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Fayat Group DYNAPAC SC2500WS Operating Instructions Manual

Paver finisher
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Operating Instructions
Paver Finisher
SD2500W / SC2500WS
Type 897 / 898
11-0419
4812074033

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Summary of Contents for Fayat Group DYNAPAC SC2500WS

  • Page 1 Operating Instructions Paver Finisher SD2500W / SC2500WS Type 897 / 898 11-0419 4812074033...
  • Page 2 www.dynapac.com...

  • Page 3: Table Of Contents

    Table of contents Preface ..................1 General safety instructions ................ 2 Laws, guidelines, accident prevention regulations ........2 Safety signs, signal words ................. 3 "Danger"! ....................3 "Warning" ! ..................... 3 "Caution" ! ....................3 "Note" ! ....................3 Other supplementary information ............... 3 Warnings ....................
  • Page 4 5.16 Hydraulic system ..................19 5.17 Material compartment (hopper) ..............19 5.18 Material transfer ..................19 5.19 Material distribution ..................19 5.20 Screed lifting device .................20 5.21 Electrical system ..................20 5.22 Permissible temperature ranges ..............20 Identification points ...................21 Warning signs ...................24 Information signs ..................27 CE marking ....................29 Instructive symbols, prohibitive symbols, warning symbols .....29 Danger symbols ..................30...
  • Page 5 Loading by crane ..................20 Towing ..................... 23 Safely parking the vehicle ................ 26 Lifting the vehicle with hydraulic lifts, lifting points ........27 Operation ................. 1 Safety regulations ..................1 Controls ...................... 3 Operating panel ..................3 Remote control ..................60 Operating the display .............
  • Page 6 (B): Remote lock active ................43 Display of the following information: .............43 "Lock menu" ..................44 "Service report" menu ................45 Display of the following information: .............45 Report for Dynapac service technician - step I ........46 Report for Dynapac service technician - step II ........47 Report for servicing carried out by the customer - step I ....48 Report for servicing carried out by the customer - step II ....49 Terminal error messages .................50...
  • Page 7 Separator fluid spraying system (o) ............. 27 Conveyor limit switches - PLC version ..........28 Conveyor limit switches - conventional version ........29 Ultrasonic auger limit switches (left and right) - PLC version ....30 Ultrasonic auger limit switches (left and right) - conventional version . 31 24 volt / 12 volt sockets (o) ..............
  • Page 8 Paver function ..................26 Quality of the layer ................26 Paving with "screed control at paving stop" and "screed charging/relieving" ..................27 General ....................27 Screed charging/relieving ..............29 Screed control with paver finisher stop / in paving operation (screed stop / paving stop / floating paving) .........29 Adjusting the pressure .................33 Setting pressure for screed control with paving stop + relieving: ..33 Interrupting/terminating operation ............35...
  • Page 9 Mounting support tube extensions ............27 Hydraulic lines ..................28 Mount guides, guide extensions and supports ........29 Auger extension chart ................30 Auger upgrading, working width 3.06m ..........32 Auger upgrading, working width 3.35m ..........32 Auger upgrading, working width 3.93m ..........32 Auger upgrading, working width 4.22m ..........
  • Page 10 Maintenance - conveyor ............1 Maintenance - conveyor ................1 Maintenance intervals ................3 Points of maintenance ................4 Chain tension, conveyor (1) ..............4 Conveyor drive - drive chains (2) ............6 Conveyor deflectors /conveyor plates (3) ..........7 Maintenance - auger assembly ..........1 Maintenance - auger assembly ..............1 Maintenance intervals ................3 Points of maintenance ................5 Outer auger bearing (1) ................5...
  • Page 11 Maintenance - engine assembly Tier 4F (o) ......1 Maintenance - engine assembly ..............1 Maintenance intervals ................3 Points of maintenance ................7 Engine fuel tank (1) ................7 Engine lube oil system (2) ..............8 Engine fuel system (3) ................ 11 Engine air filter (4) ................
  • Page 12 Bleeding the filter .................10 Ventilation filter ..................10 High-pressure filter (3) .................11 Pump distribution gear (4) ..............12 Bleeder ....................13 Hydraulic hoses (5) ................14 Marking hydraulic hoses / storage period, period of use ......16 Auxiliary flow filter (6) ................17 Maintenance - travel drive, steering ........1 Maintenance - travel drive, steering ............1 Maintenance intervals ................3 Points of maintenance ................5...
  • Page 13 F100 Tests, stopping ............... 1 Tests, checks, cleaning, stopping .............. 1 Maintenance intervals ................2 General visual inspection ................3 Check that the bolts and nuts fit firmly ............3 Inspection by an expert ................4 Cleaning ..................... 5 Cleaning the hopper ................... 6 Cleaning the conveyor and auger ..............

  • Page 15: Preface

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

  • Page 16: General Safety Instructions

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

  • Page 17: Safety Signs, Signal Words

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

  • Page 18: Warnings

    Warnings Warning on a dangerous area or hazard! Failure to observe the warnings can result in life-threatening inju- ries! Warning on danger of being pulled in! In this working area/on this element there is a danger of being pulled in by rotating or conveying elements! Only carry out activities with elements switched off! Warning on dangerous electrical voltage! All maintenance and repair work on the screed's electrical system...
  • Page 19 Warning on danger of falling! Warning on dangers posed by batteries! Warning on hazardous or irritating substances! Warning on substances which constitute a fire hazard! Warning on gas bottles!

  • Page 20: Prohibitive Symbols

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

  • Page 21: Protective Equipment

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

  • Page 22: Environmental Protection

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

  • Page 23: Additional Information

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

  • Page 24: Ce Identification And Declaration Of Conformity

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

  • Page 25: Residual Risks

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

  • Page 26: Sensibly Predictable Incorrect Usage

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

  • Page 27: A Correct Use And Application

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

  • Page 29: B Vehicle Description

    B Vehicle description Application The Dynapac 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 30: 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 31: 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 32 Engine: The paver finisher is driven by a water cooled diesel engine. For further de- tails see the technical data and the engine's instruction manual. Various engine variants in different emission classes are available as options. Stage IIIa / Tier 3 (o): There is no separate exhaust aftertreatment for this engine type when used in countries without specific regulations.
  • Page 33 Steering system/operator's platform: The fully hydraulic steering system ensures easy manoeuvrability. The small turning radius permits quick and easy manoeuvring. The operating panel can be hydraulically shifted beyond the left/right outer edge of the vehicle, providing the driver with a better view of the paving area in this position. The entire operating panel can be swivelled for operation beyond the outer edge of the vehicle, and can be additionally be locked in several positions along the control platform.
  • Page 34 Augers: The augers are driven and actuated independently from the conveyors. The left-hand and the right-hand half of the auger can be controlled separately. The drive system is fully hydraulic. The conveying direction can be changed towards the centre or towards the outside. This ensures that there is always a sufficient supply of material even if an excessive amount of material is required at one side.
  • Page 35 Crossbeams / screed lifting device: The screed lifting device is used to lift the screed during transportation. The screed's approach angle can be changed using the eccentric adjustment facility on the crossbeam. Depending on the paving condition requirements, the crossbeam can be moved backwards or forwards.

  • Page 36: Danger Zones

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

  • Page 37: Safety Devices

    Safety devices 4 5 6 7...
  • Page 38 Item Designation Hopper transport safeguard Crossbeam lock, mechanical / hydraulic (o) Main switch Emergency stop button Horn Ignition key Lights Protective roof latch (o) Fire extinguisher (o) Screed warning light (o) Covers, lateral flaps, coverings Foot brake Hazard warning flasher Rotary beacon (o) Located on both sides of the vehicle Safe operation is only possible when all operating and control elements are function-...

  • Page 39: 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 11...

  • Page 40: Allowed Angle Of Rise And Slope

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

  • Page 41: Weights 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 42: 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 43: 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 44: Travel Drive/Traction Unit

    Travel drive/traction unit Hydrostatic drive with pump and motor, Drive continuously adjustable Transmission Planetary gear Speeds (see above) Drive wheels 2 x 445/80R25 (pneumatic tyres) (water filling o) Steering wheels 4 x 560 / 390 - 300 (elastic solid rubber tyres) 2 / 4 wheel hub hydraulic motor, variable drive Front-wheel drive performance, anti-spin control...

  • Page 45: Sd2500W - Engine Engine Eu Iv / Tier 4Final (O)

    5.12 SD2500W - Engine Engine EU IV / Tier 4final (o) Make/type Cummins QSB 6.7-C173 Version 6-cylinder diesel engine (water-cooled) Performance 129 KW / 175 hp (at 2200 rpm) Pollutant emissions Stage IV / Tier 4final in accordance with: Fuel consumption, full load 33.5 l/h Fuel consumption, 2/3 load 22.4 l/h...

  • Page 46: Sd2500W - Engine Stage V (O)

    5.14 SD2500W - Engine Stage V (o) Make/type Cummins B6.7-C173 Version 6-cylinder diesel engine (water-cooled) Performance 129 KW / 175 hp (at 2200 rpm) Pollutant emissions Stage V in accordance with: Fuel consumption, full load 32.9 l/h Fuel consumption, 2/3 load 22.0 l/h Fuel tank capacity (See chapter F)

  • Page 47: Hydraulic System

    5.16 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 - Separate hydraulic circuits for options Hydraulic oil reservoir - volume (See chapter F) 5.17...

  • Page 48: Screed Lifting Device

    5.20 Screed lifting device At standstill: - Screed stop - Screed stop with pretensioning (max. pressure 40 bar) Special functions During paving: - Screed charging - Screed relieving (max. pressure 40 bar) Mechanical grade control Levelling system Optional systems with and without slope control 5.21 Electrical system On-board voltage...

  • Page 49: Identification Points

    Identification points CAUTION Danger due to missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries! - Never remove any warnings or information signs from the vehicle. - Damaged or lost warning or information signs must be replaced immediately.
  • Page 50 B 22...
  • Page 51 xxxxxxxxxxxxxxxxx B 23...

  • Page 52: Warning Signs

    Warning signs Pictogram Meaning Warning - Operating instructions! Danger due to improper operation. The vehicle personnel must have read and understood the safety, operating and maintenance instructions for the ve- hicle before the vehicle is put into opera- tion! Failure to comply with the operating and warning instructions can cause se- vere to fatal injuries.
  • Page 53 Pictogram Meaning Warning - Danger of crushing fingers and hands due to moving, accessible vehicle parts! Crushing points can cause severe inju- ries with the loss of parts of the fingers or hand. Keep your hands a safe distance away from the danger area! Caution - Danger from incorrect towing!
  • Page 54 Pictogram Meaning Warning - Hazard from hydraulic reservoir and from hydraulic oil under pressure! Escaping hydraulic oil under pressure can pierce the skin and enter into the body, causing severe or fatal injuries. Always observe the operating instructions! Warning - Danger from tyres filled with water! Handling tyres filled with water incorrect- ly can cause severe to fatal injuries.

  • Page 55: 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 56 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 57: Ce Marking

    CE marking Pictogram Meaning CE, sound output level Instructive symbols, prohibitive symbols, warning symbols Pictogram Meaning Wear ear protectors Do not enter the area! Do not spray the area or component with water! Warning on dangers posed by batteries! First aid kit B 29...

  • Page 58: Danger Symbols

    Danger symbols Pictogram Meaning - XN: Danger to health! This substance can damage your health when absorbed in the body! Substance irritating to skin, eyes and res- piratory system; can cause inflammation. Avoid contact with the human body; also avoid inhaling the vapours and seek medical advice if feeling unwell.

  • Page 59: 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 to fatal injuries! Insert crossbeam lock only at crown adjustment "zero". Cross- beam lock only for transportation! Do not enter or work under screed only secured with crossbeam lock for transportation! - Attention - Danger of high voltage...
  • Page 60 Pictogram Meaning Overview "Tyre pressure / working width / speed preselection" Overview "Tyre pressure / working width / speed preselection" B 32...

  • Page 61: Identification Label For The Paver Finisher (41)

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

  • Page 62: Explanation Of 17-Digit Pin Serial Number

    Explanation of 17-digit PIN serial number >10002014JHG002076< - Manufacturer - Family/Model - Code letter - Serial number B 34...

  • Page 63: Engine Type Plate

    Engine type plate The engine type plate (1) is affixed on top of the engine. The type plate states the engine type, serial number and engine data. Please state the engine number of the engine when ordering spare parts. See also operating instructions for the engine. B 35...

  • Page 64: Standards

    EN standards Continuous sound pressure SD2500W The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protectors are used, hearing can be impaired. The sound emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6:2006 and ISO 4872.

  • Page 65: Continuous Sound Pressure Sd2500Ws

    Continuous sound pressure SD2500WS The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protectors are used, hearing can be impaired. The sound emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6:2006 and ISO 4872.

  • Page 66: Vibration Acting On The Entire Body

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

  • Page 67: 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 68 WARNING Danger due to vehicle loading Loading or unloading the vehicle onto or from another vehi- cle poses a potential risk of accident. Vehicles can tip over on driving onto the low-bed trailer and cause severe to fatal injuries! - The transportation vehicle must always meet the requirements for transportation and be designed for this.
  • Page 69 WARNING Danger due to incorrect directing of the vehicle A banksman must be used when visibility is impaired on roads or transport roads and when loading the vehicle. Incorrectly implemented or misunderstood directions given by the banksman can cause severe to fatal injuries! The banksmen assigned for directing vehicles may only consist of personnel - who have been trained for directing machines and can...

  • Page 70: Transportation On Low-Bed Trailers

    Transportation on low-bed trailers Reduce the paver finisher and the screed to their basic widths; also remove any at- tached side plates. The maximum approach angle is indicated in the section entitled "Technical data"! Check the fill level of the operating substances so that these do not escape when driv- ing on an incline.
  • Page 71 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Fully extend the levelling cylinder. Retract the screed parts until the screed matches the basic width of the paver finisher. Deactivate set-up mode.

  • Page 72: Securing The Load

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

  • Page 73: Driving Onto The Low-Bed Trailer

    Driving onto the low-bed trailer Make sure that there are no persons in the danger area during loading. - Use the work gear and low engine speeds to drive onto the low-bed trailer. C 13 7...

  • Page 74: Lashing Equipment

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

  • Page 75: Loading

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

  • Page 76: Preparing The Vehicle

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

  • Page 77: Securing The Load

    Securing the load Securing at the 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 78: Securing At The Rear - Screed With Side Board

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

  • Page 79: Securing At The Rear - Screed Without Side Board

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

  • Page 80: After Transportation

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

  • Page 81: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and...
  • Page 82 The protective roof can be raised and lowered electrically. The exhaust pipe is lowered or raised to- gether with the roof. - Tighten bolts (1) on both sides of the roof. - Operate the switch (2) until the roof has reached the upper or lower limit position.

  • Page 83: 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 84 Operation Buttons Deactivating the function lock Activate set-up mode. Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Fully extend the levelling cylinder. Retract the screed parts until the screed matches the basic width of the paver finisher. Extend crossbeam lock.

  • Page 85: Driving Mode

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

  • Page 86: Loading By Crane

    Loading by crane WARNING Danger from suspended loads Crane and/or lifted vehicle can tip when lifted and cause injuries! - The vehicle may only be raised at the marked lifting points. - Heed the operating weight of the vehicle. - Do not enter the danger zone. - Use only lifting gear that can bear the load.
  • Page 87 Four lifting eyes (1, 2) are provided for loading the vehicle with a crane. Depending on the type of screed which is used, the paver finisher's centre of gravity, with the screed mounted, is located in the area of the front edge (3) of the rear wheel. - Secure vehicle wherever it is parked up.
  • Page 88 See section entitled "Protective roof" - Attach lifting gear to the four attachment points (1, 2). The max. permissible attachment point load at the attachment points is 73.5 kN. The permissible load applies in the vertical direction! Make sure that the paver finisher remains in a horizontal position during transportation! C 13 22...

  • Page 89: 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 90 A hand pump (5) is located under the central control platform floor panel; it must be actuated to be able to tow the machine. Pressure for releasing the traction system brakes is built up with the hand pump. - Push knob (6) into the valve body. While pumping (next step), check that the knob remains in the pressed position.
  • Page 91 - Attach the tow bar to the coupling (9) located in the bumper. Now carefully and slowly tow the paver finisher out of the construction area. Only ever tow the shortest distance to the means of transport or the next park- ing possibility.

  • Page 92: 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 93: 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 94 C 13 28...

  • Page 95: 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 forbidden! Unless otherwise specified, the controls may only be actuated when the engine...
  • Page 96 DANGER Danger due to improper operation Improper operation of the vehicles can cause severe to fatal injuries! - The vehicle may only be used in the proper manner for its intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves familiar with the contents of the operating instructions.

  • Page 97: Controls

    Controls Operating panel All detent switch functions which may pose a risk on starting the diesel engine (auger and conveyor conveying function) are set to the STOP function in the case of EMERGENCY STOP or restarting the control system. If settings are changed when the diesel engine is stopped ("AUTO"...
  • Page 98 D 13 4...
  • Page 99 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...
  • Page 100 D 13 6...
  • Page 101 Item Designation Brief description For starting and shutting off the drive engine. - On actuation, the starter is in operation - Switch the running engine OFF by pressing the button again Starter / drive Run the starter continuously for a maximum engine OFF of 20 seconds, then take a break for 1 minute! All emergency stop buttons (on the operating panel and...
  • Page 102 D 13 8...
  • Page 103 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 The vehicle must not travel at max. transport speed preselector when the hopper is full! The vehicle speed cannot be reduced to "0"...
  • Page 104 D 13 10...
  • Page 105 Item Designation Brief description Button with detent switch function and LED feedback: Front working - For switching on the front working lights lights - Switch OFF by pressing the button again ON / OFF (o) Avoid dazzling other road users! Button with detent switch function and LED feedback: - For switching on the rear working lights Rear working lights...
  • Page 106 D 13 12...
  • Page 107 Item Designation Brief description Detent switch function and LED feedback: Windscreen wip- - For switching on the windscreen wipers ers ON / OFF (o) - Switch OFF by pressing the button again Detent switch function and LED feedback: Windscreen wash- - For engaging the windscreen washer system + wind- er system + wind- screen wipers...
  • Page 108 D 13 14...
  • Page 109 Item Designation Brief description Button with detent switch function and LED feedback: Filling pump - For switching on the filling pump Fuel tank ON / OFF (o) - Switch OFF by pressing the button again Button with detent switch function and LED feedback: Seat heating - For switching on the seat heating ON / OFF (o)
  • Page 110 D 13 16...
  • Page 111 Item Designation Brief description Buttons with detent switch function and LED feedback: - for activating the parking brake when the vehicle is stationary. Parking brake The parking brake must be deactivated to start the drive the vehicle away again. D 13 17...
  • Page 112 D 13 18...
  • Page 113 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 114 D 13 20...
  • Page 115 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 Close hopper left limited space at one side or when obstacles obstruct truck unloading.
  • Page 116 D 13 22...
  • Page 117 The Truck Assist system is used for communication between the driver of the paver and the driver of the material truck. The corresponding signal system shows the truck driver which action to perform (reversing / stop / tip material / depart). Caution! Possible material damage through insuffi- NOTE cient instruction...
  • Page 118 D 13 24...
  • Page 119 Item Designation Brief description LED display Pushbutton function with LED feedback: - To change over to the "Start Tipping" signal. (YELLOW SIGNAL, running light as- cending) - Press button again to change signal over to "Pause". Tell truck "Start (YELLOW SIGNAL, flashing). Tipping"(raise truck hopper) The button LED + button LED (41) flash-...
  • Page 120 D 13 26...
  • Page 121 Item Designation Brief description LED display Pushbutton function with LED feedback: - The "Truck Assist" function runs auto- matically. - Switch OFF by pressing the button again - Press button (38) to request a truck with material / Release for truck to approach (GREEN SIGNAL) The truck is detected by a laser sensor at...
  • Page 122 D 13 28...
  • Page 123 Item Designation Brief description Pushbutton function: - To extend the left half of the screed This function is not used in vehicle configurations with Extend a screed which cannot be extended. left screed On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - To extend the right half of the screed...
  • Page 124 D 13 30...
  • Page 125 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 126 D 13 32...
  • Page 127 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. To avoid excessive conveying, the system is shut off at Left conveyor a defined material height!
  • Page 128 D 13 34...
  • Page 129 Item Designation Brief description Pushbutton function: - The conveying direction of the conveyor can be re- versed in order to slightly reverse paving material for example which may be present in the material tunnel. The function can be triggered in all modes of the conveyor.
  • Page 130 D 13 36...
  • Page 131 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 switches. - Switch OFF by pressing the button again Left auger The function is shut off by pressing the EMERGENCY...
  • Page 132 D 13 38...
  • Page 133 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 134 D 13 40...
  • Page 135 Item Designation Brief description Pushbutton function: - To manually trigger the conveying function for the left half of the auger, conveying direction inwards. Left auger "MANUAL" After triggering the function, a previously engaged Conveying "AUTO" or "MANUAL" function is switched off. direction inwards On manual triggering, the automatic function is overrid- den with reduced delivery capacity.
  • Page 136 D 13 42...
  • Page 137 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 138 D 13 44...
  • Page 139 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 Levelling cylinder be switched to "Manual"...
  • Page 140 D 13 46...
  • Page 141 Item Designation Brief description Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction. Retract / lift on left On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - To adjust the selected function in the corresponding Adjustment button: direction.
  • Page 142 D 13 48...
  • Page 143 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 preselected nominal speed and all conveying functions set to "Auto- matic" (conveyor and auger) are engaged. The main function switch must be set to the OFF position.
  • Page 144 D 13 50...
  • Page 145 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 inserted! Lift screed On actuation, the levelling function in AUTO mode is switched off.
  • Page 146 D 13 52...
  • Page 147 Item Designation Brief description Button with detent switch function and LED feedback: - Tamper ON and OFF function. - Activation is carried out by swivelling the drive lever out. - Switch OFF by pressing the button again. Tamper (screed-specific) The main function switch must be set to the OFF position.
  • Page 148 D 13 54...
  • Page 149 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 150 D 13 56...
  • Page 151 Item Designation Brief description Pushbutton function with LED feedback: - To hydraulically extend the crossbeam lock. Extend cross- Before retracting and extending the lock, raise beam lock (o) the crossbeams slightly over locking bolts (raise the screed)! Pushbutton function with LED feedback: - To hydraulically retract the screed lock.
  • Page 152 D 13 58...
  • Page 153 The "Set Assist" function prepares the paver to relocate to another section of road- works or for transportation. When the function is activated, previously selected vehicle functions are carried out to make the vehicle ready for transport. The function can be reset after relocating the paver. This restores the corresponding elements to the previously saved working condi- tion /position.

  • Page 154: Remote Control

    Remote control D 13 60...
  • Page 155 Depending on the side of the vehicle, the button blocks (A) and (B) are assigned to either the auger or the conveyor control system. The relevant element which is con- trolled is indicated by an illuminated symbol (C). Important! Do not disconnect remote controls during operation! This causes the paver finisher to be shut down! D 13 61...
  • Page 156 D 13 62...
  • Page 157 Item Designation Brief description Press in an emergency (danger to persons, impending colli- sion, etc.)! Pressing the emergency stop button switches off the en- gine, the drives and the steering system. Making way, lifting the screed or other actions are then no Emergency longer possible! Danger of accident! stop button...
  • Page 158 D 13 64...
  • Page 159 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 delivery capacity, without material control via the limit switches. Auger - Switch OFF by pressing the button again "MANUAL"...
  • Page 160 D 13 66...
  • Page 161 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. The auger function must be switched to "AUTO" or "MANUAL"...
  • Page 162 D 13 68...
  • Page 163 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 164 D 13 70...
  • Page 165 Item Designation Brief description Pushbutton function: - Plus/minus buttons for adjusting the delivery capacity. - The delivery capacity is slowed down or speeded up Conveyor delivery depending on the length of time for which the button capacity is pressed. The conveyor function must be switched to "AUTO" or "MANUAL"...
  • Page 166 D 13 72...
  • Page 167 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 168 D 13 74...
  • Page 169 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 170 D 13 76...
  • Page 171 Item Designation Brief description Pushbutton function: - Direct adjustment of the crowning with call-up of the Manual control corresponding menu showing the actual value. crowning adjustment (+) Comply with the corresponding "Screed Control" instructions! Pushbutton function: - Direct adjustment of the crowning with call-up of the Manual control corresponding menu showing the actual value.
  • Page 172 D 13 78...
  • Page 173 Item Designation Brief description Pushbutton function: - For manual actuation of the levelling cylinders on the corresponding side of the vehicle when the automatic Levelling cylinder levelling system is switched off (LED OFF). manual On adjustment, note the levelling display in the remote control display! Press in the case of emergencies and to indicate when the ve- hicle starts to move!
  • Page 174 D 13 80...
  • Page 175 Item Designation Brief description Pushbutton function: - To retract and extend the screed half on the corre- sponding side of the vehicle. Extend/retract This function is not used in vehicle configurations with a screed screed which cannot be extended. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - 2 speeds can be selected for the adjustment using the...
  • Page 176 D 13 82...
  • Page 177 Item Designation Brief description Pushbutton function: - Calling up the "travel-dependent lateral slope" menu. The nominal value for required lateral slope and the dis- Travel-dependent tance for adjusting the lateral slope can be entered in lateral slope the corresponding menu. control The function is started in the same menu.
  • Page 178 D 13 84...
  • Page 179 Item Designation Brief description Pushbutton function: - Direct adjustment of the crowning with call-up of the Manual control corresponding menu showing the actual value. crowning adjustment (+) Comply with the corresponding "Screed Control" instructions! Pushbutton function: - Direct adjustment of the crowning with call-up of the Manual control corresponding menu showing the actual value.
  • Page 180 D 13 86...

  • Page 181: D22 Operating The Display

    D 22 Operating the display D 22 1...

  • Page 182: Operation Of The Input And Display Terminal

    Operation of the input and display terminal Button layout on the display - (A) Jog dial (knob to be turned+push button): - Turn: - to select various adjustment parameters within a menu - to adjust the parameter - to select various selection possibilities within a menu - Press: to release the adjustment of a parameter - to confirm a parameter adjustment...
  • Page 183 To confirm an active/opened menu, the colour of the cor- responding symbol changes from pale to dark grey! Press the corresponding function button again to go back to the previous page. - (F) Display area for status, warning and error messages: - To show current earnings or error messages.
  • Page 184 Colour code Explanation RED - error message - Reports a serious fault that must be checked and rec- tified immediately. YELLOW - warning message - Reports a current condition that needs to be observed or rectified at short notice to ensure correct working. BLUE / GREEN - status message - Confirms an activated function.

  • Page 185: Menu Operation - Procedure For Adjusting Parameters

    Menu operation - procedure for adjusting parameters D 22 5...
  • Page 186 Example: Adjusting the screed temperature - The "Home" menu is open in the display. - Press button (A) to open the "Engine speed" menu. - The "Engine speed" menu is open in the display. - Press button (B) to open the "Screed heater" menu. - Turn jog dial (C) to make the cursor appear.

  • Page 187: Selecting And Changing An Adjustment Parameter In A Menu

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

  • Page 188: Selecting And Changing A Selection Possibility In A Menu

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

  • Page 189: Menu Structure

    Menu structure Menu of the "Home" displays Displays: - (1) Speed: - Paving (tortoise)-(m/min) / (ft/min) - Driving (hare) - (km/h) / (mph) Speed preselection is possible when at a standstill (only for paving). The preselected speed then appears in "blue". - (2) Fuel gauge ®...
  • Page 190 - (7) Extension distance - extendable part screed left (cm) / (inch) (o) - (8) Extension distance - extendable part screed right (cm) / (inch) (o) - (9) Course thickness - screed left (cm) / (inch) (o) - (10) Course thickness - screed right (cm) / (inch) (o) - (11) Crowning - (%) (o) - (12) Target slope - left / right (%) (o) - (13) Overall width screed (cm) / (inch) (o)

  • Page 191: Home" Menu - Sub-Menus

    "Home" menu - sub-menus Open the following sub-menus: - (1) Show "Home" functions / "Quick settings" - (2) Call "Engine speed" menu / Engine measured value display + sub-menus. - (3) "Paving parameters" menu + sub-menus. - (4) "Camera display" menu + sub-menus.(o) - (5) "Error memory"...

  • Page 192: Home" Functions / "Quick Settings" Menu

    "Home" functions / "Quick settings" menu Menu for directly activating various functions. - Press corresponding function button to show the functions / quick settings (1) to (6). Press once more to hide the functions again. Pressing the adjacent function button activates or deac- tivates the functions.
  • Page 193 - (4): "Joint hopper actuation" function - Both hopper halves are actuated together with one of the hopper function switch- es (open hopper / close hopper). - (5) "Automatic steering unit" function (only for caterpillar pavers) - The vehicle is steered automatically via corresponding sensing along a reference (e.g.

  • Page 194: Engine Speed" Menu / Engine Measured Value Display

    "Engine speed" menu / Engine measured value display Menu for adjusting the engine speed and for checking various measured values of the engine. - (1) Nominal speed display and adjustment parameters Adjusted directly by pressing the job dial. Adjustment is carried out in steps of 50; the engine speed is adapted directly. - (2) Actual engine speed - (3) Engine oil pressure (bar) - (4) On-board voltage (V)

  • Page 195: Material Management" Measured Value Display

    "Material management" measured value display Menu for checking the following parameters: - (1) Paving material level (%) conveyor left - (2) Paving material level (%) conveyor right - (3) Paving material level (%) auger left - (4) Paving material level (%) auger right - (5) Tamper speed (n/min) - (6) Vibrations speed (n/min) - (7) Auxiliary compactor pressure setting (bar)

  • Page 196: Screed Heater" Adjustment And Display Menu (O)

    "Screed heater" adjustment and display menu (o) Menu for adjusting the nominal screed heater temperature and for checking the actu- al temperatures and for activating the "Sectional heating" function (o) - (1) Nominal screed heater temperature display and adjustment parameters. Press encoder (A) to start the editing menu.

  • Page 197: Paving Area / Automatic Steering Unit" Menu

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

  • Page 198: Front Wheel Drive" Measured Value Display (O)

    "Front wheel drive" measured value display (o) Display of the power provided for the front wheel drive. - (1) Power display left front wheel drive. - (2) Power display right front wheel drive. - (3) Display and adjustment parameters for traction (o) - ((>):low traction - ((>>):high traction - ((>>>):maximum traction...

  • Page 199: Particulate Filter Regeneration" Menu (O)

    "Particulate filter regeneration" menu (o) 1b 2a Menu for triggering requested active filter regeneration and for disabling automatic fil- ter regeneration. - (1) Particulate filter regeneration, manual: - for triggering necessary particulate filter regeneration. Necessary regeneration is indicated by the regeneration warning sign (1a)! Please heed the notes in the "Terminal error messages"...
  • Page 200 Danger from particulate filter regeneration DANGER Improper particulate filter regeneration can cause severe to fatal injuries! - Keep the outlet of the exhaust pipe out of the reach of people and of objects that can burn, melt or explode! - There may not be any people or objects within a radius of 0.6 m of the exhaust outlet! - There may not be any objects or substances that can burn, melt or explode within a radius of 1.5 m.

  • Page 201: Paving Parameters" Menu

    "Paving parameters" menu Menu for showing and adjusting the paving parameters. - (1) Current course thickness parameter - The following course thickness parameters can be selected: - (1a) Surface course >, low paving speed - (1b) Surface course >>, high paving speed - (1c) Binder course >, low paving speed - (1d) Binder course >>, high paving speed - (1e) Foundation...
  • Page 202 - (2) Left conveyor speed (%) display and adjustment parameters - (3) Right conveyor speed (%) display and adjustment parameters - (4) Left auger speed (%) display and adjustment parameters - (5) Right auger speed (%) display and adjustment parameters - (6) Nominal tamper speed (n/min) display and adjustment parameters - (7) Nominal vibration speed (n/min) display and adjustment parameters - (8) Auxiliary compactor pressure setting (bar) display and adjustment parameters...

  • Page 203: Adjusting The Paving Parameters

    Adjusting the paving parameters Functions: - (9) "Save parameter" function As confirmation, the display changes for 5 to 10 seconds during saving. - (10): "Load parameter" function As confirmation, the display changes for 5 to 10 seconds during loading. - (11): "Parameter reset - Load factory settings" function Firstly the system requests reset confirmation.
  • Page 204 Overview "Course thickness parameters" Menu for viewing the speeds saved for all conveying and compacting elements ac- cording to the course thickness parameters. Back to the main menu: - (1) "Paving parameters" menu. D 22 24...

  • Page 205: Camera Display" Menu (O)

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

  • Page 206: Error Memory" Menu

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

  • Page 207: Detailed Display "Error Messages With Travel Drive Stop

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

  • Page 208: Detailed Display "Vehicle Warning Messages

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

  • Page 209: Detailed Display "Engine Error Messages

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

  • Page 210: Basic" Menu

    "Basic" menu The "Basic" menu can be opened from every menu, sub-menu or display. Menu for opening the following sub-menus: - (1) "Home" menu - Display and "Quick settings" menu. - (2) "Service" menu - Menu for service technician (password required) - (3) "Info &...
  • Page 211 "Service" menu Password-protected menu for various service settings. D 22 31...

  • Page 212: Info & Settings" Menu

    "Info & Settings" menu Menu for calling up various vehicle information and sub-menus for various settings. Display of the following information: - (1) Software version of the vehicle - (2) Software version of the display - (3) Engine operating hours (h) - (4) Vehicle serial numbers (17-digit PIN) / (VIN) - (5) Dynalink module number (o) (15-digit number) / (IMEI) If consultation with Technical Support is required for your vehicle, always specify the...

  • Page 213: Screed" Set-Up Menu

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

  • Page 214: Paving / Travel" Set-Up Menu

    "Paving / Travel" set-up menu Menu for setting up the vehicle and levelling functions. - (1) Display and adjustment parameters for "Delayed front hopper" - delay time (sec). (o) After closing the hopper lids, the front hopper is only raised after the adjusted time has expired.
  • Page 215 - (3) Selection "Cross levelling" - (0): Cross levelling OFF - (1): Only data display of the opposite side of the vehicle. - (2): Data display and control of the opposite side of the vehicle. - (3):Split screen on the remote controls: simultaneous data display and operation of both sides of the vehicle possible.

  • Page 216: Truck Assist / Set Assist" Set-Up Menu

    "Truck Assist / Set Assist" set-up menu Menu for setting up the "Truck Assist" and "Set Assist" functions. - (1) Selection "Truck distance" In order to adjust to the prevailing situation, the truck’s automatic detection function can be preset to 3 different distances (paver/truck). - (1.1): Shortened distance - (1.2): Medium distance - (1.3): Extended distance...
  • Page 217 - (3) Selection "Auto Save" The working condition / current position of the corresponding functions and compo- nents is saved automatically on pressing the Set Assist function button (operating panel). D 22 37...

  • Page 218: Day/Night Lighting" Set-Up Menu

    "Day/night lighting" set-up menu Menu for adjusting the illuminance of various control elements. - (2) Monitor brightness display and adjustment parameters - (2.1): daytime light (%) - (2.2): nighttime light (%) - (3) Truck Assist display and adjustment parameters - (3.1): daytime light (%) - (3.2): nighttime light (%) D 22 38...

  • Page 219: Display" Set-Up Menu

    "Display" set-up menu Menu for setting up basic display settings. - (1) Selection "System language" - English / German - (2) Selection "Units of measurement" - Metric / Imperial (US) - (3) "Time" display and adjustment parameters - h/h : min/min - 24h / PM/AM - (4) "Date"...
  • Page 220 "Camera / display" set-up menu Menu for setting up the camera display. - (1) Brightness display and adjustment parameters - (2) Contrast display and adjustment parameters - (3) Colour display and adjustment parameters Setting range 0-100% Open the following sub-menus: - (4) "Display"...

  • Page 221: Licence Text" Display

    "Licence text" display Display of the software licence text. Exit display: - (B) Back to the previous page. D 22 41...

  • Page 222: Remote Lock" Menu

    "Remote lock" menu Menu for opening the locking/unlocking function (A): Remote lock not active Display of the following information: - (1) Request number (empty), cannot be edited Open the following sub-menus: - (2) "Lock menu" - (3) "Basic menu" display Locking only possible with engine "OFF".
  • Page 223 (B): Remote lock active Display of the following information: - (1) Request number - (2) Transaction number "TAN" Function button (3) must be pressed after entering the TAN. The lock is cancelled. The TAN which is only valid once can be queried from the owner of the machine. The request number has to be stated to this end.
  • Page 224 "Lock menu" Menu for locking machine functions Open the following displays / sub-menus: - (A) "Remote lock!" warning appears - (1) When machine already locked: Open "Unlock" menu - (2) "Basic menu" display The lock function is activated by pressing function button (3). After locking, button (3) has no function and the corresponding error message (4) appears.
  • Page 225 "Service report" menu Menu for opening the lock function. Display of the following information: - (1) Operating hours - (2) Remaining operating hours until the next service - (3) Pending service scope. Service 1 / Service 2 / Service 3 (o) Open the following sub-menus: - (4) Report for Dynapac service technician - (5) Report for servicing carried out by the customer...
  • Page 226 Report for Dynapac service technician - step I Menu for entering the following parameters: - (1) Selection "Performed service" - Service 1 / Service 2 / Service 3 (o) - (2) Technician number of the Dynapac service technician - (3) PIN of the Dynapac service technician When the input field appears with a red surround, this indicates the technician number or PIN were entered incorrectly.
  • Page 227 Report for Dynapac service technician - step II Menu to confirm / forward the service report. - (1) "Service report" warning appears (1) Perform the following functions: - (2) Send service report After pressing the button, the system goes back to the "service report" mask. - (3) Back to the previous mask - (4) Back to the "Basic"...
  • Page 228 Report for servicing carried out by the customer - step I Menu for entering the following parameters: - (1) Selection "Performed service" - Service 1 / Service 2 / Service 3 (o) - (2) Technician number. - (3) PIN 1-1-1-1 When the input field appears with a red surround, this indicates the PIN was entered incorrectly.
  • Page 229 Report for servicing carried out by the customer - step II Menu to confirm / forward the service report. - (1) "Service report" warning appears (1) Perform the following functions: - (2) Send service report After pressing the button, the system goes back to the "service report" mask. - (3) Back to the previous mask - (4) Back to the "Basic"...
  • Page 230 Terminal error messages Status, warning and error messages symbols Command Symbol in the display High beam headlights control The high beam headlights are switched on. Avoid dazzling the oncoming traffic! Check direction of travel indicator Flashes whenever direction of travel indicator is activated.
  • Page 231 Command Symbol in the display Indicator lamp automatic particulate filter re- generation - deactivated Particulate filter regeneration is deactivated. Automatic regeneration should only be deacti- vated if the operating status of the paver finish- er does not permit any automatic function. see "Particulate filter regeneration"...
  • Page 232 Command Symbol in the display Indicator lamp fuel reserve + warning sound The fuel is down to the reserve level in the tank Approx. 10% remains Urgent need to refuel! Pre-heating indicator (yellow) Pre-heating is started with the ignition starter by switching the ignition on.
  • Page 233 Command Symbol in the display Pending service: A maintenance interval is about to expire. Proceed immediately with maintenance to avoid subsequent damage! Service overdue: A maintenance interval is overdue. Proceed immediately with maintenance to avoid subsequent damage! Heating status "ON": If the heating is activated, the heating sys- tem is switched off first when switching the vehicle off.
  • Page 234 Command Symbol in the display - Error message "Serious error" There is a serious error in the engine. Switch off the drive engine immediately! Error details can be viewed in the "Error memory" display menu. Lights up for a few seconds once the ignition has been switched on for checking purposes.
  • Page 235 Command Symbol in the display Engine stop: Display for all error messages with machine stop. Hydraulic filter. The hydraulic filter must be replaced. Replace filter element acc. to Maintenance Instructions! Engine oil pressure The oil pressure is insufficient. Switch off the engine immediately! For other possible errors, see engine's oper- ating instructions.
  • Page 236 Command Symbol in the display Remote Lock activated The machine lock function has been activated. The conveyor belt speed is reduced. A TAN which is only valid once can be queried from the owner of the machine. The request number has to be stated to this end.
  • Page 237 Error message drive lever If a fault is detected in the drive lever, this is shown by the corresponding indication in the display. The display appears directly but can be quit. The vehicle can be moved away from the construction site in emergency mode: - Caterpillar paver: - Turn the travel drive preselector (1) to zero.
  • Page 238 - Wheeled paver: - Turn the travel drive preselector (4) to zero. The LEDs in buttons (5) and (6) flash. - Forwards travel: Press and hold function button (5) "cruise control", speed control with "travel drive preselector " (4). - Reverse travel: Press and hold function button (6) "transport gear", speed control with "travel drive preselector "...
  • Page 239 Drive engine error codes If a fault is detected on the engine, this is shown by the corresponding indication (1) in the display. D 22 59...
  • Page 240 The error message that can be viewed in the corresponding menu contains several numerical codes, which clearly define the fault after decoding. Press the job dial to scroll through the list. It may be possible to continue operating the vehicle, depending on the severity of the error.
  • Page 241 Example: D 22 61...
  • Page 242 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 243 Error codes Scan QR-Code to access failure code chart… D 22 63...
  • Page 244 Menu structure of the setting and display menus The following illustration shows the menu structure and serves to simplify operation and the procedure in the case of various settings and displays. D 22 64...
  • Page 245 D 31 Mode of operation Operating elements on the paver finisher Control elements on the operator's control station WARNING Danger of falling from the vehicle Entering and leaving the vehicle and the driver's seat dur- ing operation poses a risk of falling from the vehicle, which can cause severe to fatal injuries! - During operation, the operator must be at the intended driver's seat and be seated properly.
  • Page 246 Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Control platform locked in central position - Operating panel locked in central position - Operating panel fixed in lowest position and engaged in rearmost setting - Steering wheel knob is at the bottom (wheeled paver) - Driver's seats swivelled to middle setting and...
  • Page 247 The protective roof can be raised and lowered electrically. The exhaust pipe is lowered or raised to- gether with the roof. - Tighten bolts (1) on both sides of the roof. - Operate the switch (2) until the roof has reached the upper or lower limit position.
  • Page 248 Ladder The ladder is used to access the control platform. The ladder can be secured in the top position: - have the ladder raised by a second person. Set the latch (1) on both sides of the ladder to the intended position. The ladder must not be locked when driving or paving! Storage space...
  • Page 249 Control platform, moveable (o) D 31 5...
  • Page 250 The control platform can be hydraulically shifted beyond the left/right outer edge of the vehicle, providing the driver with a better view of the paving area in this position. During transportation in road traffic and when transporting the vehicle on transport- ers, the control panel must be secured in the central position! Actuating the platform shift function: see operating panel.
  • Page 251 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 252 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 reduced (regardless of the drive lever position). 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 253 Protective roof (o) D 31 9...
  • Page 254 CAUTION Risk of crushing hands When closing the spring-loaded front and side windows, there is a risk of crushing which can cause injuries! - Do not reach into the danger zone. - Set the latches correctly. - Comply with further instructions in the safety manual. The protective roof is equipped with an additional front window and two side windows.
  • Page 255 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 256 Seat console The seat consoles can be swivelled for operation beyond the outer edge of the vehicle. - Press latch (1), swivel seat console to the desired position and allow latch to engage again. - Fold hinged step (2) down if necessary.
  • Page 257 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 258 Driver's seat, type II To avoid damage to health, the individu- al seat settings should be checked and adjusted before starting the vehicle. After locking the individual elements, it must no longer be possible to shift then to another position. - Horizontal setting (1).
  • Page 259 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 260 Batteries The batteries (1) of the 24 V system are located in the vehicle footwell. For the specifications, refer to chapter B, "Technical Data". For maintenance, see chapter "F". External starting only according to the instructions (see section "Starting the paver finisher, external starting...
  • Page 261 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 262 Screed lock, hydraulic (o) The screed locks must additionally be extended on both sides of the vehicle prior transportation with screed lifted. Transportation with unsecured screed leads to a risk of accidents! - Lift the screed. - Activate the function on the operating panel.
  • Page 263 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 264 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 operating panel! Engine compartment lighting (o) The engine compartment lighting can be activated when...
  • Page 265 LED working light (o) There are two LED spotlights (1) at the front and rear of the vehicle. Always align the working lights to avoid dazzling the operating personnel or oth- er road users! D 31 21...
  • Page 266 500 watt spotlight (o) There are two halogen spotlights (2) at the front of the machine and also at the back. Always align the working lights to avoid dazzling the operating personnel or oth- er road users! Danger of burning! The working lights get very hot! Do not touch working lights that are switched on or hot!
  • Page 267 Auger height adjustment ratchet (o) For mechanical adjustment of the auger height - Set the ratchet direction lever (1) to the clockwise or anti-clockwise direction. Turning anti-clockwise lowers the au- ger, turning clockwise lifts the auger. - Actuate the ratchet lever (2) - Set the desired height by alternately actuating the left and right ratchets.
  • Page 268 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 269 - 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 270 Manual separator fluid spray (o) Used to spray the parts coming into contact with asphalt with a separator emulsion. - Remove the spray (1) from its bracket. - Build up pressure by actuating the pump lever (2). - The pressure is indicated on the ma- nometer (3).
  • Page 271 Separator fluid spraying system (o) Used to spray the parts coming into contact with asphalt with a separator emulsion. Variant (A): hose package Variant (B): Hose reeling device - Possibly connect the spray hose (1) with the connecting piece (2). Only switch on the spraying system when the diesel engine is running;...
  • Page 272 Conveyor limit switches - PLC version The mechanical conveyor limit switch- es (1) or the ultrasonic conveyor limit switches (2) control the material flow on the relevant half of the conveyor. The conveyors should stop when the material has roughly reached the area below the auger tube.
  • Page 273 Conveyor limit switches - conventional version The mechanical conveyor limit switch- es (1) control the material flow on the relevant half of the conveyor. The con- veyors should stop when the material has roughly reached the area below the auger tube. This requires that the auger height has been adjusted correctly (see chapter E).
  • Page 274 Ultrasonic auger limit switches (left and right) - PLC version The limit switches control the material flow at the relevant half of the auger without contact. The ultrasonic sensor (1) is secured to the side shield via a bracket (2). - To adjust, release the clamping lever / stop screw...
  • Page 275 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 276 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 277 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/ relieving (chapter "Operating panel", "Operation"). - For pressure indication, see manome- ter (3). Pressure control valve for paving stop with relieving Valve (2) is used to set the pressure for "Screed control with paver finisher stop - float- ing stop with relieving".
  • Page 278 Central lubricating system (o): The automatic mode of the central lubri- cation system is activated as soon as the compacting elements of the screed are engaged. The pumping interval adjusted in the factory must be modified to the paving situation. It is prohibited to change the factory-set durations of pumping and break without consulting the technical customer service!
  • Page 279 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 280 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 281 Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with operation of the fire extin- guisher (2). Observe the inspection interval for the fire extinguisher! First-aid kit (o) Any dressings that have been used must be replaced immediately! Heed the expiry date of the first-aid kit! D 31 37...
  • Page 282 Rotary beacon (o) The function of the rotary beacon must be checked daily before starting work. - Place the rotary beacon onto the plug- in contact and secure with a wing bolt (1). - Raise the bracket (2), swivel to the outer position and allow to en- gage there - Slide the rotary beacon with the tube...
  • Page 283 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 284 Illuminated balloon (o) D 31 40...
  • Page 285 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 286 Installation and operation CAUTION Danger due to electric shock Electric shock can cause severe or fatal injuries - The Powermoon must always be completely unpacked, assembled and aligned before it is connected to the power grid and switched on! CAUTION Danger of squeezing! Fingers or hands can get clamped between the bracket and the holding tube!
  • Page 287 Activation is carried out on the switch cabinet. When equipped with an electric screed, it is possible for the lamps to flicker irregularly during the heating-up phase with simul- taneous operation of 500 watt spotlights (o) and the illuminated balloon (o). Preferably only one type of lighting should be used during the heating-up phase.
  • Page 288 Truck Assist (o) The Truck Assist system is used for communication between the driver of the paver and the driver of the material truck. The corresponding signal system shows the truck driver which action to perform (reversing / stop / tip material / depart). The system consists of: - Two LED light bars (1) as a signal for the truck driver and a laser sensor (2) for de- tecting the truck.
  • Page 289 Cool box (o) The cool box can be used to keep food cold and warm. - Insert the cool box (1) in the corre- sponding holder (2). - Connect up to the corresponding socket on the control platform for the necessary power supply.
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  • Page 291 D 43 Mode of 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 292 CAUTION Danger due to restricted vision Restricted vision poses a risk of injury! - Before starting work, arrange the intended driver's seat to ensure adequate vision. - Signalmen must be used when vision is restricted, also to the sides and when reversing. - Only reliable persons may be used as signalmen who must have been received instructions about their task before taking up their activity.
  • Page 293 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 294 Check! How? For larger working widths, the walkway Auger coverings plates must be extended and the auger tunnels must be covered. Folding walkways must be present at the basic screed and all extension parts and folded down accordingly. Screed covers and walkways Check that the side shields, the side plates and the covers are securely seated.
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  • Page 296 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 298 External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24V system - Additional 24V battery - Start device that is suitable for external starting (24 V/90 A).
  • Page 299 - If necessary, start the engine of the vehicle supplying power and leave to run for a while. Now try to start the other vehicle: - Press the starter button (12) to start the engine. Run the starter continuously for a maximum of 30 seconds, then take a break for 2 minutes! - If the engine still has not started after two attempts, ascertain the cause! - If the engine starts up: disconnect the starting aid cable again in reverse order.
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  • Page 301 After starting To increase the engine speed: - Press button (68) to increase engine speed. The engine speed is increased to the preset value. Let the paver finisher warm up for approx. 5 minutes if the engine is cold. D 43 11...
  • Page 302 D 43 12...
  • Page 303 Observe indicator lamps The following indicator lamps must be observed under all circumstances: For other possible errors, see engine's operating instructions. Engine coolant temperature check (A) Lights up when the engine temperature is outside of the permissible range. Stop the paver finisher (drive lever to the centre position), let the engine cool down while idling.
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  • Page 305 Travel drive oil pressure indicator lamp (D) - Must go out after starting. If the lamp does not go out: Do not switch on the traction drive! Otherwise, the entire hydraulic system could be damaged. When the hydraulic oil is cold: - Activate set-up mode function (68).
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  • Page 307 Preparation for transportation - Close the hopper with switch (34)/(35). - Engage both hopper transport safeguards. - Lift the screed completely using switch (69), set the crossbeam lock (75). - Turn the travel drive preselector (15) to zero. - Activate set-up mode function (68). - Fully extend the levelling cylinders with switch (61),(63)/(64).
  • Page 308 D 43 18...
  • Page 309 Driving and stopping the paver finisher - Set the Fast/Slow switch (33) to "Hare". - Set the preselector (15) to mark 10. - For driving, carefully tilt the drive lever (13) forward or backward according to the drive direction desired. - Adjust the speed with the preselector (15).
  • Page 310 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 311 Direction marks To ensure straight paving, a direction mark must be present or established (road edge, chalk lines or similar). - Slide the operating panel to the de- sired side and secure it. - Pull the direction indicator out of the bumper (arrow) and adjust it ac- cordingly.
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  • Page 313 Loading/conveying material - Button (59) has to be switched off. - Use switch (36)/(37) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (53)/(54) and the conveyor (47)/(48) to "Auto". - Activate function (67) to fill the vehicle for the paving process.
  • Page 314 D 43 24...
  • Page 315 Starting for paving Set the switches, levers and controls listed below to the specified positions when the screed has reached its operating temperature and a sufficient amount of material lies in front of the screed Item Travelling direction Position Drive lever Centre position Traction drive fast/slow LED OFF...
  • Page 316 Checks during paving The following points must be constantly observed during paving: Paver function - Screed heater system - Tamper and vibration - Engine oil and hydraulic oil temperature - The screed parts must be retracted and extended in time when obstacles are in the way - Uniform material transport and distribution or supply to the screed;...
  • Page 317 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 318 D 43 28...
  • Page 319 Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Function (73) Relieving (screed "lighter") Function (74) Charging (screed "heavier") The "Screed charging and relieving" functions are only effective when the paver fin- isher moves. According to the activated function, the paver finisher is automatically switched to "paving stop + relief"...
  • Page 320 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 323 Adjusting the pressure Pressure adjustments can only be made while the diesel engine is running. Therefore: - Start the diesel engine and turn the traction controller (15) back to zero (precaution against inadvertent advancing). - Activate the "floating position" using switch (70). For screed charging/relieving: - Set the drive lever (13) to the centre position.
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  • Page 325 Interrupting/terminating operation During breaks in paving (e.g. delay due to material trucks) - Determine the approximate duration. - When cooling down of the material below the minimum paving temperature must be expected, run the paver finisher empty and create an edge like the end of a layer. - Set the drive lever (13) to the centre position.
  • Page 326 D 43 36...
  • Page 327 When work is finished - Run the paver finisher empty and stop it. - Lift the screed using switch (69), set the crossbeam lock (75). - Retract the screed parts to the basic screed width and lift the auger. Where appli- cable, completely extend the levelling cylinders.
  • Page 328 Malfunctions Problems during paving Problem Cause - change in the material temperature, demixing - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long standstill times between loads - grade control reference line is not suitable - grade control jumps to the reference line Wavy surface - grade control toggles between up and down...
  • Page 329 Problem Cause - material temperature Cracks in the layer - cold screed (centre strip) - bottom plates are worn or warped - wrong crowning - material temperature - screed extendable parts are incorrectly installed Cracks in the layer - limit switch is not correctly set (outer strip) - cold screed - bottom plates are worn or warped...
  • Page 330 Malfunctions on the paver finisher or screed Malfunction Cause Remedy See operating instructions At the diesel engine Various for the engine See "External starting" (start Batteries empty Diesel engine does assistance) not start Various see "Towing" Tamper is obstructed by cold Properly heat the screed bitumen Hydraulic oil level in the tank...
  • Page 331 Malfunction Cause Remedy Control valve is defective Replace Hoppers lowers inad- Leaking hydraulic cylinder vertently Replace sleeves 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 332 Malfunction Cause Remedy Replace (fuse strip on the oper- Travel drive fuse defective ating panel) Check potentiometer, cables, Power supply interrupted connectors; replace if necessary Travel drive monitoring Replace (type-specific) defective Traction does Electro-hydraulic servo unit Replace the servo unit not work of the pump defective Check and adjust if necessary...
  • Page 333 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 334 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 335 Distribution auger Height adjustment Depending on the mix of materials, the set height distribution auger (1) – measured from its bottom edge – should lie above the material lay- er height. Grain sizes up to 16 mm Example: F0130_A1.TIF Paving thickness 10 cm Min.
  • Page 336 Mechanical adjustment with ratchet (o) - Set the ratchet direction lever (1) to the clockwise or anti-clockwise direction. Turning anti-clockwise lowers the au- ger, turning clockwise lifts the auger. - Set the desired height by alternately adjusting the right-hand and the left- hand side.
  • Page 337 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 338 - 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 339 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 vehicle.
  • Page 340 - 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 341 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 screed operating nstructions: –...
  • Page 342 Mounting extension parts Mounting the material shaft and auger extension - Secure the additional material shaft (1) to the basic unit or the adjacent material shaft with the relevant assembly parts (2) (bolts, washers, nuts). - Dismantle the assembly parts (3) of the adjacent auger blade, remove plug (4). - Guide the auger shaft extension into the auger shaft.
  • Page 343 Mounting the outer auger bearing - Dismantle the assembly parts (1) of the adjacent auger blade, remove plug (2). - Guide the outer auger bearing (3) into the auger extension. - Secure the outer auger bearing to the brace shaft with the relevant assembly parts (4) (bolts, washers, pins).
  • Page 344 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 345 Auger extension chart Symbol Meaning - (160L) - Auger blade 160mm left - (160R) - Auger blade 160mm right 160L 160R - Auger extension part 320 mm - (320L) left - Auger extension part 320 mm 320L 320R - (320R) right - Auger extension part 640 mm - (640L)
  • Page 346 Symbol Meaning Outer auger bearing Auger end bearing E 13 14...
  • Page 347 Auger upgrading, working width 3.14 m 320 L 320 R Auger upgrading, working width 3.78 m 640 L 640 R Auger upgrading, working width 4.42 m 640 L 320 R 320 L 640 R E 13 15...
  • Page 348 Auger upgrading, working width 5.06 m 320 L 960 L 320 R 960 R Auger upgrading, working width 5.70 m 640 L 960 L 960 R 640 R E 13 16...
  • Page 349 Auger upgrading, working width 6.34 m E 13 17...
  • Page 350 Auger upgrading, working width 6.98 m E 13 18...
  • Page 351 Auger upgrading, working width 7.62 m E 13 19...
  • Page 352 Auger upgrading, working width 8.26 m E 13 20...
  • Page 353 Mounting the auger brace E 13 21...
  • Page 354 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 355 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 356 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 screed operating instructions: –...
  • Page 357 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 358 - 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. Heed the alignment of the gear! All mounted guides and auger segments must be in line.
  • Page 359 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 (3) approx.
  • Page 360 Hydraulic lines For larger working widths, longer hydraulic hoses have to be used for the auger motors. 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 361 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 362 Auger extension chart Symbol Meaning - (290L) - Auger blade 290mm left - (290R) - Auger blade 290mm right 290L 290R - Auger extension part 434 mm - (434L) left - Auger extension part 434 mm 434L 434R - (434R) right - Auger extension part 868 mm - (868L)
  • Page 363 Symbol Meaning - (RL) - Extension pipe left - (RR) - Extension pipe right E 13 31...
  • Page 364 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 365 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 366 Auger upgrading, working width 6.53m E 13 34...
  • Page 367 Auger upgrading, working width 7.40m E 13 35...
  • Page 368 Auger upgrading, working width 8.00m E 13 36...
  • Page 369 Mounting the auger brace E 13 37...
  • Page 370 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 371 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 372 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 re- traction.
  • Page 373 Hopper scraper To reduce the gap between hopper and vehicle frame, the hopper scrapers (1) must be adjusted on both hopper lids. - Loosen the mounting screws (2). - Set a gap of 6 mm across the whole length of the scraper. - Retighten the mounting screws (2) properly.
  • Page 374 Crossbeam guide To warrant correct guidance of the crossbeams, the guide plates (1) at both sides of the vehicle must be adjusted to the prevailing paving conditions (e.g. positive or negative crowning, etc.). - Loosen screw remove screws (3). - Adjust guide plate to the required size (basic setting 25mm).
  • Page 375 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 376 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 377 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 378 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 379 Fitting the height sensing device Fit the sensor arm to the required side of the machine. - Place the holder (1) on the corre- sponding journal (2) of the side shield and fasten with the pin (3), bush (4) and spring washers (5). - Tighten the pin (3) so that the sensor arm is just still able to swivel.
  • Page 380 Setting up the sensor arm Before starting paving, the sensor arm must be set, with the grade control sys- tem, to its reference (cable, kerb, etc.). Sensing should be carried out in the area of the auger. - Swivel the sensor arm (2) over the reference.
  • Page 381 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 382 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 necessary, work can be carried out with just one sensor by switching over on the MOBA-matic (e.g.
  • Page 383 Mounting the big ski bracket on the crossbeam The entire big ski construction is mounted laterally on the crossbeams. To do so, the two crossbeam brackets must first be mounted. The crossbeam bracket design differs slightly depending on the paver finisher which is used. During assembly, it is possible either to bolt the brackets directly at the existing bores (A) or to secure them to the crossbeam using clamping plates (B).
  • Page 384 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 385 Mounting the centre element During assembly, it must be ensured that the round lug (1) for attaching the subse- quent modules points upwards. The centre element (2) is already fitted in the factory with 2 pre-assembled sliding parts (3) / (4), which are pushed over the two round mounting journals of the swivel arms.
  • Page 386 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 387 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...
  • Page 388 Mounting and aligning the sensors - Insert the sensor mounting (1) into the bracket (2). - Align the sensor and secure with the relevant star handle bolts. - The sensing height can be adjusted loosening star handle bolts (3). At the two outer sensor brackets, the sensor can also be mounted on the swiv- elling sensor extension arm (4).
  • Page 389 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 390 Connection diagram The three sensors are connected to the distributor box and the distributor to the ma- chine according to the following scheme. - Sensors - Front (1) - Centre (2) - Rear (3) - Distributor box (4) - Machine interface (5) E 13 58...
  • Page 391 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 392 - 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 393 Auger temperature measurement (O) A sensor can be installed to detect the material temperature in the auger area. - Fasten the sensor (1) above the basic auger width on the machine frame with the related magnetic holder (2) as shown. - Connect the connection cable (3) of the sensor to the centre socket (TEMP) of the signal converter (4).
  • Page 394 Limit switch 10.1 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 395 Screed All work required for mounting, setting up and extending the screed are described in the screed operating instructions. 11.1 Electrical connections side board - screed - Conventional version Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control to holder (1).
  • Page 396 Other connection possibilities: - Auger limit switches (5) - Grade control system (6) - External levelling system (7) - 24 volt consumers, e.g. additional lighting (8). When using an external levelling system, this must be logged in using the remote con- trol menu.
  • Page 397 11.2 Electrical connections side board - screed PLC version Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: - Set remote control on holder (1), tighten knurled screw (1a). - Connect the plug of the lead (2) with the socket (2a) on the remote control. If the remote control is not mounted, the plug has to be set on the bridge socket (3).
  • Page 398 If the side board is not connected, the socket (5) has to be connected with the bridge plug (5a). Other connection possibilities: - Auger limit switches (6) - Grade control system (7) - External levelling system (8) - 24 volt consumers, e.g. additional lighting (9). When using an external levelling system, this must be logged in using the remote con- trol menu.
  • Page 399 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 400 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 401 F 29 Maintenance overview Maintenance overview 90 100 F 29 1...
  • Page 402 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 29 2...
  • Page 403 Maintenance necessary after operating hours Assembly Chapter Conveyor Auger - type A q q q q Auger - type B q q q q Drive engine - q q q q Tier 3 / Stage IIIa Drive engine - q q q q q Tier4F / Stage IV q q q q q Drive engine - StageV...
  • Page 404 F 29 4...
  • Page 405 F 33 Maintenance - conveyor Maintenance - conveyor F 33 1...
  • Page 406 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 407 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 408 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 409 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 410 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 411 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 412 F 33 8...
  • Page 413 F 40 Maintenance - auger assembly Maintenance - auger assembly F 40 1...
  • Page 414 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 415 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 416 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 417 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 418 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 419 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 420 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 421 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 422 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 423 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 424 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 425 F 41 Maintenance - auger assembly Maintenance - auger assembly - external drive version F 41 1...
  • Page 426 Danger of being pulled in by rotating or conveying WARNING vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 427 Maintenance intervals Interval Maintenance point Note - 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 428 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 429 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 430 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 431 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 432 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 433 F 51 Maintenance - engine assembly Tier 3 (o) Maintenance - engine assembly In addition to these maintenance instructions, the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances. All mainte- nance work and service intervals itemised here are binding in nature. F 51 1...
  • Page 434 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 435 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 436 Interval Maintenance point Note - Engine air filter Check air filter - Engine air filter Dust collector Emptying - Engine air filter Air filter cartridge Replace - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system...
  • Page 437 Interval Maintenance point Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt Maintenance Maintenance during the running-in period F 51 5...
  • Page 438 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 439 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 440 - 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 441 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 442 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 443 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 444 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 dust deflectors by press- ing together the upper valve section. Clean the dust removal valve from time to time.
  • Page 445 Replace air filter insert Maintenance of the filter becomes nec- essary if: - Engine electronics service indicator - Open the air filter housing (B) at the clips (C). - Move filter element (D) to the side a lit- tle and then pull it out of the housing. - Pull out the safety element (E) and check for signs of damage.
  • Page 446 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 447 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 51 15...
  • Page 448 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 449 F 55 Maintenance - engine assembly Tier 4F (o) Maintenance - engine assembly As well as this maintenance manual, always also pay close attention to the mainte- nance manual provided by the engine manufacturer. All maintenance work and serv- ice intervals itemised here are binding in nature. F 55 1...
  • Page 450 Danger of being pulled in by rotating or conveying WARNING vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 451 Maintenance intervals Interval Points of maintenance 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...
  • Page 452 Interval Points of maintenance Note - Engine air filter Check air filter - Engine air filter Empty dust collector - Engine air filter Exchange air filter insert - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system...
  • Page 453 Interval Points of maintenance Note ® - AdBlue / DEF tank Check filling level ® - AdBlue / DEF tank ® Top up AdBlue / DEF ® - AdBlue / DEF tank Replace suction filter ® - AdBlue / DEF tank Check tank cover ®...
  • Page 454 Interval Points of maintenance Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt - Crankshaft ventilation filter Replace filter element - Exhaust system / Inspect diesel oxidation catalytic converter Maintenance Maintenance during the running-in period...
  • Page 455 Points of maintenance Engine fuel tank (1) - Check the filling level using the dis- play on the operating panel. Fill the fuel tank each time before start- ing work so that the fuel system cannot "run dry" and time-consuming venting (bleeding) can therefore be avoided.
  • Page 456 Engine lube oil system (2) Check oil level In case of correct oil level, the oil is be- tween 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 457 - 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 458 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 459 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 460 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 461 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 dust deflectors by press- ing together the upper valve section. - Open the collector housing (B) at the clips (C) and remove dust accu- mulations.
  • Page 462 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 463 Engine cooling system (5) Checking / topping up coolant The cooling water level must be checked when the system is cold. Make sure that sufficient anti-freeze and anti-corrosion agent is available (-25°C). When hot, the system is under pressure. When opening, there is a danger of scalding! - If necessary fill in a sufficient amount of coolant through the open port (A) of...
  • Page 464 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 55 16...
  • Page 465 AdBlue ® / DEF tank (6) - Check the filling level using the dis- play on the operating panel. ® Top up with AdBlue / DEF if necessary. ® Storage and handling AdBlue NOTE Diesel Exhaust Fluid (DEF) ® Incorrect handling of AdBlue / DEF can cause major dam- age to the vehicle: ®...
  • Page 466 WARNING ® Danger from AdBlue / Diesel Exhaust Fluid (DEF) ® Inadequate preparations for using AdBlue / DEF can result in severe injuries! ® AdBlue / DEF should never be in contact with the skin, ® eyes or clothing or be swallowed. Keep AdBlue / DEF out of reach of children.
  • Page 467 Danger from ammonia vapours, overpressure WARNING in the tank ® If you open the AdBlue / DEF tank cap at high tempera- tures, ammonia vapours can escape and cause injuries! ® - Only fill the AdBlue / DEF tank in well ventilated areas. ®...
  • Page 468 AdBlue ® / DEF tank - suction filter Replace filter element - To change the filter, the supply lines (B) ® at the AdBlue / DEF multi-head (A) must be dismantled and the electrical connection (plug) (C) disconnected. Use a suitable container or cloth to take up any leaked residues.
  • Page 469 - Carefully lever the multi-head (A) from the tank surface by applying a suitable slotted screwdriver around the edge. Pull the head at the same time. Do not pull the connection cable or con- nection port! - Carefully pull the multi-head up until the lower part is beneath the tank opening.
  • Page 470 Filter change < / = s/n 003055 - Loosen the fastening screw (F) of the filter. - Pull the used filter (G) from the suction pipe. - Fit the new filter onto the suction pipe and fasten with a new fastening screw (F).
  • Page 471 - Lightly grease the O-ring (H) of the multi-head. - Fold the filter element (G) in the mid- dle towards the underside of the lower part. - Tilt the lower part at an angle of about 45°. - Place the filter side and the tip of the lower part in the tank opening as shown.
  • Page 472 - Place the retaining ring (E) over the fil- ter head. - Tighten the screws (D) properly. - Then mount the supply lines (B) and connect up to the power supply (plug) (C). After installation, check correct sealing during a trial run. F 55 24...
  • Page 473 Filter change > / = s/n 003056 - Loosen the fastening screw (F) of the filter. - Pull the used filter (G) from the suction pipe. - Fit the new filter onto the suction pipe and fasten with a new fastening screw (F).
  • Page 474 - Introduce the filter side into the tank opening as shown. - Gradually introduce the whole unit I into the tank opening, using due caution. Do not push the parts with force directly into the tank opening. This will cause damage! - Position the head in the required align- ment.
  • Page 475 - Tighten the screws (D) properly. - Then mount the supply lines (B) and connect up to the power supply (plug) (C). After installation, check correct sealing during a trial run. F 55 27...
  • Page 476 AdBlue ® / DEF tank - tank cover Clean tank cover Impurities or crystals of AdBlue / DEF ® on the outside and inside of the tank cover can considerably interfere with the system! If the tank cover is visibly soiled, it must be cleaned as follows.
  • Page 477 - Wipe the gasket with a damp cloth to remove any remaining DEF crystals or dirt. - Then connect the tank cover with the previously loosened retaining tab and screw onto the tank. F 55 29...
  • Page 478 AdBlue ® / DEF dosing unit Do not disconnect the vehicle batteries until the dosing system has finished the rinsing cycle. Wait for at least 5 minutes after the ignition has been switched off before starting work dosing unit. Replace filter element - Place a suitable container under the ®...
  • Page 479 Engine drive belt (7) Check drive belt - 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 480 Crankshaft ventilation filter (8) Replace 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 necessary! - Clean the contact surface (D) of the filter and the sealing surfaces of the O-rings with a cloth and light solvent and then dry them with a clean cloth.
  • Page 481 Exhaust system - diesel oxidisation catalytic converter (9) Inspect the exhaust system Basically the exhaust system does not need any maintenance. Inspection consists of a visual check: - damaged parts? - loose screwed connections, plugs or lines? WARNING Risk from hot surfaces! During system cleaning, the exhaust temperature and the surface temperature of the exhaust system is very hot and can cause severe injuries! The exhaust and exhaust com-...
  • Page 482 F 55 34...
  • Page 483 F 57 Maintenance - engine assembly Stage V (o) Maintenance - engine assembly As well as this maintenance manual, always also pay close attention to the mainte- nance manual provided by the engine manufacturer. All maintenance work and serv- ice intervals itemised here are binding in nature. F 57 1...
  • Page 484 Danger of being pulled in by rotating or WARNING conveying vehicle parts Rotating or conveying vehicle parts can cause severe to 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 485 Maintenance intervals Interval Points of maintenance 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...
  • Page 486 Interval Points of maintenance Note - Engine air filter Check air filter - Engine air filter Empty dust collector - Engine air filter Exchange air filter insert - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system...
  • Page 487 Interval Points of maintenance Note ® - AdBlue / DEF tank Check filling level ® - AdBlue / DEF tank ® Top up AdBlue / DEF ® - AdBlue / DEF tank Replace suction filter ® - AdBlue / DEF tank Check tank cover ®...
  • Page 488 Interval Points of maintenance Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt - Exhaust system / Inspect diesel oxidisation catalytic converter Maintenance Maintenance during the running-in period F 57 6...
  • Page 489 Maintenance points 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. DANGER Danger from ultra low-sulphur diesel Ultra low-sulphur diesel (ULSD) poses a greater risk of...
  • Page 490 For filling with fuel: - Remove cover (A). - Fill in fuel through the filling port until the required fill lever is achieved. - Replace the cover (A). Clean the tank and system: - Unscrew the drain plugs (B) in both tanks and drain about 1 l fuel into a collection pan.
  • Page 491 Engine lube oil system (2) Check oil level In case of correct oil level, the oil is between the two notches of the dip- stick (A). Only check the oil level when the finisher is in a horizontal position! Too much oil in engine damages gas- kets;...
  • Page 492 - 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 493 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 494 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 495 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 496 Change extraction filter (o) The air outlet shaft (A) has to be disman- tled first in order to reach the filters. - Open engine hood, remove screws (B) underneath the shaft. - Loosen clips (C) on inside of frame and remove air outlet shaft (A). - After completing the maintenance work, fit the air outlet shaft again in re- verse order.
  • Page 497 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 dust deflectors by press- ing together the upper valve section. - Open collector housing at the clips (C) and remove dust accu- mulations.
  • Page 498 Cleaning / replacing the air filter cartridge Maintenance of the filter becomes necessary 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 safety element (G).
  • Page 499 Engine cooling system (5) Checking / topping up coolant The cooling water level must be checked when the system is cold. Make sure that sufficient anti-freeze and anti-corrosion agent is available (-25°C). When hot, the system is under pressure. When opening, there is a danger of scalding! - If necessary fill in a sufficient amount of coolant through the open port (A)
  • Page 500 Checking and cleaning the radiator fins - If necessary, remove leaves, dust or sand from the radiator. Observe engine's operating instructions! Check coolant concentration - Check the concentration using a suitable tester (hydrometer). - Adjust the concentration if necessary. Observe engine's operating instructions! F 57 18...
  • Page 501 AdBlue ® / DEF tank (6) - Check the filling level on the gauge on the operating panel. ® Top up with AdBlue / DEF if necessary. ® Storage and handling AdBlue NOTE Diesel Exhaust Fluid (DEF) ® Incorrect handling of AdBlue / DEF can cause major damage to the vehicle: ®...
  • Page 502 WARNING ® Danger from AdBlue / Diesel Exhaust Fluid (DEF) ® Inadequate preparations for using AdBlue / DEF can result in severe injuries! ® AdBlue / DEF should never be in contact with the skin, ® eyes or clothing or be swallowed. Keep AdBlue / DEF out of reach of children.
  • Page 503 Danger from ammonia vapours, WARNING overpressure in the tank ® If you open the AdBlue / DEF tank cap at high tempera- tures, ammonia vapours can escape and cause injuries! ® - Only fill the AdBlue / DEF tank in well ventilated areas. ®...
  • Page 504 AdBlue ® / DEF tank - suction filter Replace filter element - To change the filter, the supply ® lines (B) at the AdBlue / DEF multi- head (A) must be dismantled and the electrical connection (plug) (C) dis- connected. Use a suitable container or cloth to take up any leaked residues.
  • Page 505 - Carefully lever the multi-head (A) from the tank surface by applying a suitable slotted screwdriver around the edge. Pull the head at the same time. Do not pull the connection cable or con- nection port! - Carefully pull the multi-head up until lower part beneath...
  • Page 506 - Remove the clip (F) from the inlet connection of the filter (G) and remove the filter. - Examine the filter for soiling, particles and cracks. On finding particles or cracks, also check the filter of the dosing unit! - Fit the O-ring (H) in the groove on the intake pipe - Insert the inlet connection of the new filter into the tank intake pipe.
  • Page 507 - Lightly grease the O-ring (I) of the multi-head. - Tilt the lower part at an angle of about 45°. - Gradually insert the lower part in the tank opening, proceeding carefully. Do not push the parts with force directly into the tank opening.
  • Page 508 - Place the retaining ring (E) over the fil- ter head. - Tighten the screws (D) properly. - Then mount the supply lines (B) and connect up to the power supply (plug) (C). After installation, check correct sealing during a trial run. F 57 26...
  • Page 509 AdBlue ® / DEF tank - tank cover Clean tank cover Impurities or crystals of AdBlue / DEF ® on the outside and inside of the tank cov- er can considerably interfere with the system! If the tank cover is visibly soiled, it must be cleaned as follows.
  • Page 510 Check tank for damage. On finding any damage, replace tank. Flush DEF tank with distilled water and clean with compressed air. - Check filler neck for cracks and other damage. On finding any damage, replace filler neck. Clean the filler neck with warm water and a clean cloth.
  • Page 511 - Fit the tank drain plug and screw tight (5 Nm). - Fit the filler neck strainer (B) in the tank. Insert the filler neck unit in the tank. Turn counter-clockwise until the unit locks. - Fit the tank cover and tighten by hand until it locks.
  • Page 512 AdBlue ® / DEF dosing unit After turning the engine off, let the DEF flow back and release pressure before working on the DEF system. Depressu- rising can take up to 15 minutes. It is still possible for residual pressure to remain in the system.
  • Page 513 Replace filter element Check the area around the seal and filter housing for any leaks. DEF leaks leave white deposits. Comply with section on "Cleaning and checking for reusability". Remove loose foreign particles with compressed air. Remove soiling with a clean damp cloth to ensure no soiling can land in the DEF dosing unit.
  • Page 514 - Pull filter element (B) out of the unit. To do so, pull and turn at the same time. Take up any dripping DEF. Use a dry, clean, lint-free cloth. Dry unit. Dispose of anti-freeze membrane and filter element. - If there is a risk that soiled DEF has flowed through the DEF dosing sys- tem, check the DEF filter prior to dis- posal.
  • Page 515 Cleaning and checking for reusability - Check the thread of the DEF dosing unit. This is particularly important if the cover of the DEF dosing unit was de- fective. If the thread of the DEF dosing unit is damaged, replace the complete DEF dosing unit.
  • Page 516 Installation - Insert a new filter element in the DEF dosing unit. Press the filter up to check that it fits properly. Place a new anti-freeze membrane over the filter element. The sealing bead of the anti-freeze membrane must fit fully in the notch of the pump housing.
  • Page 517 Engine drive belt (7) Check drive belt - 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 518 Exhaust system - diesel oxidisation catalytic converter (8) Inspect the exhaust system Basically the exhaust system does not need any maintenance. Inspection consists of a visual check: - damaged parts? - loose screwed connections, plugs or lines? WARNING Risk from hot surfaces! During system cleaning, the exhaust temperature and the surface temperature of the exhaust system is very hot and can cause severe injuries! The exhaust and exhaust com-...
  • Page 519 F 61 Maintenance - hydraulic system Maintenance - hydraulic system F 61 1...
  • Page 520 WARNING Danger due to hydraulic oil Hydraulic oil under high pressure can cause severe to fatal injuries! - Only competent staff should work on the hydraulic system! - Any hydraulic hoses that are cracked or soaked through must be replaced immediately. - Depressurise the hydraulic system.
  • Page 521 WARNING Danger from residual pressure in hydraulic lines Residual pressure in the hydraulic system can cause severe or fatal injuries! - Proceed as follows before working on the hydraulic system: 1. Place the machine on a level surface, secure it against accidentally rolling away and activate the parking brake if necessary.
  • Page 522 Maintenance intervals Interval Maintenance point Note - Hydraulic oil tank - Check fill level - Hydraulic oil tank - Top up with oil - Hydraulic oil tank - Change oil and clean - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank - Change and vent the suction/re- turn flow hydraulic filter...
  • Page 523 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 524 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 from 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 525 10.1 Points of maintenance Hydraulic oil tank (1) - Check oil level on sight glass (A). The hydraulic oil should have reached a temperature of at least 50°C for the check. If all the cylinders are extended, the level can fall below the sight glass. The movable control platform (o) must be moved to the left when doing so.
  • Page 526 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 527 Suction/return flow hydraulic filter (2) Carry out filter replacement according to the interval or the indicator lamp in the operating panel! - Remove cover securing screws (A) and lift off cover. - Disassemble the removed unit into: - Cover (B) - Separating plate (C) - Filter (D) - Dirt trap (E)
  • Page 528 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 529 High-pressure filter (3) The filter elements must be replaced when the maintenance indicator (A) turns red. The vehicle's hydraulic system contains 3 high-pressure filters. - Unscrew filter housing (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge. - Replace the seal ring of the filter housing.
  • Page 530 Pump distribution gear (4) - Check oil level check on sensor rod (A). The oil level must lie between the upper and lower marks. For filling in the oil: - Pull out the dipstick (A) completely. - Replenish new oil through the dipstick opening (B).
  • Page 531 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 13...
  • Page 532 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 533 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 534 Marking hydraulic hoses / storage period, period of use A number stamped onto the screwed connection provides information about the date of manufacture (A) (month / year) and the maximum pressure per- mitted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.
  • Page 535 Auxiliary flow filter (6) The hydraulic oil change is omitted on use of an auxiliary flow filter! The quality of the oil must be checked regularly. The oil level must be topped up if necessary! Replacing filter element: - Release the threaded cover connection (A) then open the non-return valve briefly to lower the oil level in the filter, then close the non-return valve again.
  • Page 536 F 61 18...
  • Page 537 F 72 Maintenance - travel drive, steering Maintenance - travel drive, steering F 72 1...
  • Page 538 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 539 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 540 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 541 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 through the aperture.
  • Page 542 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 543 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 544 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 545 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 546 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 547 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 548 F 72 12...
  • Page 549 F 83 Maintenance - electrical system Maintenance - electrical system F 83 1...
  • Page 550 Danger of being pulled in by rotating WARNING or conveying vehicle parts Rotating or conveying vehicle parts can cause severe or fatal injuries! - Do not enter the danger zone. - Do not reach into rotating or conveying parts. - Only wear close-fitting clothing. - Comply with the warning and information signs on the vehicle.
  • Page 551 Maintenance intervals Interval Maintenance point Note Check fill level of battery acid q Top up with distilled water Apply grease to battery terminals - Alternator Insulation monitoring, check elec- tric system is functioning - Alternator Visual check for pollution or damage - Check the cooling air openings for pollution or clogging, clean if necessary.
  • Page 552 Maintenance points Batteries (1) Maintenance of batteries The batteries are factory-filled with the correct quantity of acid. The fluid level should come up to the top mark. If re- quired, top up the battery, but only use distilled water to do so! The battery terminal clamps must be free of oxide and protected with a special terminal grease.
  • Page 553 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 554 Alternator (2) Electrical system insulation monitoring 3 SEC The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an insula- tion error has occurred on the heating sections or consumers. - Start the paver finisher's drive engine.
  • Page 555 Cleaning the alternator alternator must regularly checked for excessive dirt and must be cleaned if necessary. - The air intake (1) and fan shroud (2) must be kept free of dirt. Cleaning with a high-pressure cleaner is not permissible! F 83 7...
  • Page 556 Electrical fuses / relays (3) Fuses The fuses installed may differ depending on equipment. Function F1.2 Main fuse 1 F1.2 Main fuse 2 F1.3 Diesel engine preheating ignition system F1.4 Engine T4F F1.5 Raise / lower roof Levelling Brake light Operating panel / emergency stop Brake sensor F 83 8...
  • Page 557 Function Auger working light Screed / England stop button / front-wheel drive Truck Assist Heating system Left / right remote control Screed T4F Adblue heating Engine control unit Engine T4F system Sensor move platform / pave IR Connector 24V Sensor auger height Hazard flashers Operating panel Diagnostic interface control unit / display...
  • Page 558 Function Front working lights Seat heating Rear working lights Windscreen wiper Central lubrication Main fuse lighting Left-hand parking lights Parking lights, right Operating panel illumination Low-beam headlights High-beam headlights Control voltage raise / lower roof * Raise roof * Lower roof * * The fuses are under the control platform.
  • Page 559 Relays in the engine compartment Function Engine start F 83 11...
  • Page 560 Relays in terminal box The relays installed may differ depending on equipment. Function Ignition Drive engine start / stop Master / slave / screed controller Engine start Front lighting Rear lighting Auger lighting front Horn Parking light T4F - Adblue heating F 83 12...
  • Page 561 Function T4F - Adblue heating T4F - Adblue heating Diesel pump Adblue supply module Flashers Rotary beacon Seat heating Windscreen wiper Windscreen washer system Reverse buzzer Central lubrication Light in accordance with German Road Traffic Regulations High beam / low beam Coming home light Coming home light Preheating ignition system...
  • Page 562 Relay in connection box under the operating platform Function Raise roof Lower roof F 83 14...
  • Page 563 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 564 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 565 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 566 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 567 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 568 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 569 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 570 F 90 8...
  • Page 571 F 100 Tests, stopping ... Tests, checks, cleaning, stopping F 100 1...
  • Page 572 Maintenance intervals Interval Maintenance point Note - General visual inspection - Check that the bolts and regularly nuts fit firmly q - Inspection by an expert q - Cleaning q - Cleaning sensors q - Preserving the paver finisher Maintenance Maintenance during the running-in period F 100 2...
  • Page 573 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 574 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 575 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 576 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 577 Cleaning optical or acoustic sensors Heavily soiled sensors can have a negative effect on measuring results or functions. Daily cleaning with a dry, lint-free cloth. F 100 7...
  • Page 578 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 579 Operating the vehicle in special climatic conditions or environments. Salty air in coastal regions, high UV radiation, sand, soil or changing conditions may cause permanent damage to vehicle parts and surfaces. There may be visible corrosion or changes to the surfaces. This has a negative impact on preserving the value of the machine! NOTE Caution! Possible damage to or destruction of parts!
  • Page 580 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 581 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 582 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 583 F 115 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 machine failure.
  • Page 584 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 115 2...
  • Page 585 F 115 3...
  • Page 586 Capacities Substance Volume Diesel engine Engine oil litres (with oil filter change) 23,0 litres (Tier 3) Engine cooling system Cooling liquid 23.0 litres (Tier 4F) litres (Tier3 ) Fuel tank Diesel fuel litres (Tier4F; StageV) litres (Tier3 ; Tier4F) Hydraulic oil reservoir Hydraulic oil litres (StageV)
  • Page 587 Operating substance specifications Drive engine TIER 4i, 4F / Stage IIIb, IV; V (o)- fuel specification Low-sulphur diesel fuel is prescribed for correct operation of the exhaust-gas treat- ment system! The maximum sulphur level must not exceed 15 ppm! If low-sulphur diesel fuel is not used, the prescribed exhaust values cannot be met and damage will be caused to the engine and to the exhaust-gas treatment system! Danger of explosion! Never mix diesel fuel with ethanol, petrol or alcohol! Diesel fuel contaminated with water or dirt can cause serious damage to the fuel sys-...
  • Page 588 Hydraulic system Dynapac AGIP Chevron Caltex Fuchs Mobil Shell Castrol -Tellus Oil Hydraulic Rando Rando S2 V46 Hyspin HDZ 46 HDZ 46 -Tellus S2 AWH-M 46 VX46 (*) = recommended Pump distribution gear Esso / Dynapac Aral Fuchs Mobil Shell Castrol Exxon -Spirax S4...
  • Page 589 Auger bevel gear type B Esso / Dynapac Aral Fuchs Mobil Shell Exxon -Spirax S2 G 80W-90 -Spirax G80W-90 (*) = recommended 3.10 Grease Esso / Dynapac Aral Fuchs Mobil Shell Chevron Exxon Paver -High -Gadus S5 Grease Temp T460 1.5 Premium2 F 115 7...
  • Page 590 3.11 Drive engine - AdBlue ® / DEF ® For correct operation of the exhaust gas treatment system, the use of AdBlue / DEF fluid is prescribed pursuant to ISO 22241-1 respectively DIN 70070! For vehicles operating in North America, the use of a DEF fluid with API approval is urgently recommended! ®...
  • Page 591 3.13 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 (*) Shell Natural HF-E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46 Aral Vitam EHF 46 Finke...
  • Page 592 F 115 10...
  • Page 594 www.dynapac.com...

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