyor delivery depending on the length of time for which the button capacity is pressed. The conveyor function must be switched to "AUTO" or "MANUAL"...
  • Page 166 D 11 72...
  • Page 167 Item Description 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 168 D 11 74...
  • Page 169 Item Description 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 170 D 11 76...
  • Page 171 Item Description Brief description Pushbutton function: - For manual actuation of the levelling cylinders on the corresponding side of the vehicle when the automatic Levelling cylinder 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 172 D 11 78...

  • Page 173: D22 Operating The Display

    D 22 Operating the display D 22 1...

  • Page 174: Operation Of The Input And Display Terminal

    Operation of the input and display terminal Button layout on the display - (A) Jog dial (knob to be turned+push button): - Turn: - to select various adjustment parameters within a menu - to adjust the parameter - to select various selection possibilities within a menu - Press: to release the adjustment of a parameter - to confirm a parameter adjustment...
  • Page 175 To confirm an active/opened menu, the colour of the cor- responding symbol changes from pale to dark grey! - (F) Display area for status, warning and error messages: - To show current earnings or error messages. The colour of the symbol indicates whether it is a status, warning or error message. Colour code Explanation RED - error message...

  • Page 176: Menu Operation - Procedure For Adjusting Parameters

    Menu operation - procedure for adjusting parameters D 22 4...
  • Page 177 Example: Adjusting the screed temperature - The "Home" menu is open in the display. - Press button (A) to open the "Engine Speed" menu. - The "Engine Speed" menu is open in the display. - Press button (B) to open the "Screed Heater" menu. - Turn jog dial (C) to make the cursor appear.

  • Page 178: Selecting And Changing An Adjustment Parameter In A Menu

    Selecting and changing an adjustment parameter in a menu - Press jog dial (C) to activate the parameter adjustment. A blue frame appears around the top adjustment parameter in the menu. - Turn jog dial (C) in the corresponding direction until the blue frame is around the required adjustment parameter.

  • Page 179: Selecting And Changing A Selection Possibility In A Menu

    Selecting and changing a selection possibility in a menu - Press jog dial to activate the parameter adjustment. A blue frame appears around the top selection possibility in the menu. - Turn jog dial in the corresponding direction until the blue frame is around the re- quired selection possibility.

  • Page 180: Menu Structure

    Menu structure Menu of the "Home" displays Displays: - (1) Speed: - Paving (tortoise)-(m/min) / (ft/min) - Driving (hare) - (km/h) / (mph) A speed preselection at standstill is possible (only for paving) - (2) Fuel gauge ® - (3) Level AdBlue / DEF tank (o) If the level is too low, a warning also appears.
  • Page 181 - (7) Extension distance - extendable part screed left (cm) / (inch) (o) - (8) Extension distance - extendable part screed right (cm) / (inch) (o) - (9) Course thickness - screed left (cm) / (inch) (o) - (10) Course thickness - screed right (cm) / (inch) (o) - (11) Crowning - (%) (o) - (12) Target slope - left / right (%) (o) - (13) Overall width screed (cm) / (inch) (o)

  • Page 182: Home" Menu - Sub-Menus

    "HOME" menu - sub-menus Open the following sub-menus: - (1) Show "Home" functions / "Quick Settings" - (2) Call "Engine Speed" menu / Engine measured value display + sub-menus. - (3) "Paving Parameters" menu + sub-menus. - (4) "Camera display" menu + sub-menus.(o) - (5) "Error Memory"...
  • Page 183 If the corresponding function button of an opened sub-menu is pressed again, the Home menu appears and the sub-menu display remains. D 22 11...

  • Page 184: Home" Functions / "Quick Settings

    "Home" functions / "Quick Settings" Menu for directly activating various functions. - Press corresponding function button to show the functions / quick settings (1) to (6). Press once more to hide the functions again. Pressing the adjacent function button activates or deac- tivates the functions.
  • Page 185 - (4): "Joint hopper actuation" function - Both hopper halves are actuated together with one of the hopper function switches (open hopper / close hopper). - (5) "Automatic steering unit" function (only for caterpillar pavers) - The vehicle is steered automatically via corresponding sensing along a reference (e.g.

  • Page 186: Engine Speed" Menu / Engine Measured Value Display

    "Engine Speed" menu / Engine measured value display Menu for adjusting the engine speed and for checking various measured values of the engine. - (1) Nominal speed display and adjustment parameters Adjusted directly by pressing the job dial. Adjustment is carried out in steps of 50; the engine speed is adapted directly. - (2) Actual engine speed - (3) Engine oil pressure (bar) - (4) On-board voltage (V)
  • Page 187 "Material Management" measured value display Menu for checking the following parameters: - (1) Paving material level (%) conveyor left - (2) Paving material level (%) conveyor right - (3) Paving material level (%) auger left - (4) Paving material level (%) auger right - (5) Tamper speed (n/min) - (6) Vibrations speed (n/min) D 22 15...
  • Page 188 "Screed Heater" adjustment and display menu (o) Menu for adjusting the nominal screed heater temperature and for checking the actu- al temperatures and for activating the "Sectional heating" function (o) - (1) Nominal screed heater temperature display and adjustment parameters. Press encoder (A) to start the editing menu.

  • Page 189: Paving Area / Automatic Steering Unit" Menu

    "Paving Area / Automatic Steering Unit" menu Menu for retrieving and resetting the current paving area, for showing the steering monitoring and resetting the steering monitoring reference. - (1) Current paving distance (m) - Reset / set value to zero: Select function (1.1) with the job dial and press to reset. As confirmation, the display changes for 5 to 10 seconds during reset.

  • Page 190: Front Wheel Drive" Measured Value Display (O)

    "Front wheel drive" measured value display (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. - (3) Display and adjustment parameters for traction (o) - ((>):low traction - ((>>):high traction - ((>>>):maximum traction...

  • Page 191: Particulate Filter Regeneration" Menu (O)

    "Particulate filter regeneration" menu (o) 1b 2a Menu for triggering requested active filter regeneration and for disabling automatic fil- ter regeneration. - (1) Particulate filter regeneration, manual: - for triggering necessary particulate filter regeneration. Necessary regeneration is indicated by the regeneration warning sign (1a)! Please heed the notes in the "Terminal error messages"...
  • Page 192 Danger from particulate filter regeneration DANGER Improper particulate filter regeneration can cause severe to fatal injuries! - Keep the outlet of the exhaust pipe out of the reach of peo- ple and of objects that can burn, melt or explode! - There may not be any people or objects within a radius of 0.6 m of the exhaust outlet! - There may not be any objects or substances that can burn,...

  • Page 193: Paving Parameters" Menu

    "Paving parameters" menu Menu for showing and adjusting the paving parameters. - (1) Current course thickness parameter - The following course thickness parameters can be selected: - (1a) Surface course >, low paving speed - (1b) Surface course >>, high paving speed - (1c) Binder course >, low paving speed - (1d) Binder course >>, high paving speed - (1e) Foundation...
  • Page 194 - (2) Left conveyor speed (%) display and adjustment parameters - (3) Right conveyor speed (%) display and adjustment parameters - (4) Left auger speed (%) display and adjustment parameters - (5) Right auger speed (%) display and adjustment parameters - (6) Nominal tamper speed (n/min) display and adjustment parameters - (7) Nominal vibration speed (n/min) display and adjustment parameters Tamper and vibration range depending on screed type.

  • Page 195: Adjusting The Paving Parameters

    Adjusting the paving parameters Functions: - (8) "Save Parameter" function As confirmation, the display changes for 5 to 10 seconds during saving. - (9): "Load Parameter" function As confirmation, the display changes for 5 to 10 seconds during loading. - (10): "Parameter Reset - Load Factory Settings" function Firstly the system requests reset confirmation.
  • Page 196 Overview "Course Thickness Parameters" Menu for viewing the speeds saved for all conveying and compacting elements ac- cording to the course thickness parameters. Back to the main menu: - (1) "Paving Parameters" menu. D 22 24...

  • Page 197: Camera Display" Menu (O)

    "Camera display" menu (o) Machine parts partly concealed from view can be displayed by the camera system. When this function is called up, display camera 1 appears. - (1) Show camera 1 display. - (2) Show camera 2 display. D 22 25...

  • Page 198: Error Memory" Menu

    "Error Memory" menu Menu for retrieving existing error messages. - (1) Number of error messages with travel drive stop. - Open detailed display "Error Messages With Travel Drive Stop": (1.1). - (2) Number of vehicle warning messages. - Open detailed display "Vehicle Warning Messages": (2.1). - (3) Number of engine error messages.

  • Page 199: Detailed Display "Error Messages With Travel Drive Stop

    Detailed display "Error Messages With Travel Drive Stop" Display of existing error messages in a table. - (1) Error code. - (2) Error description. - (3) Designation of the faulty part as per BMK/EIC list. Press the job dial to scroll through the list. D 22 27...

  • Page 200: Detailed Display "Vehicle Warning Messages

    Detailed display "Vehicle Warning Messages" Display of existing error messages in a table. - (1) Error code. - (2) Error description. - (3) Designation of the faulty part as per BMK/EIC list. Press the job dial to scroll through the list. - Delete list of error messages: (4).

  • Page 201: Detailed Display "Engine Error Messages

    Detailed display "Engine Error Messages" Display of existing error messages in a table. - (1) SPN code. - (2) FMI code. - (3) OC error frequency. All error messages can be identified in the section "Error codes drive engine". Press the job dial to scroll through the list. D 22 29...

  • Page 202: Basic" Menu

    "Basic" menu The "Basic" menu can be opened from every menu, sub-menu or display. Menu for opening the following sub-menus: - (1) "Home" menu - Display and quick settings menu. - (2) "Service" menu - Menu for service technician (password required) - (3) "Info &...

  • Page 203: Service" Menu

    "Service" menu Password-protected menu for various service settings. D 22 31...

  • Page 204: Info & Settings" Menu

    "Info & Settings" menu Menu for calling up various vehicle information and sub-menus for various settings. Display of the following information: - (1) Software version of the vehicle - (2) Software version of the display - (3) Engine operating hours (h) If consultation with Technical Support is required for your vehicle, always specify the software version! Open the following sub-menus:...

  • Page 205: Screed" Set-Up Menu

    "Screed" set-up menu Menu for setting up the basic screed settings and screed functions. - (1) Display and adjustment parameters for "Delayed Screed Start" - delay time (sec) On swivelling the drive lever, the floating function is only activated once an adjusted time has elapsed.

  • Page 206: Paving / Travel" Set-Up Menu

    "Paving / Travel" set-up menu Menu for setting up the vehicle and levelling functions. - (1) Display and adjustment parameters for "Delayed Front Hopper" - delay time (sec). ((o) After closing the hopper lids, the front hopper is only raised after the adjusted time has expired.
  • Page 207 - (3) Selection "Cross Levelling" - (0): Cross levelling OFF - (1): Only data display of the opposite side of the vehicle. - (2): Data display and control of the opposite side of the vehicle. - (3): Split screen on the remote controls: simultaneous data display and operation of both sides of the vehicle possible.

  • Page 208: Truck Assist / Set Assist" Set-Up Menu

    "Truck Assist / Set Assist" set-up menu Menu for setting up the "Truck Assist" and "Set Assist" functions. - (1) Selection "Truck Distance" In order to adjust to the prevailing situation, the truck’s automatic detection function can be preset to 3 different distances (paver/truck). - (1.1): Shortened distance - (1.2): Medium distance - (1.3): Extended distance...

  • Page 209: Day/Night Lighting" Set-Up Menu

    "Day/Night Lighting" set-up menu Menu for adjusting the illuminance of various control elements. - (2) Monitor brightness display and adjustment parameters - (2.1): daytime light (%) - (2.2): nighttime light (%) - (3) Truck Assist display and adjustment parameters - (3.1): daytime light (%) - (3.2): nighttime light (%) D 22 37...

  • Page 210: Display" Set-Up Menu

    "Display" set-up menu Menu for setting up basic display settings. - (1) Selection "System Language" - English / German - (2) Selection "Units of measurement" - Metric / Imperial (US) - (3) "Time" display and adjustment parameters - h/h : min/min - 24h / PM/AM - (4) "Date"...

  • Page 211: Licence Text" Display

    "Camera / display" set-up menu Menu for setting up the camera display. - (1) Brightness display and adjustment parameters - (2) Contrast display and adjustment parameters - (3) Colour display and adjustment parameters Setting range 0-100% Open the following sub-menus: - (4) "Display"...
  • Page 212 "Licence text" display Display of the software licence text. Open the following sub-menus: - (1) "Display" set-up menu. - (2) "Camera / display" set-up D 22 40...

  • Page 213: Terminal Error Messages

    Terminal error messages Status, warning and error messages symbols Command Symbol in the display High beam headlights control The high beam headlights are switched on. Avoid dazzling the oncoming traffic! Check direction of travel indicator Flashes whenever direction of travel indicator is activated.
  • Page 214 Command Symbol in the display Indicator lamp automatic particulate filter re- generation - deactivated Particulate filter regeneration is deactivated. Automatic regeneration should only be deacti- vated if the operating status of the paver finish- er does not permit any automatic function. see "Particulate filter regeneration"...
  • Page 215 Command Symbol in the display Indicator lamp fuel reserve + warning sound The fuel is down to the reserve level in the tank Approx. 10% remains Urgent need to refuel! Pre-heating indicator (yellow) Pre-heating is started with the ignition starter by switching the ignition on.
  • Page 216 Command Symbol in the display Pending service: A maintenance interval is about to expire. Proceed immediately with maintenance to avoid subsequent damage! Service overdue: A maintenance interval is overdue. Proceed immediately with maintenance to avoid subsequent damage! Heating status "ON": xxxxxxxxx xxxxxxxxx Switching off front-wheel drive:...
  • Page 217 Command Symbol in the display - Error message "Serious error" There is a serious error in the engine. Switch off the drive engine immediately! Error details viewed "Error Memory" display menu. Lights up for a few seconds once the ignition has been switched on for checking purposes.
  • Page 218 Command Symbol in the display Engine stop: Display for all error messages with machine stop. Hydraulic filter. The hydraulic filter must be replaced. Replace filter element acc. to Maintenance Instructions! Engine oil pressure The oil pressure is insufficient. Switch off the engine immediately! For other possible errors, see engine's operating instructions.
  • Page 219 Command Symbol in the display Engine stop: Display for all error messages with machine stop. D 22 47...

  • Page 220: Drive Engine Error Codes

    Drive engine error codes If a fault is detected on the engine, this is shown by the corresponding indication (1) in the display. D 22 48...
  • Page 221 The error message that can be viewed in the corresponding menu contains several numerical codes, which clearly define the fault after decoding. Press the job dial to scroll through the list. It may be possible to continue operating the vehicle, depending on the severity of the error.
  • Page 222 Example: D 22 50...
  • Page 223 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 224: Error Codes

    Error codes Scan QR-Code to access failure code chart… D 22 52...

  • Page 225: 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 22 53...
  • Page 226 D 22 54...

  • Page 227: D30 Mode Of Operation

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

  • Page 228: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and...
  • Page 229 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. - Connect the pump lever (1) to the pump (2). - Tighten bolts (3) on both sides of the roof.

  • Page 230: Ladder

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

  • Page 231: Control Platform, Moveable (O)

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

  • Page 232: Control Platform Lock (O)

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

  • Page 233: Operating Panel

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

  • Page 234: Protective Roof (O)

    Protective roof (o) D 30 8...

  • Page 235: Windscreen Wiper

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

  • Page 236: Emergency Actuation Control Platform, Movable

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

  • Page 237: Seat Console

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

  • Page 238: Driver's Seat, Type I

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

  • Page 239: Driver's Seat, Type Ii

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

  • Page 240: Fuse Box

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

  • Page 241: Batteries

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

  • Page 242: Hopper Transport Safeguard

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

  • Page 243: Screed Lock, Hydraulic (O)

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

  • Page 244: Paving Thickness Indicator

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

  • Page 245: Auger Lighting ((O)

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

  • Page 246: Led Working Light (O)

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

  • Page 247: Watt Spotlight (O)

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

  • Page 248: Auger Height Adjustment Ratchet (O)

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

  • Page 249: Sensor Rod / Sensor Rod Extension

    Sensor rod / sensor rod extension The sensor rod acts as an orientation aid for the vehicle driver during paving. Along the defined paving route, the vehicle driver can use the sensor rod to follow a tensioned reference wire or another marking. The sensor rod runs along the reference wire or over the marking.
  • Page 250 - 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 251: Manual Separator Fluid Spray (O)

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

  • Page 252: Separator Fluid Spraying System (O)

    Separator fluid spraying system (o) Used to spray the parts coming into contact with asphalt with a separator emulsion. - 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 253: Conveyor Limit Switches - Plc Version

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

  • Page 254: Conveyor Limit Switches - Conventional Version

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

  • Page 255: Ultrasonic Auger Limit Switches (Left And Right) - Plc Version

    Ultrasonic auger limit switches (left and right) - PLC version The limit switches control the material flow at the relevant half of the auger without contact. The ultrasonic sensor (1) is secured to the side shield via a bracket (2). - To adjust, release the clamping lever / stop screw (3) and adjust the sensor's angle.

  • Page 256: Ultrasonic Auger Limit Switches (Left And Right) - Conventional Version

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

  • Page 257: Volt / 12 Volt Sockets (O)

    24 volt / 12 volt sockets (o) A socket (1) is located behind the left/ right seat consoles. Additional working lights can be 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 258: Pressure Control Valve For Screed Charging/Relieving

    Pressure control valve for screed charging/relieving A valve (1) is used to set the pressure for additional screed charging/relieving. Switching on, see screed charging/re- lieving (chapter "Operating panel", "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 259: Central Lubricating System (O)

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

  • Page 260: Lane Clearer (O)

    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 261: Screed Eccentric Adjustment

    Screed eccentric adjustment To pave thicker layers of material, if the piston rods in the levelling cylinder are operating close to their limit position and if the desired paving thickness cannot be reached, it is possible to alter the ap- proach angle of the screed by adjusting the eccentric.

  • Page 262: Push Roller Crossbar, Adjustable

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

  • Page 263: Push Roller Crossbar, Hydraulically Extendable (O)

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

  • Page 264: Fire Extinguisher (O)

    Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with operation of the fire extin- guisher (2). Observe the inspection interval for the fire extinguisher! First-aid kit (o) Any dressings that have been used must be replaced immediately! Heed the expiry date of the first-aid kit! D 30 38...

  • Page 265: Rotary Beacon (O)

    Rotary beacon (o) The function of the rotary beacon must be checked daily before starting work. - Place the rotary beacon onto the plug-in contact and secure with a wing bolt (1). - Raise the bracket (2), swivel to the out- er position and allow to engage there - Slide the rotary beacon with the tube (3) out to the desired height and secure with...

  • Page 266: Fuelling Pump (O)

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

  • Page 267: Illuminated Balloon (O)

    Illuminated balloon (o) D 30 41...
  • Page 268 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 269: Installation And Operation

    Installation and operation CAUTION Danger due to electric shock Electric shock can lead to serious injuries or death - Always wait to connect the Powermoon to the power supply and switch it on until after it has been completely unpacked, assembled and aligned. CAUTION Danger of squeezing! Fingers or hands can be pinched between the bracket and...

  • Page 270: Decommissioning

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

  • Page 271: Truck Assist (O)

    Truck Assist (o) The Truck Assist system is used for communication between the driver of the paver and the driver of the material truck. The corresponding signal system shows the truck driver which action to perform (reversing / stop / tip material / depart). The system consists of: - Two LED light bars (1) as a signal for the truck driver and a laser sensor (2) for de- tecting the truck.
  • Page 272 D 30 46...

  • Page 273: D41 Mode Of Operation

    D 41 Mode of operation Preparing for operation Required devices and aids To avoid delays on site, check before starting work whether or not the following de- vices and aids are present: - Wheel loader for transporting heavy extension parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separator fluids (emulsion) and manual injector...
  • Page 274 CAUTION Danger due to restricted vision Restricted vision poses a risk of injury! - Before starting work, arrange the intended driver's seat to ensure adequate vision. - Signalmen must be used when vision is restricted, also to the sides and when reversing. - Only reliable persons may be used as signalmen who must have been received instructions about their task before taking up their activity.

  • Page 275: Before Starting Work (In The Morning Or When Starting Paving)

    Before starting work (in the morning or when starting paving) - Heed the safety instructions. - Check the personal protective equipment. - Take an inspection walk around the paver finisher and check for leaks and damages. - Install parts removed for transportation or for the night. - When screed is operated with the optional gas heating system, open the closing valves and the main shut-off valve.
  • Page 276 Check! How? For larger working widths, the walkway Auger coverings plates must be extended and the auger tunnels must be covered. Folding walkways must be present at the basic screed and all extension parts and folded down accordingly. Screed covers and walkways Check that the side shields, the side plates and the covers are securely seated.
  • Page 277 D 41 5...

  • Page 278: Starting The Paver Finisher

    Starting the paver finisher Before starting the paver finisher Before starting the diesel engine and beginning operation, the following steps must be performed: - Daily maintenance of the paver finisher (see chapter F). Check the operating hours counter to determine whether further maintenance work should be conducted.
  • Page 279 D 41 7...

  • Page 280: External Starting (Starting Aid)

    External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24V system - Additional 24V battery - Start device that is suitable for external starting (24 V/90 A).
  • Page 281 - 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. Run the starter continuously for a maximum of 30 seconds, then take a break for 2 minutes! - If the engine still has not started after two attempts, ascertain the cause! - If the engine starts up: disconnect the starting aid cable again in reverse order.
  • Page 282 D 41 10...

  • Page 283: After Starting

    After starting To increase the engine speed: - Press button (68) 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 284 D 41 12...

  • Page 285: Observe Indicator Lamps

    Observe indicator lamps The following indicator lamps must be observed under all circumstances: For other possible errors, see engine's operating instructions. Engine coolant temperature check (A) 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 286 D 41 14...

  • Page 287: Travel Drive Oil Pressure Indicator Lamp (D)

    Travel drive oil pressure indicator lamp (D) - Must go out after starting. If the lamp does not go out: Do not switch on the traction drive! Otherwise, the entire hydraulic system could be damaged. When the hydraulic oil is cold: - Activate set-up mode function (68).
  • Page 288 D 41 16...

  • Page 289: Preparation For Transportation

    Preparation for transportation - Close the hopper with switch (34)/(35). - Engage both hopper transport safeguards. - Lift the screed completely using switch (69), set the crossbeam lock (75). - Turn the travel drive preselector (15) to zero. - Activate set-up mode function (68). - Fully extend the levelling cylinders with switch (61),(63)/(64).
  • Page 290 D 41 18...

  • Page 291: Driving And Stopping The Paver Finisher

    Driving and stopping the paver finisher - Set the Fast/Slow switch (33) 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. - Adjust the speed with the preselector (15).

  • Page 292: Preparations For Paving

    Preparations for paving Separator fluid Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator fluid. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). F0147_A1.TIF Screed heater system Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem- perature) before paving begins.
  • Page 293 Direction marks To ensure straight paving, a direction mark must be present or established (road edge, chalk lines or similar). - Slide the operating panel to the de- sired side and secure it. - Pull the direction indicator out of the bumper (arrow) and adjust it ac- cordingly.
  • Page 294 D 41 22...

  • Page 295: Loading/Conveying Material

    Loading/conveying material - Button (59) 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 (53)/(54) and the conveyor (47)/(48) to "Auto". - Activate function (67) to fill the vehicle for the paving process.
  • Page 296 D 41 24...

  • Page 297: Starting For Paving

    Starting for paving Set the switches, levers and controls listed below to the specified positions when the screed has reached its operating temperature and a sufficient amount of material lies in front of the screed Item Travelling direction Position Drive lever Centre position Traction drive fast/slow LED OFF...

  • Page 298: Checks During Paving

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

  • Page 299: Paving With "Screed Control At Paving Stop" And "Screed Charging/Relieving

    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.
  • Page 300 D 41 28...

  • Page 301: Screed Charging/Relieving

    Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Function (73) Relieving (screed "lighter") Function (74) 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 302 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.
  • Page 303 D 41 31...
  • Page 304 D 41 32...

  • Page 305: Adjusting The Pressure

    Adjusting the pressure Pressure adjustments can only be made while the diesel engine is running. Therefore: - Start the diesel engine and set the traction controller (15) to zero (precaution against inadvertent advancing). - Activate the "floating position" using switch (70). For screed charging/relieving: - Set the drive lever (13) to the centre position.
  • Page 306 D 41 34...

  • Page 307: Interrupting/Terminating Operation

    Interrupting/terminating operation During breaks in paving (e.g. delay due to material trucks) - Determine the approximate duration. - When cooling down of the material below the minimum paving temperature must be expected, run the paver finisher empty and create an edge like the end of a layer. - Set the drive lever (13) to the centre position.
  • Page 308 D 41 36...

  • Page 309: When Work Is Finished

    When work is finished - Run the paver finisher empty and stop it. - Lift the screed using switch (69), set the crossbeam lock (75). - Retract the screed parts to the basic screed width and lift the auger. Where appli- cable, completely extend the levelling cylinders.

  • Page 310: Malfunctions

    Malfunctions Problems during paving Problem Cause - change in the material temperature, demixing - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long standstill times between loads - grade control reference line is not suitable - grade control jumps to the reference line Wavy surface - grade control toggles between up and down...
  • Page 311 Problem Cause - 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 312: Malfunctions On The Paver Finisher Or Screed

    Malfunctions on the paver finisher or screed Malfunction Cause Remedy See operating instructions for the At the diesel engine 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 313 Malfunction Cause Remedy Control valve is defective Replace Hoppers lowers Leaking seals of the inadvertently Replace hydraulic cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot Screed relieving or charg- Switch must be in the centre be lifted ing is switched on position...
  • Page 314 Malfunction Cause Remedy Replace (fuse strip on the oper- Travel drive fuse defective ating panel) Check potentiometer, cables, Power supply interrupted connectors; replace if necessary Travel drive monitoring Replace (type-specific) defective Traction does Electro-hydraulic servo unit Replace the servo unit not work of the pump defective Check and adjust if necessary...

  • Page 315: E11 Set-Up And Modification

    E 11 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, auger, screed or screed lifting devices. Unless otherwise specified, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Move drive lever into centre position and turn preselector controller to zero, remove...

  • Page 316: Distribution Auger

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

  • Page 317: Mechanical Adjustment With Ratchet (O)

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

  • Page 318: Height Adjustment For Large Working Widths / With Brace

    Height adjustment for large working widths / with brace Auger height adjustment for large working widths can be carried out with a hinged brace: Only adjust the height of the auger with the slewing bracket retaining pins removed! - Remove the slewing bracket (3) split pin (1) and retaining pin (2) on both sides of the vehicle.
  • Page 319 - 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"! In the case of large working widths with double braces, the procedure must be carried out on both pairs of braces (6) / (7)!

  • Page 320: Auger Extension

    Auger extension Auger_DEM.bmp Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. Refer to the appropriate chapter "Set-up and modification" in the screed operating in- structions: – 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 321: Mounting Extension Parts

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

  • Page 322: Mounting The Outer Auger Bearing

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

  • Page 323: Mounting The Auger End Bearing

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

  • Page 324: Auger Extension Chart

    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 640mm...
  • Page 325 Symbol Meaning Outer auger bearing Auger end bearing E 11 11...

  • Page 326: Auger Upgrading, Working Width 3.14 M

    Auger upgrading, working width 3.14 m 320 L 320 R Auger upgrading, working width 3.78 m 640 L 640 R Auger upgrading, working width 4.42 m 640 L 320 R 320 L 640 R E 11 12...

  • Page 327: Auger Upgrading, Working Width 5.06 M

    Auger upgrading, working width 5.06 m 320 L 960 L 320 R 960 R Auger upgrading, working width 5.70 m 640 L 960 L 960 R 640 R E 11 13...

  • Page 328: Auger Upgrading, Working Width 6.34 M

    Auger upgrading, working width 6.34 m E 11 14...

  • Page 329: Auger Upgrading, Working Width 6.98 M

    Auger upgrading, working width 6.98 m E 11 15...

  • Page 330: Auger Upgrading, Working Width 7.62 M

    Auger upgrading, working width 7.62 m E 11 16...

  • Page 331: Auger Upgrading, Working Width 8.26 M

    Auger upgrading, working width 8.26 m E 11 17...

  • Page 332: Auger Upgrading, Working Width 8.90 M

    Auger upgrading, working width 8.90 m E 11 18...

  • Page 333: Auger Upgrading, Working Width 9.54 M

    Auger upgrading, working width 9.54 m E 11 19...

  • Page 334: Auger Upgrading, Working Width 10.18 M

    Auger upgrading, working width 10.18 m E 11 20...

  • Page 335: Auger Upgrading, Working Width 10.82 M

    Auger upgrading, working width 10.82 m E 11 21...

  • Page 336: Auger Upgrading, Working Width 11.46 M

    Auger upgrading, working width 11.46 m E 11 22...

  • Page 337: Auger Upgrading, Working Width 12.10 M

    Auger upgrading, working width 12.10 m E 11 23...

  • Page 338: Auger Upgrading, Working Width 12.74 M

    Auger upgrading, working width 12.74 m E 11 24...

  • Page 339: Mounting The Auger Brace

    Mounting the auger brace E 11 25...
  • Page 340 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 341: Aligning The Auger

    Aligning the auger - Loosen lock nuts (26). Note the left-hand thread (L) and right-hand thread (R) mark on the brace! - Extend or shorten the braces (17) by rotating both adjustment rods (21) until all mounted material shafts align with the auger. The adjustment rod (21) is equipped with a bore (27) on the left and right.
  • Page 342 In the case of large working widths with double braces, the procedure must be carried out on both lower pairs of braces (30) / (31) and both upper pairs of braces (32) / (33)! E 11 28...

  • Page 343: Material Shaft, Hinged

    Material shaft, hinged To close the gap between the auger box and the screed's side board, hinged ma- terial shafts can be mounted on 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 344: Hopper Scraper

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

  • Page 345: Crossbeam Guide

    Crossbeam guide To warrant correct guidance of the crossbeams, the guide plates (1) at both sides of the vehicle must be adjusted to the prevailing paving conditions (e.g. positive or negative crowning, etc.). - Loosen screw remove screws (3). - Adjust guide plate to the required size (basic setting 25mm).

  • Page 346: Offsetting The Screed

    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 347: Levelling

    Levelling Slope controller During operation, no work may be car- ried out on the slope control linkage or the slope controller! - Mount the slope control linkage (1) in the intended position between the two crossbeams. - Mount the slope controller (2) on the slope control linkage's...
  • Page 348 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 349 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 350 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 351 - Sensor bracket, extendable (7) - Arm extension (8) 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 352 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 353 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 354 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 355 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. - Place the extension module (1) onto the centre element (2) and secure with a bolt (3).
  • Page 356 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 357 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 358 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 359 Connection diagram The three sensors are connected to the distributor box and the distributor to the ma- chine according to the following scheme. - Sensors - Front (1) - Centre (2) - Rear (3) - Distributor box (4) - Machine interface (5) E 11 45...
  • Page 360 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 361 - 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 362 Automatic steering unit E 11 48...
  • Page 363 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 364 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 365 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 366 Emergency stop during feeder operation If the function is not in use, the bridge connector must be fitted to the corre- sponding socket, as otherwise the travel drive is blocked! E 11 52...
  • Page 367 Auger temperature measurement (O) A sensor can be installed to detect the material temperature in the auger area. - Fasten the sensor (1) above the basic auger width on the machine frame with the related magnetic holder (2) as shown. - Connect the connection cable (3) of the sensor to the centre socket (TEMP) of the signal converter (4).
  • Page 368 Limit switch Auger limit switches (left and right) - mount PLC version The auger's ultrasonic limit switch is mounted on both sides on the side board's handrail. - Place the sensor bracket (1) onto the handrail, align it and tighten with a wing bolt (2).
  • Page 369 Special accessories 10.1 Material bucket Application The additional bucket is placed in the open hopper and secured in position. It is used to take larger volumes of material provided by a feeder. The material bucket may only be used in the following combinations: MH2500 - bucket, short (universal bucket): SD2500C, SD2500CS MH2550 - bucket, long: SD2550C, SD2550CS E 11 55...
  • Page 370 Description of assemblies and functions Item Description 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 11 56...
  • Page 371 Technical data Dimensions, bucket MH2500 - short version 3700 3700 E 11 57...
  • Page 372 Dimensions, bucket MH2550 - long version 3690 3690 3000 E 11 58...
  • Page 373 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 11 59...
  • Page 374 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 375 11.1 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! 11.2 Warning signs Pictogram Meaning - Warning - hot surface - risk of burning! Hot surfaces can cause severe injuries! Keep your hands at a safe distance from the danger area! Use protective clothing...
  • Page 376 11.4 Instructive symbols, prohibitive symbols, warning symbols No. Pictogram Meaning - Do not open - hazard! E 11 62...
  • Page 377 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 378 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 379 Lashing E 11 65...
  • Page 380 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 381 Loading with the crane - MH2500 E 11 67...
  • Page 382 Loading with the crane - MH2550 E 11 68...
  • Page 383 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 384 Lash the bucket in the paver E 11 70...
  • Page 385 The following explanations for securing the bucket in the paver act as examples for correct usage in a Dynapac paver finisher. When combining different brands, the bucket must be secured according to the avail- able possibilities. Dynapac does not assume any warranty for damage caused by the bucket being in- correctly secured! The paver finisher must have the necessary number of lashing points with a lashing strength of LC 5,000 daN.
  • Page 386 Mode of operation E 11 72...
  • Page 387 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 388 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 389 Screed All work required for mounting, setting up and extending the screed are described in the screed operating instructions. 12.1 Electrical connections side board - screed Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control to holder (1).
  • Page 390 Other connection possibilities: - Auger limit switches (5) - Grade control system (6) - External levelling system (7) - 24 volt consumers, e.g. additional lighting (8). When using an external levelling system, this must be logged in using the remote con- trol menu.
  • Page 391 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 392 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 393 F 28 Maintenance review Maintenance review 90 100 F 28 1...
  • Page 394 Maintenance required after the fol- lowing service hours Assembly Chapter Conveyor Auger q q q q Engine - Tier3 / q q q q Stage IIIa Engine - Tier4i / q q q q Stage IIIb Engine- Tier4F / q q q q q Stage IV Hydraulics q q q...
  • Page 395 F 31 Maintenance - conveyor Maintenance - conveyor F 31 1...
  • Page 396 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 397 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 398 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 399 Check / replace chain: At the latest, the conveyor chains (A) must be replaced when their elongation has progressed so far that they can no longer be re-tensioned. Chain links must not be removed to shorten the chain! Incorrectly dividing the chains would lead to the destruction of the drive wheels! If components have to be replaced as a...
  • Page 400 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 401 Conveyor deflectors / conveyor plates (3) At the latest, the conveyor deflectors (A) must be replaced when their lower edg- es are worn or reveal holes. The conveyor chain is not offered pro- tection by worn conveyor deflectors! - Remove conveyor deflector bolts. - Remove the conveyor deflectors from the material tunnel.
  • Page 402 F 31 8...
  • Page 403 F 40 Maintenance - auger assembly Maintenance - auger assembly F 40 1...
  • Page 404 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 405 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 406 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 407 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 408 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 409 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 410 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 411 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 412 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 413 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 414 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 415 F 50 Maintenance - engine assembly Tier 3 (o) Maintenance - engine assembly In addition to these maintenance instructions, the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances. All mainte- nance work and service intervals itemised here are binding in nature. F 50 1...
  • Page 416 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 417 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 418 Interval Maintenance point Note - Engine air filter Check air filter - Engine air filter Dust collector Emptying - Engine air filter Air filter cartridge Replace - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system...
  • Page 419 Interval Maintenance point Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt Maintenance Maintenance during the running-in period F 50 5...
  • Page 420 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 421 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 422 - 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 423 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 424 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 425 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 426 Engine air filter (4) Empty dust collector - Empty the dust removal valve (A) on the air filter housing by compressing the discharge slot. - Remove any baked on dust by press- ing together the upper valve section. Clean the dust removal valve from time to time.
  • Page 427 Replace air filter insert Maintenance of the filter becomes nec- essary if: - Engine electronics service indicator - Open the air filter housing (B) at the clips (C). - Move filter element (D) to the side a lit- tle and then pull it out of the housing. - Pull out the safety element (E) and check for signs of damage.
  • Page 428 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 429 Checking and cleaning the radiator fins - If necessary, remove leaves, dust or sand from the radiator. Observe engine's operating instructions Checking coolant concentration - Check the concentration using a suitable tester (hydrometer). - Adjust the concentration if necessary. Observe engine's operating instructions F 50 15...
  • Page 430 Engine drive belt (6) Check drive belts - Check the drive belt for damage. Small transverse cracks in the belt are acceptable. In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces, belt re- placement is necessary. Observe engine's operating instructions Replace drive belt Observe engine's operating instructions...
  • Page 431 F 52 Maintenance - engine assembly Tier 4i (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 52 1...
  • Page 432 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 433 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 434 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 435 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 (>129 KW (o)) Inspect the particulate filter Maintenance Maintenance during the running-in period...
  • Page 436 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 437 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 438 - 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 439 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 440 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 441 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 442 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 443 Cleaning / replacing the air filter car- tridge Maintenance of the filter becomes nec- essary if: - Engine electronics service indicator - Open the collector housing (B) at the clips (C). - Open the collector housing (D) at the clips (E). - Pull out the filter element (F) and safe- ty element (G).
  • Page 444 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 445 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 52 15...
  • Page 446 Engine drive belt (6) Check drive belts - Check the drive belt for damage. Small transverse cracks in the belt are acceptable. In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces, belt re- placement is necessary. Observe engine's operating instructions Replace drive belt Observe engine's operating instructions...
  • Page 447 Crankshaft ventilation filter (7) 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 448 Exhaust system - particulate filter (8) Inspect the particulate filter The particular filter must be dismantled for full inspection. A detailed description can be found in the operating manual for the engine. All safety instructions can be found in the operating manual for the engine, togeth- er with the details of the prescribed tor- ques or needed aids (e.g.
  • Page 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457 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 458 - 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 459 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 460 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 461 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 462 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 463 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 464 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 465 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 466 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 467 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 468 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 469 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 470 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 471 - 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 472 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 473 - 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 474 - 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 475 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 476 - 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 477 - 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 478 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 479 - 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 480 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 481 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 482 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 483 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 484 F 54 36...
  • Page 485 F 60 Maintenance - hydraulic system Maintenance - hydraulic system F 60 1...
  • Page 486 WARNING Danger due to hydraulic oil Hydraulic oil under high pressure can cause severe to fatal injuries! - Only competent staff should work on the hydraulic system! - Any hydraulic hoses that are cracked or soaked through must be replaced immediately. - Depressurise the hydraulic system.
  • Page 487 WARNING Danger from residual pressure in hydraulic lines Residual pressure in the hydraulic system can cause severe or fatal injuries! - Proceed as follows before working on the hydraulic system: 1. Place the machine on a level surface, secure it against accidentally rolling away and activate the parking brake if necessary.
  • Page 488 Maintenance intervals Interval Maintenance point Note - Hydraulic oil tank - Check fill level - Hydraulic oil tank - Top up with oil - Hydraulic oil tank - Change oil and clean - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank - Change and vent the suction/re- turn flow hydraulic filter...
  • Page 489 Interval Maintenance point Note - Pump distribution gear - Check oil level - Pump distribution gear - Top up oil - Pump distribution gear - Change oil - Pump distribution gear - Check bleeder - Pump distribution gear - Clean bleeder - Hydraulic hoses - Visual inspection - Hydraulic system...
  • Page 490 Points of maintenance Hydraulic oil tank (1) - Check oil level on sight glass (A). The hydraulic oil should have reached a temperature of at least 50°C for the check. The oil level must be up to the centre of the sight glass when the cylinders are retracted.
  • Page 491 To change oil: - To drain the hydraulic oil unscrew the drain plug (D) at the bottom of the tank. - Collect the oil in a container using a funnel. - When fastening the screw again after draining, make sure to use a new seal. When using the drainage hose (o): - Unscrew seal cap (E).
  • Page 492 Suction/return flow hydraulic filter (2) Carry out filter replacement according to the interval or the indicator lamp in the operating panel! - Remove cover securing screws (A) and lift off cover. - Disassemble the removed unit into: - Cover (B) - Separating plate (C) - Filter (D) - Dirt trap (E)
  • Page 493 Bleeding the filter - Fill the opened filter housing with hy- draulic oil up to approx. 2 cm below the top edge. - If the oil level drops, replenish oil again. Slow oil level reduction of approx. 1 cm / min. is normal! - If the oil level remains stable, slowly insert the assembled unit with new fil- ter element into the housing and tight-...
  • Page 494 High-pressure filter (3) The filter elements must be replaced when the maintenance indicator (A) turns red. The vehicle's hydraulic system contains 3 high-pressure filters. - Unscrew filter housing (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge. - Replace the seal ring of the filter housing.
  • Page 495 Pump distribution gear (4) - Check oil level check on sensor rod (A). The oil level must lie between the upper and lower marks. For filling in the oil: - Pull out the dipstick (A) completely. - Replenish new oil through the dipstick opening (B).
  • Page 496 Bleeder The bleeder (A) can be found on the rear of the pump distribution gear housing. - The functioning of the bleeder must be ensured. If soiling has occurred, the bleeder should be cleaned. F 60 12...
  • Page 497 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 498 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 499 Marking hydraulic hoses / storage period, period of use A number stamped onto the screwed connection provides information about the date of manufacture (A) (month / year) and the maximum pressure per- mitted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.
  • Page 500 Auxiliary flow filter (6) The hydraulic oil change is omitted on use of an auxiliary flow filter! The quality of the oil must be checked regularly. The oil level must be topped up if necessary! Replacing filter element: - Release the threaded cover connection (A) then open the non-return valve briefly to lower the oil level in the filter, then close the non-return valve again.
  • Page 501 F 74 Maintenance – drive units Maintenance – drive units F 74 1...
  • Page 502 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 503 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 504 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 505 WARNING Danger from pretensioned springs Incorrectly performed maintenance and repair work can cause severe or fatal injuries! - Always observe the maintenance instructions. - Do not perform any unauthorised maintenance or repair work to pretensioned springs. - Comply with all further information in these instructions and in the safety manual.
  • Page 506 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 507 - 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 508 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 509 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 510 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 511 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 512 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 513 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 514 F 74 14...
  • Page 515 F 81 Maintenance - electrical system Maintenance - electrical system F 81 1...
  • Page 516 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 517 Maintenance intervals Interval Maintenance point Note Check fill level of battery acid q Top up with distilled water Apply grease to battery terminals - Alternator Insulation monitoring, check elec- ((o) tric system is functioning - Alternator Visual check for pollution or damage ((o) - Check the cooling air openings...
  • Page 518 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 clamps must be free of oxide and protected with a special terminal grease.
  • Page 519 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 520 Alternator (2) Electrical system insulation monitoring 3 SEC The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an insula- tion error has occurred on the heating sections or consumers. - Start the paver finisher's drive engine.
  • Page 521 Cleaning the alternator alternator must regularly checked for excessive dirt and must be cleaned if necessary. - The air intake (1) and fan shroud (2) must be kept free of dirt. Cleaning with a high-pressure cleaner is not permissible! F 81 7...
  • Page 522 Electrical fuses / relays (3) Fuses The fuses installed may differ depending on equipment. Function F1.2 Main fuse 1 F1.2 Main fuse 2 F1.3 Diesel engine preheating ignition system F1.4 Engine T4F Levelling Brake light Operating panel / emergency stop Brake sensor Auger working light F 81 8...
  • Page 523 Function Screed / England stop button / front-wheel drive Truck Assist Heating system Left / right remote control Screed T4F Adblue heating Engine control unit Engine T4F system Sensor move platform / pave IR Connector 24V Sensor auger height Hazard flashers Operating panel Diagnostic interface control unit / display Diagnostic interface engine...
  • Page 524 Function Seat heating Rear working lights Windscreen wiper Central lubrication Main fuse lighting Left-hand parking lights Parking lights, right Operating panel illumination Low-beam headlights High-beam headlights F 81 10...
  • Page 525 Relays in the engine compartment Function Engine start F 81 11...
  • Page 526 Relays in terminal box The relays installed may differ depending on equipment. Function Ignition Drive engine start / stop Master / slave / screed controller Engine start Front lighting Rear lighting Auger lighting front Horn Parking light T4F - Adblue heating F 81 12...
  • Page 527 Function T4F - Adblue heating T4F - Adblue heating Diesel pump Adblue supply module Flashers Rotary beacon Seat heating Windscreen wiper Windscreen washer system Reverse buzzer Central lubrication Light in accordance with German Road Traffic Regulations High beam / low beam Coming home light Coming home light Preheating ignition system...
  • Page 528 F 81 14...
  • Page 529 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 530 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 531 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 532 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 533 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 534 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 535 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 536 F 90 8...
  • Page 537 F 100 Tests, stopping ... Tests, checks, cleaning, stopping F 100 1...
  • Page 538 Maintenance intervals Interval Maintenance point Note - General visual inspection - Check that the bolts and regularly nuts fit firmly q - Inspection by an expert q - Cleaning q - Cleaning sensors q - Preserving the paver finisher Maintenance Maintenance during the running-in period F 100 2...
  • Page 539 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 540 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 541 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 542 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 543 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions. Daily cleaning with a dry, lint-free cloth. F 100 7...
  • Page 544 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 545 Operating the vehicle in special climatic conditions or environments. Salty air in coastal regions, high UV radiation, sand, soil or changing conditions may cause permanent damage to vehicle parts and surfaces. There may be visible corrosion or changes to the surfaces. This has a negative impact on preserving the value of the machine! NOTE Caution! Possible damage to or destruction of parts!
  • Page 546 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 547 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 548 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 549 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 550 F 114 2...
  • Page 551 Capacities Substance Volume Fuel tank Diesel fuel litres Diesel engine Engine oil litres (with oil filter change) 28.0 litres (Tier 3 / 4i) Engine cooling system Cooling liquid 32.0 litres (Tier 4F) Hydraulic oil reservoir Hydraulic oil litres Pump distribution gear Gearbox oil litres litres...
  • Page 552 Operating substance specifications Drive engine TIER 4i, 4F / Stage IIIb, IV (o)- fuel specification Low-sulphur diesel fuel is prescribed for correct operation of the exhaust-gas treat- ment system! The maximum sulphur level must not exceed 15 ppm! If low-sulphur diesel fuel is not used, the prescribed exhaust values cannot be met and damage will be caused to the engine and to the exhaust-gas treatment system! Risk of explosion! Never mix diesel fuel with ethanol, petrol or alcohol! Diesel fuel contaminated with water or dirt can cause serious damage to the fuel sys-...
  • Page 553 Hydraulic system Dynapac AGIP Chevron Caltex Fuchs Mobil Shell Finke -Tellus Oil Hydraulic Rando Rando S2 V46 Aviaticon HDZ 46 HDZ 46 -Tellus S2 HV 46 VX46 (*) = recommended Pump distribution gear Esso / Dynapac Aral Fuchs Mobil Shell Exxon -Spirax S4 Gear Oil...
  • Page 554 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 555 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 556 2.11 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 (*) Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 Finke...
  • Page 558 www.dynapac.com...

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