Atlas Copco Dynapac SD2500W Operation & Maintenance Manual
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Atlas Copco Dynapac SD2500W Operation & Maintenance Manual

Paver finisher
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OPERATION & MAINTENANCE
Paver Finisher
Dynapac
SD2500W / SD2500WS
Typ 897 / 898
4812008813 (A5)
04-0513
Keep for later use in document compartment
Valid for:
_________________ - _________________
_________________ - _________________

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  • Page 1 OPERATION & MAINTENANCE Paver Finisher Dynapac SD2500W / SD2500WS Typ 897 / 898 4812008813 (A5) 04-0513 Keep for later use in document compartment Valid for: _________________ - _________________ _________________ - _________________...
  • Page 2 www.atlascopco.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 Screed lifting device .................17 5.17 Electrical system ..................17 5.18 Permissible temperature ranges ..............17 Location of instruction labels and identification plates ......18 Warning signs ...................21 Information signs ..................24 CE marking ....................26 Instructive symbols, prohibitive symbols, warning symbols .....26 Danger symbols ..................27 Further warnings and operating instructions ..........28 Identification label for the paver finisher (41) ........30...
  • Page 5 Lifting the vehicle with hydraulic lifts, lifting points ........25 Operation ................. 1 Safety regulations ..................1 Controls ...................... 3 Operating panel ..................3 Special functions ..................52 Reversible conveyor ................52 Remote control ..................55 Operation ................. 1 Operation of the input and display terminal ..........1 Button layout on the display ..............
  • Page 6 Operation .................1 Operating elements on the paver finisher ..........1 Control elements on the operator's control station ........1 Protective roof (o) ...................2 Ladder ....................4 Storage space ..................4 Control platform, moveable (o) ...............5 Control platform lock (o) .................6 Operating panel ..................7 Service brake ("foot brake") (o) ..............8 Protective cabin (o) ................9 Windscreen wiper .................10 .Emergency actuation control platform, movable .........11...
  • Page 7 Installation and operation ..............41 Maintenance ..................42 Replacing the lamp ................42 Operation ................. 1 Preparing for operation ................1 Required devices and aids ..............1 Before starting work (in the morning or when starting paving) ....3 Check list for the machine operator ............3 Starting the paver finisher ................
  • Page 8 Set-up and modification ............1 Special notes on safety ................1 Optional assemblies ...................2 Distribution auger ..................3 Height adjustment ..................3 Grain sizes up to 16 mm ................3 Grain sizes > 16 mm ................3 Mechanical adjustment with ratchet (o) ............4 Hydraulic adjustment (o) ................4 Height adjustment for large working widths / with brace -Auger Type A- ...5 Height adjustment for large working widths / with brace -Auger Type B- ...7 Auger extension -Auger Type A- ..............9...
  • Page 9 Offsetting the screed ................43 Lift axle ..................... 44 Levelling ....................46 Slope controller ..................46 Mounting the sensor arm ................. 47 Mounting the grade control system ............47 Setting up the sensor arm ................ 48 Big ski 9 m, big ski 13 m ................. 49 Mounting the big ski bracket on the crossbeam ........
  • Page 10 Maintenance - auger assembly ..........1 Maintenance - auger assembly ..............1 Maintenance intervals ................3 Points of maintenance ................5 Outer auger bearing (1) ................5 Auger planetary gear (2) ................6 Drive chains of the augers (3) ..............7 Auger box (4) ..................8 Seals and sealing rings (5) ..............9 Gearbox bolts Check tightening (6) ............10 Mounting screws - Outer auger bearing Check tightening (7) ....11 Auger blade (8) ..................12...
  • Page 11 Pump distribution gear (4) ..............11 Bleeder ....................12 Hydraulic hoses (5) ................13 Marking hydraulic hoses / storage period, period of use ..... 15 Auxiliary flow filter (6) ................16 Maintenance - travel drive, steering ........1 Maintenance - travel drive, steering ............1 Maintenance intervals ................
  • Page 12 F100 Tests, stopping ................1 Tests, checks, cleaning, stopping ..............1 Maintenance intervals ................2 General visual inspection ................3 Check that the bolts and nuts fit firmly ............3 Inspection by an expert ................4 Cleaning .....................5 Cleaning the hopper ...................6 Cleaning the conveyor and auger ..............6 Preserving the paver finisher ..............7 Shutdowns for up to 6 months ..............7 Shutdowns lasting from 6 months to 1 year ..........7...

  • Page 13: Preface

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

  • Page 14: General Safety Instructions

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

  • Page 15: Safety Signs, Signal Words

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

  • Page 16: Warnings

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

  • Page 18: Prohibitive Symbols

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

  • Page 19: Protective Equipment

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

  • Page 20: Environmental Protection

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

  • Page 21: Additional Information

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

  • Page 22: Ce Identification And Declaration Of Conformity

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

  • Page 23: Residual Risks

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

  • Page 24: Sensibly Predictable Incorrect Usage

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

  • Page 25: A Correct Use And Application

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

  • Page 27: B Vehicle Description

    B Vehicle description Application The Dynapac SD2500W / SD2500WS paver finisher is a wheeled paver finisher which is used for paving bituminous mixed material, roll-down or lean-mixed concrete, track- laying ballast and unbound mineral aggregates for foundations for paving.

  • Page 28: Description Of Assemblies And Functions

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

  • Page 29: Vehicle

    Vehicle Construction The paver finisher has a welded steel frame on which the individual components are mounted. The large drive wheels together with the front tandem shaft jointly compensate the irregularities of the soil and as a result of the suspension of the screed they guarantee a particularly high paving precision.
  • Page 30 Engine: The paver finisher is driven by a water cooled diesel engine. For further de- tails see the technical data and the engine's instruction manual. Traction unit: The front axle is a tandem swing axle. As the wheels are not mounted on non-uniform lifting arms, the second front wheel is subject to a heavier load on the shorter lifting arm.
  • Page 31 Material compartment (hopper): The hopper inlet is equipped with a conveyor sys- tem that empties the hopper and transfers the material to the auger. The hopper can hold approx. 13.0 t. To facilitate emptying and to improve material transport, each of the lateral covers of the hopper can be hydraulically moved.
  • Page 32 Levelling/slope control system: The slope control system (o) can be used to regulate the traction point on the left-hand or the right-hand side with a defined difference to the opposite side. To determine the actual value, the two traction crossbeams are linked with a slope control rod.

  • Page 33: Danger Zones

    Danger zones WARNING Danger for persons in the danger zone Persons in the danger zone can suffer severe or fatal inju- ries from movements and functions of the vehicle! - Never stand in the danger zone of the vehicle! - During operation, only the vehicle operator and the screed personnel are allowed on the vehicle or in the danger zone.

  • Page 34: Safety Devices

    Safety devices 4 5 6 7...
  • Page 35 Item Designation Hopper transport safeguard Screed lock, mechanical / hydraulic (o) Main switch Emergency stop button Horn Ignition key Lights Protective roof latch (o) Fire extinguisher (o) Screed warning light (o) Covers, lateral flaps, coverings Foot brake Hazard warning flasher Rotary beacon (o) Located on both sides of the vehicle Safe operation is only possible if the control and safety devices are functioning...

  • Page 36: Technical Data, Standard Configuration

    Technical data, standard configuration Dimensions (all dimensions in mm) 2125 500 425 2240 6100 6380 2055 2550 3140 3250 For screed technical data, refer to the screed operating instructions. B 10...

  • Page 37: Allowed Angle Of Rise And Slope

    Allowed angle of rise and slope max 15° max 15° max 15° max 15° Before operating your vehicle in an inclined position (gradient, slope, lateral inclina- tion) which is above the specified limit value, please consult the customer service de- partment for your vehicle! Permissible approach angle max 16°...

  • Page 38: Weights Sd2500W (All Weights In T)

    Weights SD2500W (all weights in t) Paver finisher without screed approx. 13.2 - 14.7 Paver finisher with screed: - V5100 approx. 16.5 - 18.0 With extension parts for max. working width, additionally max.: With filled hopper approx. 13.0 Additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.

  • Page 39: Performance Data Sd2500W

    Performance data SD2500W V5100TV(E) 2,55 2,00 5,10 7,30 V5100TV 2,55 2,00 5,10 7,30 V6000TV(E) 3,00 2,45 6,00 7,50 V6000TV 3,00 2,45 6,00 7,50 Transport speed 0 - 20 km/h Operating speed 0 - 30 m/min Paving height -100 - 300 Max.

  • Page 40: Performance Data Sd2500Ws

    Performance data SD2500WS V5100TV(E) 2,55 2,00 5,10 8,80 V5100TV 2,55 2,00 5,10 8,80 V5100TH 2,55 2,00 5,10 6,60 V6000TV(E) 3,00 2,45 6,00 9,00 V6000TV 3,00 2,45 6,00 9,00 V6000TVH 3,00 2,45 6,00 7,50 Transport speed 0 - 20 km/h Operating speed 0 - 30 m/min Paving height...

  • Page 41: Traction Driv/De/Chassis

    Traction driv/De/chassis Continuously variable hydrostatic drive, with Drive pump and engine Transmission Planetary gear Speeds (see above) 2 x 445/80R25 (air filled tyres) (water filled tyres Drive wheels Steering wheels 4 x 560 / 390 - 300 (elastic solid rubber tyres) 2 / 4 wheel hub hydro-motor, variable drive per- Front wheel drive formance, Anti-spin control...

  • Page 42: Hydraulic System

    5.12 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) 5.13...

  • Page 43: Screed Lifting Device

    5.16 Screed lifting device At standstill: - Screed stop - Screed stop with pretensioning (max. pressure 50 bar) Special functions During paving: - Screed charging - Screed relieving (max. pressure 50 bar) Mechanical grade control Levelling system Optional systems with and without Slope control system 5.17 Electrical system...

  • Page 44: Location Of Instruction Labels And Identification Plates

    Location of instruction labels and identification plates CAUTION Danger from missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries! - Never remove any warnings or information signs from the vehicle. - Damaged or lost warning or information signs must be replaced immediately.
  • Page 45 B 19...
  • Page 46 xxxxxxxxxxxxxxxxx B 20...

  • Page 47: Warning Signs

    Warning signs Pictogram Meaning Warning - Operating instructions! Danger due to improper operation. The machine personnel must have read and understood the safety, operating and maintenance instructions for the ma- chine before the machine is put into op- eration! Failure to comply with the operating and warning instructions can cause severe or fatal injuries.
  • Page 48 Pictogram Meaning Warning - Danger of crushing fingers and hands with moving, accessible machine parts! Crushing points can cause severe inju- ries with the loss of parts of the fingers or hand. Keep your hands at a safe distance from the danger area! Caution - Danger from incorrect tow- ing!
  • Page 49 Pictogram Meaning Warning - Hazard from hydraulic res- ervoir and from hydraulic oil under pressure! Escaping hydraulic oil under pressure can pierce the skin and enter into the body, causing severe or fatal injuries. Always observe the operating instruc- tions! Warning - Danger from tyres filled with water! Handling tyres filled with water incorrect-...

  • Page 50: Information Signs

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

  • Page 52: Ce Marking

    CE marking No. Pictogram Meaning CE, sound output level Instructive symbols, prohibitive symbols, warning symbols Pictogram Meaning Wear ear protection devices Do not enter the area! Do not spray the area or part with water! Warning on dangers posed by batteries! First aid kit B 26...

  • Page 53: Danger Symbols

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

  • Page 54: Further Warnings And Operating Instructions

    Further warnings and operating instructions Pictogram Meaning - Warning - Hazard from unsupported screed! If the screed sags, this can cause severe or fatal injuries! Insert screed lock only at crown adjustment "zero". Screed lock only for transportation! Do not enter or work under screed only secured with screed lock for transportation! - Caution - Danger of high voltage in...
  • Page 55 Pictogram Meaning Overview "Tyre pressure / working width / speed preselection" Overview "Tyre pressure / working width / speed preselection" B 29...

  • Page 56: Identification Label For The Paver Finisher (41)

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

  • Page 57: Standards

    EN standards Continuous sound pressure SD2500W, Cummins QSB 6.7-C173 The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protection devices are used, hearing can be impaired. 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 58: Continuous Sound Pressure Sd2500Ws, Cummins Qsb 6.7-C173

    Continuous sound pressure SD2500WS, Cummins QSB 6.7-C173 The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protection devices are used, hearing can be impaired. 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 59: Vibration Acting On The Entire Body

    Vibration acting on the entire body When the machine is used properly, the weighted effective acceleration values at the driver’s seat of a = 0.5 m/s according to DIN EN 1032 are not exceeded. Vibrations acting on hands and arms When the machine is used properly, the weighted effective acceleration values at the driver’s seat of a = 2.5 m/s...
  • Page 60 B 34...

  • Page 61: C13 Transportation

    C 13 Transportation Safety regulations for transportation Accidents can happen when the paver finisher and the screed are not properly pre- pared for transportation or when transportation is carried out improperly! Reduce both the paver finisher and the screed to their basic widths. Remove all pro- truding parts (such as the automatic levelling system, auger limit switches, aprons, etc.).

  • Page 62: Transportation On Low-Bed Trailers

    Transportation on low-bed trailers Reduce the paver finisher and the screed to their basic widths; also remove any at- tached side plates. The maximum approach angle is indicated in the section entitled "Technical data"! Check the fill level of the operating substances so that these do not escape when driv- ing on an incline.
  • Page 63 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safe- guards. Lift the screed. Extend levelling cylinders completely. Retract the screed parts until the screed matches the basic width of the paver fin- isher.

  • Page 64: Securing The Load

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

  • Page 65: Driving Onto The Low-Bed Trailer

    Driving onto the low-bed trailer Make sure that there are no persons in the danger area during loading. - Use the work gear and low engine speeds to drive onto the low-bed trailer. C 13 5...

  • Page 66: Lashing Equipment

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

  • Page 67: Loading

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

  • Page 68: Preparing The Machine

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

  • Page 69: Securing The Load

    Securing the load Securing at the front and at the sides Step 1: fasten lashing chains 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. Fasten the lashing chains as shown.

  • Page 70: Securing At The Rear - Screed With Side Board

    Securing at the rear - screed with side board Diagonal lashing secures the paver finisher at the rear, at right angles to the direction of travel using the lashing points on the paver finisher (eyebolts) and on the low-load trailer. Fasten the lashing straps as shown. Screw the supplied eyebolts (7) first of all in the holes provided in the arms.

  • Page 71: Securing At The Rear - Screed Without Side Board

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

  • Page 72: Control Panel Transport Safeguard

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

  • Page 73: After Transportation

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

  • Page 74: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof. - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and in lowest...
  • Page 75 The protective roof can be raised and lowered with a manual hydraulic pump. The exhaust pipe is lowered or raised to- gether with the roof. "Screw lock" version (A) - Connect the pump lever (1) to the pump (2). - Lower the roof: The locks (3) on both sides of the roof must be released.

  • Page 76: Transportation

    Transportation Reduce the paver finisher and the screed to their basic widths; also remove any at- tached side plates. Preparations - Prepare the paver finisher for transportation (see chapter D). - Remove all overlaying or loose parts from finisher and screed (see also Operating instructions for the screed).
  • Page 77 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safe- guards. Lift the screed. Extend levelling cylinders completely. Retract the screed parts until the screed matches the basic width of the paver fin- isher.

  • Page 78: Driving Mode

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

  • Page 79: Loading By Crane

    Loading by crane WARNING Danger from suspended loads Crane and/or raised vehicle can tilt when lifted and cause severe to fatal injuries! - The vehicle may only be raised at the marked lifting points. - Heed the operating weight of the vehicle. - Do not enter the danger zone.
  • Page 80 Four lifting eyes (1, 2) are provided for loading the vehicle with a crane. Depending on the type of screed which is used, the paver finisher's centre of gravity (3), with the screed mounted, is located in the area of the leading edge of the rear wheel.
  • Page 81 See section entitled "Protective roof" - Attach lifting gear to the four attachment points (1, 2). The max. permissible attachment point load is 73.5 kN. The permissible load applies in the vertical direction! Make sure that the paver finisher remains in a horizontal position during transporta- tion! C 13 21...

  • Page 82: Towing

    Towing Heed all regulations and apply all safety measures applicable for towing heavy con- struction machines. The towing vehicle must be capable of securing the paver finisher, even on slopes. Use only approved tow bars! If necessary, remove any attachments and accessories from the paver finisher and the screed until the basic width has been attained.
  • Page 83 A hand pump (1) is located under the middle floor plate of the control platform; 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 84: Safely Parking The Vehicle

    Safely parking the vehicle When the paver finisher is parked at a lo- cation accessible to the public, it must be secured in such a way that unauthorised persons or playing children cannot dam- age the vehicle. - Pull off the ignition key and the main switch (1) and take it with you –...

  • Page 85: Lifting The Vehicle With Hydraulic Lifts, Lifting Points

    Lifting the vehicle with hydraulic lifts, lifting points The hydraulic lift must be rated for at least 10t. Always choose a horizontal surface with adequate load rating as installation surface for the hydraulic lift! Make sure that the hydraulic lift is securely and correctly positioned! The hydraulic lift is only intended to lift a load and not as a support.
  • Page 86 C 13 26...

  • Page 87: D13 Operation

    D 13 Operation Safety regulations Starting the engine, the travel drive, the conveyor, the auger, the screed or the lifting devices can cause injuries or even the death of persons. Make sure before starting any of these devices that no-one is working at, in or be- neath the paver finisher or within its danger area! - Do not start the engine or do not actuate any controls when this is expressly forbid- den!
  • Page 88 DANGER Danger due to improper operation Improper operation of the vehicle can cause severe to fatal injuries! - The vehicle may only be used in the stipulated manner for its intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves familiar with the contents of the operating instructions.

  • Page 89: Controls

    Controls Operating panel All detent switch functions which may pose a risk on starting the diesel engine (auger and conveyor conveying function) are set to the STOP function in the case of EMER- GENCY STOP or restarting the control system. If settings are changed when the die- sel engine is stopped ("AUTO"...
  • Page 90 D 13 4...
  • Page 91 Item Designation Brief description Direction of travel Use when changing direction of travel on roads. indicator ("flasher") Four switch positions can be selected: - 0: Light OFF - 1: Parking lights ON (+operating panel lighting) Illumination switch - 2: Low-beam headlights ON (+operating panel lighting) - 3: High-beam headlights ON (+operating panel lighting) Avoid dazzling the oncoming traffic! Always have the warning lights on when moving the ma-...
  • Page 92 D 13 6...
  • Page 93 Item Designation Brief description For switching on the paver finisher functions and for continu- ously regulating the road speed – forward or reverse. Zero position: Engine in neutral; no travel drive; - To swivel the drive lever out, release by pulling the handle Depending on the position of the drive lever, the following func- tions can be activated: 1.
  • Page 94 D 13 8...
  • Page 95 Item Designation Brief description For setting the maximum speed that can be reached when the drive lever is at its stop. The scale roughly matches the speed in m/min (during paving). Travel drive prese- The vehicle must not travel at max. transport speed lector when the hopper is full! The vehicle speed cannot be reduced to "0"...
  • Page 96 D 13 10...
  • Page 97 Item Designation Brief description Button with detent switch function and LED feedback: - For switching on the front working lights Working lights, front - Switch OFF by pressing the button again ON / OFF (o) Avoid dazzling other road users! Button with detent switch function and LED feedback: - For switching on the rear working lights Working...
  • Page 98 D 13 12...
  • Page 99 Item Designation Brief description Pushbutton function with LED feedback: - To move the control panel to the left The platform lock must be released before moving the Move control plat- control platform! form to the left On actuation, note danger zones of moving parts of the vehicle! Pushbutton function with LED feedback: - To move the control panel to the right...
  • Page 100 D 13 14...
  • Page 101 Item Designation Brief description Pushbutton function with LED feedback: - To hydraulically extend the screed lock. Extend screed l ock (o) Before retracting and extending, lift the crossbeams slightly over the locking bolts (lift screed)! Pushbutton function with LED feedback: - To hydraulically retract the screed lock.
  • Page 102 D 13 16...
  • Page 103 Item Designation Brief description not used not used not used Detent switch function and LED feedback: Extraction - To actuate the asphalt fume control system ON / OFF (o) - Switch OFF by pressing the button again Detent switch function and LED feedback: Windscreen wip- - For switching on the windscreen wipers ers ON / OFF (o)
  • Page 104 D 13 18...
  • Page 105 Item Designation Brief description Pushbutton function: - To close the left half of the hopper Separate actuation (o): Is required when paving in spaces where there is only Left hopper limited space at one side or when obstacles obstruct Close truck unloading.
  • Page 106 D 13 20...
  • Page 107 Item Designation Brief description Pushbutton function: - To extend the left half of the screed This function is not used in vehicle configurations with a Left screed screed which cannot be extended. Extend On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - To extend the right half of the screed...
  • Page 108 D 13 22...
  • Page 109 Item Designation Brief description Pushbutton function: - To manually trigger the conveying function for the left half of the auger, conveying direction outwards. Left auger "MANUAL" For manual triggering, the auger function must be conveying direction switched to "AUTO" or "MANUAL" outwards On manual triggering, the automatic function is overrid- den with reduced delivery capacity.
  • Page 110 D 13 24...
  • Page 111 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left conveyor is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switch- es in the material tunnel. - Switch OFF by pressing the button again Left conveyor The function is shut off by pressing the EMERGENCY...
  • Page 112 D 13 26...
  • Page 113 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left conveyor is switched on continuously with full delivery capacity, without material control via the limit switches in the material tunnel. - Switch OFF by pressing the button again. - Reverse conveyor: Keep button pressed for approx.
  • Page 114 D 13 28...
  • Page 115 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left half of the auger is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switch- - Switch OFF by pressing the button again Left auger The function is shut off by pressing the EMERGENCY...
  • Page 116 D 13 30...
  • Page 117 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the left half of the auger is switched on continuously with full delivery capacity, without material control via the limit switches. - Switch OFF by pressing the button again Left auger The function is shut off by pressing the EMERGENCY "MANUAL"...
  • Page 118 D 13 32...
  • Page 119 Item Designation Brief description Button with detent switch function and LED feedback: - For manual actuation of the levelling cylinders when the automatic levelling system is switched off. - Switch OFF by pressing the button again The corresponding switch on the remote control must Adjustment be switched to "Manual"...
  • Page 120 D 13 34...
  • Page 121 Item Designation Brief description Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction. Retract / lift on left On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction.
  • Page 122 D 13 36...
  • Page 123 Item Designation Brief description Pushbutton function with LED feedback: - For lifting the screed (LED ON) and for switching off the "Screed floating position" function Check whether the screed transport safeguard is insert- Lift screed On actuation, note danger zones of moving parts of the vehicle! Button with detent switch function and LED feedback The main function switch must be set to the OFF posi-...
  • Page 124 D 13 38...
  • Page 125 Item Designation Brief description Detent switch function and LED feedback: Filling function for the paving process. The diesel engine's speed is increased to the preselect- ed nominal speed and all conveying functions set to "Au- tomatic" (conveyor and auger) are engaged. The main function switch must be set to the OFF po- sition.
  • Page 126 D 13 40...
  • Page 127 Item Designation 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 128 D 13 42...
  • Page 129 Item Designation Brief description Button with detent switch function and LED feedback: - For relieving the screed to influence the traction force and compaction ratio. Screed relieving - Switch OFF by pressing the button again or switching between screed relieving and screed charging. To preset the hydraulic oil pressure, switch this button and the "Set-up mode"...
  • Page 130 D 13 44...
  • Page 131 Item Designation Brief description Buttons with detent switch function and LED feedback: - To preselect the speed level - transport speed On restarting, the speed is set to operating speed (tor- toise). Travel drive fast When the "trailer“ (o) function is activated, the (hare) - transport gear can only be selected if the trailer is Transport gear...
  • Page 132 D 13 46...
  • Page 133 Item Designation Brief description Buttons with detent switch function and LED feedback. (LED ON = ready) - The speed control is activated by pressing the foot brake. The speed obtained after slowing down is held auto- matically. Tempomat (cruise control) - Pressing the button again switches the function off (LED ON) and the machine is accelerated to the speed set by the drive lever and the preselection po-...
  • Page 134 STOP D 13 48...
  • Page 135 Item Designation Brief description not used not used Lights up when a serious error has occurred on the engine. Switch off the drive engine immediately! Error message The error code can be called up using the switch "Serious error" "Call up error / malfunction". (red) Lights up for a few seconds once the ignition has been switched on for checking purposes.
  • Page 136 STOP D 13 50...
  • Page 137 Item Designation Brief description Battery charge in- Must go out after starting when the engine revs up. dicator (red) If the light does not go out, switch off the engine not used Indicates that there is a drive engine fault. Depending on the type of fault, the vehicle can temporarily continue to be operat- ed or, in the case of serious faults, should be shut down imme- diately to prevent further damage from occurring.

  • Page 138: Special Functions

    Special functions Reversible conveyor D 13 52...
  • Page 139 The conveyor's direction can be reversed in order to slightly reverse any paving ma- terial which may be positioned just in front of the auger. This enables e.g. material losses to be avoided during transportation. - Switch the main function switch (1) to the "off" position (LED off). - Keep one or both buttons (2) depressed for approx.
  • Page 140 D 13 54...

  • Page 141: Remote Control

    Remote control Depending on the side of the vehicle, the button blocks (A) and (B) are assigned to either the auger or the conveyor control system. The relevant element which is con- trolled is indicated by an illuminated symbol (C). Important! Do not disconnect remote controls during operation! This causes the paver finisher to be shut down! D 13 55...
  • Page 142 D 13 56...
  • Page 143 Item Designation Brief description In the case of an emergency (danger to persons, possible col- lision, etc.), press in the button! Pressing the emergency stop button switches the engine, the drives and the steering system off. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents! button...
  • Page 144 D 13 58...
  • Page 145 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the corresponding half of the auger is switched on continuously with full deliv- ery capacity, without material control via the limit switches. Auger - Switch OFF by pressing the button again "MANUAL"...
  • Page 146 D 13 60...
  • Page 147 Item Designation Brief description Pushbutton function: - Plus/minus buttons for adjusting the delivery capacity. - The delivery capacity is slowed down or speeded up Auger delivery depending on the length of time for which the button capacity is pressed. For adjustment purposes, the auger function must be switched to "AUTO"...
  • Page 148 D 13 62...
  • Page 149 Item Designation Brief description Button with detent switch function and LED feedback: - The conveying function of the corresponding half of the conveyor is switched on continuously with full de- livery capacity, without material control via the limit switches. Conveyor - Switch OFF by pressing the button again "MANUAL"...
  • Page 150 D 13 64...
  • Page 151 Item Designation Brief description Pushbutton function: - Plus/minus buttons for adjusting the delivery capacity. - The delivery capacity is slowed down or speeded up Conveyor depending on the length of time for which the button delivery capacity is pressed. For adjustment purposes, the conveyor function must be switched to "AUTO"...
  • Page 152 D 13 66...
  • Page 153 Item Designation Brief description Button with detent switch function and LED feedback: Operating mode - Operating mode "AUTO" (LED ON): levelling levelling engages automatically when the drive lever "AUTO" / is swivelled out for paving operation. "MANUAL" - Operating mode "MANUAL" (LED OFF): left levelling switched off.
  • Page 154 D 13 68...
  • Page 155 Item Designation Brief description Button with detent switch function and LED feedback: Operating mode - Operating mode "AUTO" (LED ON): levelling levelling engages automatically when the drive lever "AUTO" / is swivelled out for paving operation. "MANUAL" - Operating mode "MANUAL" (LED OFF): right levelling switched off.
  • Page 156 D 13 70...
  • Page 157 Item Designation Brief description Pushbutton function: - For manual actuation of the levelling cylinders on the corresponding side of the vehicle when the Levelling cylinder automatic levelling system is switched off (LED OFF). manual On adjustment, note the levelling display in the remote control display! Pushbutton function: - To retract and extend the screed half on the corre-...
  • Page 158 D 13 72...

  • Page 159: D21 Operation

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

  • Page 160: Command Symbols

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

  • Page 161: Menu Operation

    Menu operation D 21 3...
  • Page 162 Example: Screed heater menu - Turn the encoder (A) until the desired menu appears in the display area (H). - Press button (E) to call up the heater menu. - Turn the encoder (A) again until the selection field (red frame) is positioned over the desired parameter to be adjusted.

  • Page 163: Main Menu

    Main menu Display and function menu Displays: - (1) Speed: - paving operation (m/min) - driving mode (km/h) - (2) Actual temperature of the screen heater (°C) - (3) Fuel gauge - (4) Conveyor filling level left/right - (5) Distance travelled counter (m) - (6) Operating hours (h) - (7) Time of day (hh/mm) - (8) Used paving parameters from the parameter memory...
  • Page 164 Red cross: Emergency mode active. Hare with wheels: Trailer (o) connected. When the trailer (o) is connected, all screed, auger and levelling functions are locked, apart from lifting/lowering screed. D 21 6...
  • Page 165 Functions: Pressing encoder (A) calls up the available menus or func- tions in the start screen. The menus are called up by pressing the adjacent func- tion button. Pressing the adjacent func- tion button activates or deac- tivates the functions. If the relevant symbol is covered with a red cross, the function is deactivated.
  • Page 166 Functions: - (26) "Eco mode" function - The engine speed is constantly regulated to 1600 rpm. - (27) "Automatic steering unit" function - The vehicle is steered automatically via corresponding sensing along a reference (e.g. cable). When the automatic steering unit is activated, the steering potentiometer is deactivated.
  • Page 167 Active / inactive display function Pressing the adjacent func- tion button activates or deac- tivates the functions. If the relevant symbol is cov- ered with a red cross, the function is deactivated. D 21 9...

  • Page 168: Engine Speed" Menu

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

  • Page 169: Measured Value Display Drive Engine

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

  • Page 170: Paving Parameters" Menu

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

  • Page 171: Paving Parameters Load

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

  • Page 172: Actual Value Display Auger, Conveyor, Tamper, Vibration(O)

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

  • Page 173: Menu Paving Area / Automatic Steering Unit

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

  • Page 174: Set-Up Menu - "Delayed Screed Start

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

  • Page 175: Menu "Camera Display

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

  • Page 176: Menu "Front Wheel Drive" (O)

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

  • Page 177: Menu - "Error Memory

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

  • Page 178: Display "Engine Error Messages

    Display "Engine error messages" Display of existing error mes- sages in a table. This is shown separately from warning messages and error messages with engine stop. - (1) SPN code. - (2) FMI code. - (3) OC error frequency. All error messages can be identified in the section "Error codes drive engine".
  • Page 179 Menu "System information & basic settings" Display of the following infor- mation: - (1) Time (hh/mm/ss) - (2) Date (dd/mm/yyyy) - (3) Software version, travel drive computer - (4) Software version, terminal - (5) Operating hours (h) If consultation with Technical Support is required for your vehicle, always specify the software version! The following set-up menus can be called up directly: - (6) "Service"...

  • Page 180: Menu "Service

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

  • Page 181: Set-Up Menu "Levelling

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

  • Page 182: Set-Up Menu "Terminal Settings

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

  • Page 183: Terminal Error Messages

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

  • Page 184: Drive Engine Error Codes

    Drive engine error codes STOP If a fault has been detected on the drive engine, this is indicated by the corresponding warning lamp (1) / (2) and appears at the same time as a warning message in the display. The error message that can be called up in the display contains several numerical codes, which uniquely define the fault af- ter decoding.
  • Page 185 Example: STOP Explanation: Warning light and display signal a serious fault on the drive engine with automatic or necessary engine shut-down. Display: SPN: FMI: Cause: Cable break on sensor for rail pressure. Effect: Engine shut-down. Frequency: Fault occurs for the 1st time. Notify customer service of the error number displayed on your paver finisher;...

  • Page 186: Error Codes

    Error codes D 21 28...
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  • Page 193: Menu Structure Of The Setting And Display Menus

    Menu structure of the setting and display menus The following illustration shows the menu structure and serves to simplify operation and the procedure in the case of various settings and displays. D 21 35...
  • Page 194 D 21 36...
  • Page 195 D 31 Operation Operating elements on the paver finisher Control elements on the operator's control station WARNING Danger of falling from the vehicle Entering and leaving the vehicle and the driver's seat dur- ing operation poses the danger of falling from the vehicle which can cause severe to fatal injuries! - During operation, the operator must be at the intended driver's seat and be seated properly.
  • Page 196 Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof. - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and in lowest...
  • Page 197 The protective roof can be raised and lowered with a manual hydraulic pump. The exhaust pipe is lowered or raised to- gether with the roof. "Screw lock" version (A) - Connect the pump lever (1) to the pump (2). - Lower the roof: The locks (3) on both sides of the roof must be released.
  • Page 198 Ladder The ladder is used to access the control platform. The ladder can be secured in the top po- sition: - have the ladder raised by a second person. Set the latch (1) on both sides of the ladder to the intended position. The ladder must not be locked when driving or paving! Storage space...
  • Page 199 Control platform, moveable (o) D 31 5...
  • Page 200 The control platform can be hydraulically shifted beyond the left/right outer edge of the vehicle, providing the driver with a better view of the paving area in this position. During transportation in road traffic and when transporting the vehicle on transporters, the control platform must be secured in the central position! Actuating the platform shift function: see operating panel.
  • Page 201 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 202 Service brake ("foot brake") (o) The brake pedal is in front of the driver's seat. When the brake is actuated, the speed of the travel drive is automatically re- duced (regardless of the drive lever po- sition). If the vehicle was brought to a standstill with the service brake, it cannot be driv- en away again until after the drive lever has been put into neutral!
  • Page 203 Protective cabin (o) D 31 9...
  • Page 204 CAUTION Risk of crushing hands When closing the spring-loaded front and side windows, there is a risk of crushing which can cause injuries! - Do not reach into the danger area. - Set the latches correctly. - Comply with further instructions in the safety manual. The protective roof is equipped with an additional front window and two side windows.
  • Page 205 .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 206 Seat console The seat consoles can be swivelled for operation beyond the outer edge of the vehicle. - Press latch (1), swivel seat console to the desired position and allow latch to engage again. - Fold hinged step (2) down if neces- sary.
  • Page 207 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 208 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 209 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 31 15...
  • Page 210 Batteries The batteries (1) of the 24 V system are located in the vehicle footwell. For the specifications, refer to chapter B, ”Technical Data”. For maintenance, see chapter "F". External starting only according to the instructions (see section "Starting the paver finisher, external starting (starting aid)") Main battery switch...
  • Page 211 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) above the hopper cylinder's piston rod.
  • Page 212 Screed lock, hydraulic (o) The screed locks must additionally be extended on both sides of the vehicle prior to transportation with the screed lifted. Transportation with unsecured screed leads to a risk of accidents! - Lift the screed. - Activate the function on the operating panel.
  • Page 213 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 214 Auger lighting (o) Two swivelling headlights (1) are located on the auger box for illuminating the au- ger compartment. - They are engaged together with the working lights. These are activated together with the other working lights on the operating panel! Engine compartment lighting (o) The engine compartment lighting can be...
  • Page 215 LED working light (o) There are two LED spotlights (1) at the front of the machine and also at the back. Always align the working lights to avoid dazzling the operating personnel or other road users! D 31 21...
  • Page 216 500 watt spotlight (o) There are two halogen spotlights (2) at the front of the machine and also at the back. Always align the working lights to avoid dazzling the operating personnel or other road users! Danger of burning! The working lights get very hot! Do not touch working lights that are switched on or hot!
  • Page 217 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 218 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 219 - 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 220 Manual separator fluid spray (o) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. - Remove the spray (1) from its bracket. - Build up pressure by actuating the pump lever (2). - The pressure is indicated on the ma- nometer (3).
  • Page 221 Separator fluid spraying system (o) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. - Connect the spray hose (1) with quick- action coupling (2). Only switch on the spraying system when the diesel engine is running; other- wise, the battery will be discharged.
  • Page 222 Conveyor limit switches - PLC version The mechanical conveyor limit switches (1) or the ultrasonic conveyor limit switches (2) control the material flow on the relevant half of the conveyor. The conveyors should stop when the materi- al has roughly reached the area below the auger tube.
  • Page 223 Conveyor limit switches - conventional version The mechanical conveyor limit switches (1) control the material flow on the rele- vant half of the conveyor. The conveyors should stop when the material has roughly reached the area below the au- ger tube. This requires that the auger height has been adjusted correctly (see chapter E).
  • Page 224 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 225 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 226 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 227 Pressure control valve for screed charging/relieving A valve (1) is used to set the pressure for additional screed charging/relieving. Switching on, see screed charging/re- lieving (chapter "Operating panel", "Operation"). - For pressure indication, see manome- ter (3). Pressure control valve for paving stop with relieving This is used to set the pressure for "Screed control with paver finisher stop - floating stop with relieving".
  • Page 228 Central lubrication system (o) The central lubrication system is activat- ed in automatic mode as soon as the drive engine is started. - Pumping time: 4 min - Pause time: It is prohibited to change the factory-set durations of pumping and break without consulting the technical customer serv- ice! Changing the duration of lubrication and...
  • Page 229 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 230 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 231 Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with fire extinguisher (2) oper- ation. Observe the inspection intervals for the fire extinguisher! First-aid kit (o) Any dressings that have been used must be replaced immediately! Heed the expiry date of the first-aid kit! D 31 37...
  • Page 232 Rotary beacon (o) The function of the rotary beacon must be checked daily before starting work. - Place the rotary beacon onto the plug- in contact and secure with a wing bolt (1). - Raise the bracket (2), swivel to the outer position and allow to engage there - Slide the rotary beacon with tube (3) to...
  • Page 233 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 234 Illuminated balloon (o) The illuminated balloon generates shadow-reducing and anti-dazzle light. The illuminated balloon makes the paver finisher higher and wider. Note the passage height of bridges and tunnels and the enlarged vehicle width. Always disconnect the power supply before working on the illuminated balloon! Never look directly in the balloon when it is switched on! The illuminated balloon must not be used in the vicinity of highly flammable materials (e.g.
  • Page 235 Danger due to electric shock. Voltage flashover poses the risk of severe or fatal injuries! Heed the following safety distances to high-voltage lines: < 125KV 5m > 125KV 15m The illuminated balloon must not be operated if the electric supply cables or connectors are damaged.
  • Page 236 When equipped with an electric screed, it is possible for the lamps to flicker irregularly during the heating-up phase with simultaneous operation of 500 watt spotlights (o) and the illuminated balloon (o). Preferably only one type of lighting should be used during the heating-up phase. Maintenance Occasionally clean or replace the air filter (9) beneath the connection plate.
  • Page 237 D 43 Operation Preparing for operation Required devices and aids To avoid delays on site, check before starting work whether or not the following devices and aids are present: - Wheel loader for transporting heavy extension parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separator fluids (emulsion) and manual injector - Two filled propane gas bottles...
  • Page 238 CAUTION Danger due to restricted vision Restricted vision poses a risk of injury! - Before starting work, arrange the intended driver's seat so as to warrant adequate vision. - Signalmen must be used when vision is restricted, also to the sides and when reversing. - Only reliable persons may be used as signalmen who must have been received instructions about their task before taking up their activity.
  • Page 239 Before starting work (in the morning or when starting paving) - Heed the safety instructions. - Check the personal protective equipment . - Take an inspection walk around the paver finisher and check for leaks and damages. - Install parts removed for transportation or for the night. - When screed is operated with the optional gas heating system, open the closing valves and the main shut-off valve.
  • Page 240 Check! How? For larger working widths, the walkway Auger coverings plates must be extended and the auger tunnels must be covered. Folding walkways must be present at the basic screed and all extension parts Screed covers and walkways and folded down accordingly. Check that the side shields and the cov- ers fit firmly.
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  • Page 242 Starting the paver finisher Before starting the paver finisher Before starting the diesel engine and beginning operation, the following steps must be performed: - Daily maintenance of the paver finisher (see chapter F). Check the operating hours counter to determine whether further maintenance work should be conducted.
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  • Page 244 External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24 V system - Additional 24 V battery - Start device that is suitable for external starting (24 V/90 A).
  • Page 245 - If necessary, start the engine of the vehicle supplying power and leave to run for a while. Now try to start the other vehicle: - Press the starter button (12) to start the engine. Do not let the starter run perma- nently for more than 30 seconds;...
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  • Page 247 After starting To increase the engine speed: - Press button (65) to increase engine speed. The engine speed is increased to the preset value. Let the paver finisher warm up for approx. 5 minutes if the engine is cold. D 43 11...
  • Page 248 STOP D 43 12...
  • Page 249 Observe indicator lamps The following indicator lamps must be observed under all circumstances: For further possible faults, refer to the Engine operating instructions. Engine coolant temperature check (79) Lights up when the engine temperature is outside of the permissible range. Stop the paver finisher (drive lever to the centre position), let the engine cool down while idling.
  • Page 250 STOP D 43 14...
  • Page 251 Oil pressure indicator lamp for the travel drive (87) - Must go out after starting. If the lamp does not go out: Do not switch on the traction drive! Otherwise, the entire hydraulic system could be damaged. When the hydraulic oil is cold: - Activate set-up mode function (65).
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  • Page 253 Preparation for transportation Transportation is only permitted with the driver sitting on the left as this is the side with the service brake pedal! - Close the hopper with switch (36)/(37). - Engage both hopper transport safeguards. - Lift the screed completely using switch (62), set the crossbeam lock. - Turn the travel drive preselector (15) to zero.
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  • Page 255 Driving and stopping the paver finisher - Set the Fast/Slow switch (72) to "Hare". - Set the preselector (15) to mark 10. - For driving, carefully tilt the drive lever (13) forward or backward according to the drive direction desired. - Adjust the speed with the preselector (15).
  • Page 256 Preparations for paving Separator fluid Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator fluid. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). F0147_A1.TIF Screed heater system Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem- perature) before paving begins.
  • Page 257 Direction marks To ensure straight paving, a direction mark must be present or established (road edge, chalk lines or similar). - Slide the operating panel to the de- sired side and secure it. - Pull the direction indicator out of the bumper (arrow) and adjust it accord- ingly.
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  • Page 259 Loading/conveying material - Button (68) has to be switched off. - Use switch (36)/(37) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (54)/(55) and the conveyor (50)/(51) to "Auto". - Activate function (64) to fill the vehicle for the paving process.
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  • Page 261 Starting for paving Set the switches, levers and controls listed below to the specified positions when the screed has reached its operating temperature and a sufficient amount of material lies in front of the screed: Item Travelling direction Position Drive lever Centre position Traction drive fast/slow Tortoise-operating speed...
  • Page 262 Checks during paving The following points must be constantly observed during paving: Paver function - Screed heater system - Tamper and vibration - Engine oil and hydraulic oil temperature - The screed parts must be retracted and extended in time when obstacles are in the - Uniform material transport and distribution or supply to the screed;...
  • Page 263 Paving with "screed control at paving stop" and "screed charging/relieving" General The screed hydraulics can be influenced in three different ways to attain optimum paving results: - Paving stop + relief when the paver finisher is halting, - floating paving when the paver finisher is driving, - floating paving with screed charging or relieving when the paver finisher is driving.
  • Page 264 D 43 28...
  • Page 265 Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Function (70) Relieving (screed "lighter") Function (71) Charging (screed "heavier") The "Screed charging and relieving" functions are only effective when the paver fin- isher moves. According to the activated function, the paver finisher is automatically switched to "paving stop + relief"...
  • Page 266 The pressure to be applied depends on the load-bearing capacity of the material. If necessary, the pressure must be readjusted or changed as required during the first stops until the lower edge of the screed no longer leaves any marks when the finisher moves on again.
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  • Page 269 Adjusting the pressure Pressure adjustments can only be made while the diesel engine is running. There- fore: - Start the diesel engine and turn the traction controller (15) back to zero (precaution against inadvertent advancing). - Activate the "floating position" using switch (63). For screed charging/relieving: - Set the drive lever (13) to the centre position.
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  • Page 271 Interrupting/terminating operation During breaks (e.g. the material supply truck is late) - Determine the approximate duration. - When cooling down of the material below the minimum paving temperature must be expected, run the paver finisher empty and create an edge like the end of a lay- - Set the drive lever (13) to the centre position.
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  • Page 273 When work is finished - Run the paver finisher empty and stop it. - Lift the screed using switch (62), set the crossbeam lock. - Retract the screed parts to the basic screed width and lift the auger. Where appli- cable, completely extend the levelling cylinders.
  • Page 274 Malfunctions Problems during paving Problem Reason - change in the material temperature, demixing - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long standstill times between loads - grade control reference line is not suitable - grade control jumps to the reference line Wavy surface - grade control toggles between up and down...
  • Page 275 Problem Reason - material temperature Cracks in the layer - cold screed (centre strip) - bottom plates are worn or warped - wrong crowning - material temperature - screed extendable parts are incorrectly installed Cracks in the layer - limit switch is not correctly set (outer strip) - cold screed - bottom plates are worn or warped...
  • Page 276 Malfunctions on the paver finisher or screed Malfunction Reason Remedy See operating instructions for the At the diesel engine Diverse engine See "External starting" (start Batteries empty Diesel engine does assistance) not start Diverse see "Towing" Tamper is obstructed by cold Properly heat the screed bitumen Hydraulic oil level in the tank...
  • Page 277 Malfunction Reason Remedy Control valve is defective Replace Hoppers lowers inad- Leaking seals of the hydrau- vertently Replace lic cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot be Screed relieving or charging Switch must be in the centre lifted is switched on position...
  • Page 278 Malfunction Reason Remedy Replace (fuse strip on the oper- Travel drive fuse defective ating panel) Check potentiometer, cables, Power supply interrupted connectors; replace if necessary Travel drive monitoring Replace (type-specific) defective Traction does not Electro-hydraulic servo unit Replace the servo unit work of the pump defective Check and adjust if necessary...
  • Page 279 E 13 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, au- ger, screed or screed lifting devices. Unless otherwise specified, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Move drive lever into centre position and turn preselector controller to zero, remove...
  • Page 280 Optional assemblies Two different auger systems are available as options: Check which auger type is used in your machine and comply with the corresponding installation, operation and maintenance instructions! Auger -Type A- Central drive Auger -Type B- External drive E 13 2...
  • Page 281 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 282 Mechanical adjustment with ratchet (o) - Set the ratchet direction lever (1) to the clockwise or anti-clockwise direc- tion. Turning anti-clockwise lowers the auger, turning clockwise lifts the au- ger. - Set the desired height by alternately adjusting the right-hand and the left- hand side.
  • Page 283 Height adjustment for large working widths / with brace -Auger Type A- 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 284 - Extend or shorten the braces by rotating the adjustment rods (5) until the retaining pins can be inserted. - Retighten the lock nuts (4). - Install the split pin (1) and retaining pin (2). Each time the height is adjusted, the auger must be realigned via the braces! See section "Aligning the auger"! E 13 6...
  • Page 285 Height adjustment for large working widths / with brace -Auger Type B- Auger height adjustment for large working widths can be carried out with a hinged brace: Only adjust the height of the auger with the support retaining pins removed! - Remove the support (3) split pins (1) and retaining pin (2) on both sides of the ve- hicle.
  • Page 286 - Extend or shorten the braces by rotating the adjustment rods (5) until the retaining pins can be inserted. - Retighten the lock nuts (4). - Install the split pin (1) and retaining pin (2). Each time the height is adjusted, the auger must be realigned via the braces! See section "Aligning the auger"! E 13 8...
  • Page 287 Auger extension -Auger Type A- Auger_DEM.bmp Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. Refer to the appropriate chapter "Set-up and modification" in the Operating instruc- tions for the screed: –...
  • Page 288 Mounting extension parts Mounting the material shaft and auger extension - Secure the additional material shaft (1) to the basic unit or the adjacent material shaft with the relevant assembly parts (2) (bolts, washers, nuts). - Dismantle the assembly parts (3) of the adjacent auger blade, remove plug (4). - Insert the auger shaft extension into the auger shaft.
  • Page 289 Mounting the outer auger bearing - Dismantle the assembly parts (1) of the adjacent auger blade, remove plug (2). - Insert the outer auger bearing (3) into the auger extension. - Secure the outer auger bearing to the brace shaft with the relevant assembly parts (4) (bolts, washers, pins).
  • Page 290 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 291 Auger extension chart Symbol Meaning - Auger blade 160 mm - (160L) left - Auger blade 160 mm 160L 160R - (160R) right - Auger extension part 320mm - (320L) left - Auger extension part 320mm 320L 320R - (320R) right - Auger extension part 640mm - (640L)
  • Page 292 Symbol Meaning Outer auger bearing Auger end bearing E 13 14...
  • Page 293 Auger upgrading, working width 3.14m 320 L 320 R Auger upgrading, working width 3.78m 640 L 640 R Auger upgrading, working width 4.42m 640 L 320 R 320 L 640 R E 13 15...
  • Page 294 Auger upgrading, working width 5.06m 320 L 960 L 320 R 960 R Auger upgrading, working width 5.70m 640 L 960 L 960 R 640 R E 13 16...
  • Page 295 Auger upgrading, working width 6.34m E 13 17...
  • Page 296 Auger upgrading, working width 6.98m E 13 18...
  • Page 297 Auger upgrading, working width 7.62m E 13 19...
  • Page 298 Auger upgrading, working width 8.26m E 13 20...
  • Page 299 Mounting the auger brace E 13 21...
  • Page 300 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 301 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 302 Auger extension -Auger Type B- Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. Refer to the appropriate chapter "Set-up and modification" in the Operating instruc- tions for the screed: –...
  • Page 303 Mounting extension parts Mount auger extension Before pulling the gear off, the auger extremities must be supported with a block of wood or similar to prevent any damage. - Loosen the clamping bolts (1) on the support tube. Then turn in the centre expan- sion bolt (2) to expand the clamping joint.
  • Page 304 - Mount the required extension parts (5). Make sure that the shaft end is clean! - Push in the telescopic tube (3). When doing so, make sure that the drive of the au- ger gear (6) is pushed all the way over the shaft end of the auger extension part and that the auger threads match.
  • Page 305 Mounting support tube extensions If the auger widths exceed 6.50 m, an auger crossbeam extension must be mounted. - Loosen the clamping bolts (1) on the support tube. Then turn in the centre expan- sion bolt (2) to expand the clamping joint. - Pull the telescopic tube (3a) approx.
  • Page 306 Hydraulic hoses For larger working widths, longer hydraulic hoses have to be used for the auger mo- tors. These long hoses are included in the scope of delivery for this working width. When connecting or disconnecting hydraulic hoses, hydraulic fluid can spurt out at a high pressure.
  • Page 307 Mount guides, guide extensions and supports To ensure an optimum material flow – especially in the case of large paving widths – guides (1) must be installed. - Secure the additional guide (1) to the basic unit or the adjacent guide with the rel- evant assembly parts (2) (bolts, washers, bearing plates).
  • Page 308 Auger extension chart Symbol Meaning - Auger blade 290mm - (290L) left - Auger blade 290mm 290L 290R - (290R) right - Auger extension part 434mm - (434L) left - Auger extension part 434mm 434L 434R - (434R) right - Auger extension part 868mm - (868L) right - Auger extension part 868m...
  • Page 309 Symbol Meaning - Extension pipe - (RL) left - Extension pipe - (RR) right E 13 31...
  • Page 310 Auger upgrading, working width 3.06m +300L 300L 300R +300R 290 L 290 R Auger upgrading, working width 3.35m +345L 300L 300R +345R 434 R 434 L Auger upgrading, working width 3.93m 500R 300R +345R +345L 300L 500L 290 L 290 R 434 L 434 R E 13 32...
  • Page 311 Auger upgrading, working width 4.22m 500R 300R +345R +345L 300L 500L 868 L 868 R Auger upgrading, working width 5.08m +345L 500L 700L 700R 500R +345R 434 L 434 R 868 L 868 R Auger upgrading, working width 5.66m +345L 500L 700L 700R...
  • Page 312 Auger upgrading, working width 6.53m E 13 34...
  • Page 313 Auger upgrading, working width 7.40m E 13 35...
  • Page 314 Auger upgrading, working width 8.00m E 13 36...
  • Page 315 Mounting the auger brace E 13 37...
  • Page 316 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 317 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 (14) by rotating both adjustment rods (18) until all mounted guides and auger segments are in line. The adjustment rod (18) is equipped with a bore (27) on the left and right.
  • Page 318 Material shaft, hinged -Auger Type A- To close the gap between auger box and side board of the screen, hinged material shafts can be fitted to both sides of the auger. The hinged material shafts swivel up due to the material pressure which is exerted and swivel in due to screed retraction.
  • Page 319 Hopper scraper To reduce the gap between hopper and machine frame, the hopper scrapers (1) must be adjusted at both hopper halves. - Loosen the mounting screws (2). - Adjust a gap of 6 mm across the whole length of the scraper. - Retighten the mounting screws (2) properly.
  • Page 320 Crossbeam guide To warrant correct guidance of the crossbeams, the guide plates (1) at both sides of the vehicle must be adjusted to the prevailing paving conditions (e.g. positive or negative crowning, etc.). - Loosen screw (2) and remove screws (3). - Adjust guide plate to the required size (basic setting 25mm).
  • Page 321 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 322 Lift axle The axis load of the front axle can be reduced for travelling on public roads. The pen- dulum-mounted front axle is locked mechanically in a position that ensures that only the rear pair of wheels of the front axle are on the ground. Check the local regulations with regard to the permissible axle loads! E 13 44...
  • Page 323 Block front axle: - Drive the front wheels of the front axle onto a sufficiently large edge or ramp so that the two rear wheels of the front axle swivel down. - Switch off the machine and prevent it from rolling away! - On both sides of the machine, mount the axle locking mechanism (1) to the shackle (3) provided for this purpose on the main frame, using the corresponding assembly parts (2).
  • Page 324 Levelling Slope controller During operation, no work may be car- ried out on the slope control linkage or the slope controller! - Mount the slope control linkage (1) in the intended position between the two crossbeams. - Mount the slope controller (2) on the slope control linkage's retaining plate (3).
  • Page 325 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 326 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 327 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 328 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 329 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 330 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 331 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 332 Extending the big ski The big ski can be extended to both the 9 m and 13 m versions. Structure of the 9 m version: Extension part at the front/rear each. Structure of the 13 m version: Two extension parts at the front/rear each.
  • Page 333 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 334 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 335 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 336 Connection diagram The three sensors are connected to the distributor box and the distributor to the machine according to the following scheme. - Sensors - Front (1) - Centre (2) - Rear (3) - Distributor box (4) - Machine interface (5) E 13 58...
  • Page 337 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 338 - 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 339 Limit switch Auger limit switches (left and right) - mounting the PLC version The auger's ultrasonic limit switch is mounted on both sides on the side board's handrail. - Place the sensor bracket (1) onto the handrail, align it and tighten with a wing bolt (2).
  • Page 340 Screed The Operating instructions for the screed cover all work required for mounting, setting up and extending the screed. Electrical connections Establish the following connections on the rear of the remote control brackets (1) when the mechanical assemblies have been mounted and set up: PLC version: - Auger limit switches (2) - Remote control (3)
  • Page 341 11.1 Machine operation without remote control / side board The machine can only be driven without connected remote control corresponding bridge connectors have been fitted on both sides of the machine. Side board with mounted remote bracket: - Fit bridge connector (1) in the socket of the remote control and secure with cap.
  • Page 342 E 13 64...
  • Page 343 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 344 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 345 F 27 Maintenance review Maintenance review 90 100 F 27 1...
  • Page 346 Optional assemblies Two different auger systems are available as options: Check which auger type is used in your machine and comply with the corresponding installation, operation and maintenance instructions! Auger -Type A- Central drive Auger -Type B- External drive F 27 2...
  • Page 347 Maintenance required after the following service hours Assembly Chapter Conveyor q q q q Auger - Type A Auger - Type B q q q q q q q q Engine Hydraulic system q q q q q q Wheel chassis Electrical system q q q q Lubrication points...
  • Page 348 F 27 4...
  • Page 349 F 33 Maintenance - conveyor Maintenance - conveyor F 33 1...
  • Page 350 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 351 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 352 Points of maintenance Chain tension, conveyor (1) Check chain tension: When correctly tensioned, the conveyor chain hangs approx. 40 mm below the crossbeam of the front axle. The conveyor chains should not be too tight or too slack. An excessively taut chain can cause the chain to be stopped or to break when material falls into the 40mm...
  • Page 353 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 354 Conveyor drive - drive chains (2) To check the chain tension: At the chain protection is a scale (A) which indicates the dip of the chain. - Move the chain in the long hole of the chain protection: If the tension has been set properly, the chain must be able to move freely ap- prox.
  • Page 355 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 356 F 33 8...
  • Page 357 F 40 Maintenance - auger assembly Maintenance - auger assembly F 40 1...
  • Page 358 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 359 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 360 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 361 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 362 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 363 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 364 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 365 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 366 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 367 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 368 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 369 F 41 Maintenance - auger assembly Maintenance - auger assembly - external drive version F 41 1...
  • Page 370 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 371 Maintenance intervals Interval Maintenance point Note - Outer auger bearing - Lubricate - Auger centre bearing - Lubricate - Auger gear neck bearing - Lubricate - Auger bevel gear - Check oil level - Auger bevel gear - Top up oil - Auger bevel gear - Change oil Auger blade -...
  • Page 372 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 each time work is finished. Lubricate the outer auger bearing while they are warm to force out any bitumen residues.
  • Page 373 Centre auger bearing (2) The centre bearing (A) must be lubricat- ed on the left-hand side of the auger. To do so, the bevel gear unit must be pulled off. The centre bearing must be lubricated when in a warm state to force out any bi- tumen residues.
  • Page 374 Auger, gear neck bearing (3) Remove the socket head cap screw plug (A) on the gear neck and replace the screw located underneath with an M10x1 grease nipple. Using a grease gun, inject 10 strokes into it. Remove the grease nipple and screw both screws back in.
  • Page 375 Auger bevel gear (left/ right) (4) - For oil level check unscrew and re- move the inspection bolt/filler screw (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 376 Auger blade (5) If the surface of the auger blade (A) be- comes sharp-edged, the diameter of the auger is reduced and the blades have to be replaced. - Dismantle nuts (B) and bolt (C) and re- move the worn auger blade. Risk of injury due to sharp-edged parts! Auger blades must be installed play- free;...
  • Page 377 F 53 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 53 1...
  • Page 378 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 379 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 380 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 381 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 Maintenance Maintenance during the running-in period F 53 5...
  • Page 382 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 383 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 384 - 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 385 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 386 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 387 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 388 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 389 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 390 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 391 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 53 15...
  • Page 392 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 393 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 394 F 53 18...
  • Page 395 F 61 Maintenance - hydraulic system Maintenance - hydraulic system F 61 1...
  • Page 396 WARNING Danger from hydraulic oil Hydraulic oil under high pressure can cause severe to fatal injuries! - Only competent staff should work on the hydraulic system! - Any hydraulic hoses that are cracked or soaked through must be replaced immediately. - Depressurise the hydraulic system.
  • Page 397 Maintenance intervals Interval Maintenance point Note - Hydraulic oil tank - Check fill level - Hydraulic oil tank - Top up with oil - Hydraulic oil tank - Change oil and clean - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank - Intake / return hydraulic filter;...
  • Page 398 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 399 Safety instructions for working on the hydraulic system The vehicle's hydraulic system has two hydraulic reservoirs! Before working on the hydraulic system, depressurise the system and secure it fron inadvertent starting! Before working on the travel drive hy- draulic circuit: wait for 15 minutes after turning the die- sel engine off! The hydraulic reservoirs (A) are on the frame crossbeam at the rear axle.
  • Page 400 Points of maintenance Hydraulic oil tank (1) - Check oil level on sight glass (A). The oil level must be up to the centre of the sight glass when the cylinders are re- tracted. If all the cylinders are extended, the level can fall below the sight glass.
  • Page 401 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 402 Suction/return flow hydraulic filter (2) Carry out filter replacement according to the interval or the indicator lamp in the operating panel! - Remove cover mounting screws (A) and lift off cover. - Disassemble the removed unit into: - Cover (B) - Separating plate (C) - Filter (D) - Dirt trap (E)
  • Page 403 Bleeding the filter - Fill the opened filter housing with hy- draulic oil up to approx. 2 cm below the top edge. - If the oil level drops, replenish oil again. Slow oil level reduction of approx. 1 cm / min.
  • Page 404 High-pressure filter (3) The filter elements must be replaced when the maintenance indicator (A) turns red. The vehicle's hydraulic system contains 3 high-pressure filters. - Unscrew filter housing (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge. - Replace the seal ring of the filter hous- ing.
  • Page 405 Pump distribution gear (4) - Oil level check on dipstick (A). The oil level must lie between the upper and lower marks. For filling in the oil: - Pull out the dipstick (A) completely. - Replenish new oil through the dipstick opening (B).
  • Page 406 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 61 12...
  • Page 407 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 408 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 409 Marking hydraulic hoses / storage pe- riod, period of use A number stamped onto the threaded connection provides information about the date of manufacture (A) (month / year)and the maximum pressure permit- ted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.
  • Page 410 Auxiliary flow filter (6) The hydraulic oil change is omitted on use of an auxiliary flow filter! The quality of the oil must be checked regularly. The oil level must be topped up if neces- sary! Replacing filter element: - Release the threaded cover connection (A) then open the non-return valve briefly to lower the oil level in the filter, then close the non-return valve again.
  • Page 411 F 72 Maintenance - travel drive, steering Maintenance - travel drive, steering F 72 1...
  • Page 412 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 413 Maintenance intervals Interval Maintenance point Note - Planetary gear - Check oil level - Planetary gear - Top up oil - Planetary gear - Change oil - Planetary gear - Check oil quality Maintenance Maintenance during the running-in period F 72 3...
  • Page 414 Interval Maintenance point Note - Drive wheels - Check tyres for damage - Drive wheels - Replace tyres - Drive wheels - Check air pressure - Drive wheels - Adjust air pressure - Drive wheels - Check wheel nuts - Drive wheels - Tighten wheel nuts - Lubrication points Lubricate king pins...
  • Page 415 Points of maintenance Planetary gear (1) - Turn the rear wheel 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 th- rough the aperture.
  • Page 416 Drive wheels (2) Check tyres / replace tyres: - Check the tyres on a daily basis for signs of damage, cracks or blister for- mation. Regularly check compliance with the minimum profile depth. Replace damaged or worn tyres immediately. F 72 6...
  • Page 417 Replacing/dismantling and installing the wheels The jack must be rated for at least 10t. The jack is only intended to lift a load and not as a support. Work should only be per- formed to and under raised vehicles when they have been secured and correctly sup- ported to prevent them tilling over and rolling or sliding away.
  • Page 418 Check air pressure / adjust air pres- sure: Never work with the tyre pressure too high or too low! Please consult the following tables for the necessary air pressures. Check the air pressure at valve (A), ad- just if necessary. Check the tyre pressure in cold conditi- on.
  • Page 419 Air pressure table Depending on the equipment, the corresponding table is also affixed to the machine as a label. - (A): Recommended air pressure - (B): Max. / min. air pressure at operating speed - (C): Max. / min. air pressure at transportation speed - (D): Screed type - (E): Max.
  • Page 420 Check wheel nuts / tighten wheel nuts: Following wheel replacement, check the wheel nuts after the running-in time. - Check / tighten all wheel nuts using a torque wrench as shown. Adjust the torque to 510Nm. F 72 10...
  • Page 421 Lubrication points (3) Manual lubrication does not apply for ve- hicles with central lubrication system. King pins Each of the four king pins is equipped with one lubricating nipple (A). Steering The lubricating nipples (B) are on the rear axle of the main frame and supply the steering linkage with grease via a lu- brication line.
  • Page 422 F 72 12...
  • Page 423 F 83 Maintenance - electrical system Maintenance - electrical system F 83 1...
  • Page 424 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 425 Maintenance intervals Interval Maintenance point Note Filling level of battery electrolyte - check q Top up with distilled water Apply grease to battery terminals - Alternator Electrical system insulation moni- toring Check function - Alternator Visual check for pollution or dam- - Check the cooling air openings for pollution or clogging, clean if nec- essary.
  • Page 426 Points of maintenance Batteries (1) Maintenance of batteries The batteries are factory-filled with the correct quantity of acid. The fluid level should come up to the top mark. If re- quired, top up the battery, but only use distilled water to do so! The battery terminal clips must be free of oxide and protected with a special termi- nal grease.
  • Page 427 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 428 Alternator (2) Electrical system insulation monitoring The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an in- sulation error has occurred on the heat- ing sections or consumers.
  • Page 429 Insulation faults If an insulation fault occurs during operation, and the indicator lamp displays an insu- lation fault, the operator may proceed as follows: - Switch the switches of all external equipment and the heating system to OFF and press the reset button for at least 3 seconds to delete the fault. - If the indicator lamp does not go out, the fault lies in the generator.
  • Page 430 Cleaning the generator generator must regularly checked for excessive dirt and must be cleaned if necessary. - The air intake (1) and fan shroud (2) must be kept free of dirt. Cleaning with a high-pressure cleaner is not permissible! F 83 8...
  • Page 431 Electrical fuses / relays (3) Main fuses Fuses in terminal box Relays in terminal box Main fuses (A) F1.1 Main fuse F1.2 Main fuse F 83 9...
  • Page 432 Fuses in terminal box (B) F 83 10...
  • Page 433 Screed Screed Levelling Engine start / emergency stop not used not used Hazard flashers Emergency stop / remote steering Emulsion spraying system Travel drive sensors Electric heating Conveyor sensors 12V socket not used not used 24V socket Display voltage supply Keyboard voltage supply Engine compartment lighting Rotary beacon...
  • Page 434 Left-hand parking lights Parking lights, right Parking light Low-beam headlights High-beam headlights F 83 12...
  • Page 435 Relays in terminal box (C) F 83 13...
  • Page 436 Ignition Travel drive computer voltage supply Travel drive computer voltage supply Engine start Travel drive computer control voltage Keyboard / display Front working lights Rear working lights Horn Start inhibit, emergency stop Start inhibit Rotary beacon Seat heating Windscreen wiper Windscreen washer system Reverse buzzer Diesel pump...
  • Page 437 Relays in the engine compartment (E) Engine start F 83 15...
  • Page 438 F 83 16...
  • Page 439 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 440 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 441 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 442 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 443 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 444 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 445 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 446 F 90 8...
  • Page 447 F 100 Tests, stopping ... Tests, checks, cleaning, stopping F 100 1...
  • Page 448 Maintenance intervals Interval Maintenance point Note - General visual inspection - Check that the bolts and regularly nuts fit firmly q - Inspection by an expert q - Cleaning q - Preserving the paver finisher Maintenance Maintenance during the running-in period F 100 2...
  • Page 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457 F 113 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 458 Optional assemblies Two different auger systems are available as options: Check which auger type is used in your machine and comply with the corresponding installation, operation and maintenance instructions! Auger -Type A- Central drive Auger -Type B- External drive F 113 2...
  • Page 459 F 113 3...
  • Page 460 Capacities Substance Volume Diesel engine Engine oil litres (with oil filter change) Engine cooling system Cooling liquid 32.0 litres Fuel tank Diesel fuel litres Hydraulic oil reservoir Hydraulic oil litres Pump distribution gear Gearbox oil litres Planetary gear Gearbox oil litres Travel drive Planetary gear...
  • Page 461 Keep fuel and fuel system free of water and impurities! Observe the instructions for fuel recommendations and the specification in the main- tenance instructions of the engine manufacturer! Drive engine - Lube oil Esso / Atlas Copco Aral Fuchs Mobil Shell...
  • Page 462 Hydraulic system Atlas Copco AGIP Chevron Caltex Fuchs Mobil Shell Hydraulic Rando Rando -Tellus Oil HDZ 46 HDZ 46 S2 V46 (*) = recommended Pump distribution gear Esso / Dynapac Aral Fuchs Mobil Shell Exxon -Spirax S4 -Titan ATF ATF HDX...
  • Page 463 Auger bevel gear type B Esso / Dynapac Aral Fuchs Mobil Shell Exxon Gear Oil -Spirax S2 G 80W-90 (*) = recommended 3.10 Grease Esso / Dynapac Aral Fuchs Mobil Shell Chevron Exxon Paver -High -Gadus S5 Grease Temp T460 1.5 Premium2 (*) = recommended F 113 7...
  • Page 464 3.11 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Atlas Copco Hydraulic 120 (*) Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46...
  • Page 465 Parts & Service Training We offer our customers training courses on DYNAPAC equipment in our dedicated factory training centre. We hold regular training courses in this training centre as well as courses outside the scheduled hours. Service Please contact one of our responsible service outlets if you encounter any operational problems or have enquiries about spare parts.
  • Page 466 www.atlascopco.com...

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