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Fayat DYNAPAC F1800C Operation & Maintenance Manual

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OPERATION & MAINTENANCE
Paver Finisher
F1800C
Type 910
02-0516
4812018414

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Summary of Contents for Fayat DYNAPAC F1800C

  • Page 1 OPERATION & MAINTENANCE Paver Finisher F1800C Type 910 02-0516 4812018414...
  • 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 Identification points ...................17 Warning signs ...................20 Information signs ..................23 CE marking ....................25 Instructive symbols, prohibitive symbols, warning symbols .....26 Danger symbols ..................27 Further warnings and operating instructions ..........28 Identification label for the paver finisher (41) ........29 Explanation of 17PIN serial number ............30 Engine type plate ..................31 EN standards ....................32 Continuous sound pressure level .............32...
  • Page 5 D30.18 Operation ................1 Operating elements on the paver finisher ..........1 Control elements on the operator's control station ........1 Protective roof (o) .................. 2 Control platform, telescoping seat consoles .......... 5 Operating panel ..................6 Service brake ("foot brake") (o) ............. 6 Seat console ..................
  • Page 6 D40.18 Mode of operation ..............1 Preparing for operation ................1 Required devices and aids ..............1 Before starting work (in the morning or when starting paving) ....3 Check list for the machine operator ............3 Starting the paver finisher ................6 Before starting the paver finisher ............6 "Normal"...
  • Page 7 Auger limit switches (left and right) - mount PLC version ......11 Auger limit switches (left and right) - mount conventional version ... 12 Maintenance ................1 Notes regarding safety ................1 F20.18 Maintenance review ............... 1 Maintenance review ................... 1 F31.18 Maintenance - conveyor ............
  • Page 8 F60.18 Maintenance - hydraulic system ........... 1 Maintenance - hydraulic system ..............1 Maintenance intervals ................4 Points of maintenance ................6 Hydraulic oil tank (1) ................6 Suction/return flow hydraulic filter (2) .............8 Ventilation filter ..................8 High-pressure filter (3) ................9 High-pressure filter (4) .................10 Pump distribution gear (5) ..............11 Bleeder ....................12 Hydraulic hoses (6) ................13...
  • Page 9 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 11: 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 12: 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 13: 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 14: 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 15 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 16: 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 17: 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 18: 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 19: 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 20: 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 21: 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 22: 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 23: 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 25: B Vehicle Description

    B Vehicle description Application The Dynapac F1800C paver finisher is a paver finisher with a caterpillar drive which is used for paving bituminous mixed material, roll-down or lean-mixed concrete, track- laying ballast and unbound mineral aggregates for foundations for paving.

  • Page 26: Description Of Assemblies And Functions

    Description of assemblies and functions Item Designation Material compartment (hopper) Truck push rollers Sensor rod (direction indicator) Caterpillar drive Levelling cylinder for paving thickness Traction roller Crossbeam pull bar Paving thickness indicator Crossbeam Travel drive of the caterpillar drive Auger Screed Operator’s platform Operating panel (can be moved to either side)

  • Page 27: Vehicle

    Vehicle Construction The paver finisher has a welded steel frame on which the individual components are mounted. The caterpillar drives compensate uneven areas on the ground; the suspension of the attached screed additionally helps to attain high paving precision. The continuously adjustable hydrostatic travel drive allows the speed of the paver fin- isher to be matched to all work conditions.
  • Page 28 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. Drive unit: Both caterpillar drives are directly driven by separate drives. They operate directly, without any drive chains which require maintenance or servicing. The tension of the caterpillar chains can be readjusted using tensioners.
  • Page 29 Material compartment (hopper): The hopper inlet is equipped with a conveyor sys- tem that empties the hopper and transfers the material to the auger. The hopper can hold approx. 10.5 t. To facilitate emptying and achieve even material transfer, each of the lateral covers of the hopper can be hydraulically folded in.
  • Page 30 Levelling/slope control system: The slope control system (o) allows the traction point to be regulated at the left-hand or the right-hand side with a defined difference to the opposite side. To determine the actual value, the two traction crossbeams are linked with a slope control rod.

  • Page 31: 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 32: Safety Devices

    Safety devices 4 5 6 7...
  • Page 33 Item Designation Hopper transport safeguard Crossbeam lock, mechanical Main switch Emergency stop button Horn Ignition key Lights Protective roof latch (o) Fire extinguisher (o) Screed warning light (o) Covers, lateral flaps, coverings Rotary beacon (o) Located on both sides of the vehicle Safe operation is only possible when all operating and control elements are function- ing correctly and when all safety devices are in position.

  • Page 34: Technical Data, Standard Configuration

    Technical data, standard configuration Dimensions (all dimensions in mm) 1910 2090 5020 5270 1200 1800 3040 3150 For screed technical data, refer to the screed operating instructions. B 10...

  • Page 35: 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 36: Weights (All Weights In T)

    Weights (all weights in t) Paver finisher without screed approx. 8.9 Paver finisher with screed: - V3500 approx. 10.5 With extension parts for max. approx. 0.52 working width, additionally max.: With filled hopper approx. 10.5 additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.

  • Page 37: Capacity Data

    Capacity data V3500TV 1.75 3.50 Transport speed 0 - 4 km/h Operating speed 0 - 25 m/min Paving height -120 - 200 Max. grain size Theoretical paving performance B 13...

  • Page 38: Travel Drive/Traction Unit

    Travel drive/traction unit Drive Hydrostatic drive, continuously controllable Two separately driven caterpillar drives Drive unit with rubber grouser chains Turning capacity Turning on the spot Speed See above Engine EU 3A / Tier 3 (o) Make/type Deutz TD 2.9 L4 Version 4-cylinder diesel engine Performance...

  • Page 39: Material Compartment (Hopper)

    5.10 Material compartment (hopper) Volume Approx. 4.8 m = approx. 10.5 t Minimum inlet height, centre 520 mm Minimum inlet height, outside 605 mm Hopper width, outside, open 3400 mm 5.11 Material transfer Type Dual conveyor belt Width 2 x 350 mm Conveyors Left and right auger separately controllable Drive...

  • Page 40: Screed Lifting Device

    5.13 Screed lifting device At standstill: Special functions - Screed stop Mechanical grade control Levelling system Optional systems with and without slope control 5.14 Electrical system On-board voltage 24 V Batteries 2 x 12 V, 74Ah Generator (o) 12.5 kVA / 400V 5.15 Permissible temperature ranges Operation...

  • Page 41: 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 42 B 18...
  • Page 43 xxxxxxxxxxxxxxxxx B 19...

  • Page 44: 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 vehicle before the vehicle is put into operation! Failure to comply with the operating and warning instructions can cause severe or fatal injuries.
  • Page 45 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! - Warning - spring-loaded component! Performing work incorrectly can cause...
  • Page 46 Pictogram Meaning - Warning - danger from improper trans- portation! Always sit down with the seatbelt fas- tened to drive the vehicle forwards/in re- verse at transport speed! Driving the vehicle when standing up / without the seatbelt fastened can cause severe or fatal injuries.

  • Page 47: Information Signs

    Information signs Pictogram Meaning - Operating instructions Position of the storage compartment. - Lifting point Lifting the machine is only permitted at these lifting points! - Lashing point Lashing the machine is only permitted at these points! - Main battery switch Position of the main battery switch.
  • Page 48 Pictogram Meaning - Engine oil Position of the filling and control point. - Engine oil drainage point Position of the drainage 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.

  • Page 49: Ce Marking

    Pictogram Meaning - Gear oil drainage point Position of the drainage point. CE marking No. Pictogram Meaning - CE, sound output level B 25...

  • Page 50: Instructive Symbols, Prohibitive Symbols, Warning Symbols

    Instructive symbols, prohibitive symbols, warning symbols No. Pictogram Meaning - Wear ear protectors - Do not spray the area or component with water! - Warning on dangers posed by batteries! - First aid kit B 26...

  • Page 51: Danger Symbols

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

  • Page 52: Further Warnings And Operating Instructions

    Further warnings and operating instructions Pictogram Meaning - Warning - hazard from unsupported screed! If the screed sags, this can cause severe or fatal injuries! Insert crossbeam lock only at crown adjustment "zero". Screed lock only for transportation! Do not charge the screed or work under it if it is only secured by the crossbeam lock! - Attention - danger of high voltage in...

  • Page 53: Identification Label For The Paver Finisher (41)

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

  • Page 54: Explanation Of 17Pin Serial Number

    Explanation of 17PIN serial number >10002014JHG002076< - Manufacturer - Family/Model - Check letter - Serial number B 30...

  • Page 55: 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 31...

  • Page 56: Standards

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

  • Page 57: 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 58 B 34...

  • Page 59: C10.18 Transportation

    C 10.18Transportation 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 60: 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 61 Operation Travelling direction Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Insert the transportation safeguards of the screed. Fully extend the levelling cylinder. Retract the screed parts until the screed matches the basic width of the paver finisher.

  • Page 62: 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 63: Driving Onto The Low-Bed Trailer

    Driving onto the low-bed trailer Make sure that there are no persons in the danger area during loading. NOTE Caution! Possible collision of parts - When driving up inclines, lock the lane clearer in the upper position. - Use the work gear and low engine speeds to drive onto the low-bed trailer. C 10.18 5...

  • Page 64: 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 65: Loading

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

  • Page 66: Preparing The Vehicle

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

  • Page 67: Securing The Load

    Securing the load Securing at the front 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. Shackles have to be used: To ensure that lashing chains can be fitted securely on the left and on the right, a shackle has to be fitted at each of the lashing points (1) provid- ed on the paver finisher for the lashing equipment...

  • Page 68: Securing At The Rear

    Securing at the rear 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. Fasten the lashing chains as shown. Permissible angles see "Securing at the front". C 10.18 10...

  • Page 69: After Transportation

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

  • Page 70: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Both seat consoles pushed in. - Backrests and armrests of driver's seats tilted forwards. - Operating panel in lowest position and locked with the vandalism protection facility.
  • Page 71 Version The exhaust pipe is lowered or raised together with the roof. - Connect the pump lever (1) to the pump (2). - Tighten bolts (3) on both sides of the roof. - Set the adjustment lever (4) to the "Raise" or "Lower" position. - Operate the pump lever (1) until the roof has reached the upper or lower limit position.
  • Page 72 Version - Connect the pump lever (1) to the pump (2). - Tighten bolts (3) on both sides of the roof. - Set the adjustment lever (4) to the "Raise" or "Lower" position. - Operate the pump lever (1) until the roof has reached the upper or lower limit position.

  • Page 73: 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 Screed op- erating instructions).
  • Page 74 Operation Travelling direction Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Insert the transportation safeguards of the screed. Fully extend the levelling cylinder. Retract the screed parts until the screed matches the basic width of the paver finisher.

  • Page 75: Driving Mode

    Driving mode Operation Travelling direction 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 preselector to "zero".

  • Page 76: 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 77 Example: 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 area (3) of the vehicle. - Secure vehicle wherever it is parked up.
  • Page 78 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 73.0 kN. The permissible load applies in the vertical direction! Make sure that the paver finisher remains in a horizontal position during transportation! C 10.18 20...

  • Page 79: 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 80 Two high-pressure cartridges (6) are lo- cated on both of the travel drive pumps (5). The following activities must be carried out to activate the towing function: - Loosen lock nut (7) half a turn. - Screw in the bolt (8) until increased re- sistance occurs.

  • Page 81: 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 82: 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 83: D10.18 Operation

    D 10.18 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 express- ly forbidden!
  • Page 84 DANGER Danger due to improper operation Improper operation of the vehicles can cause severe to fatal injuries! - The vehicle may only be used in the proper manner for its intended purpose. - The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves famil- iar with the contents of the operating instructions.

  • Page 85: Controls

    Controls Operating panel NOTE Heed any possible start inhibit! - All detent switch functions that can pose a hazard when the diesel engine starts up (turning to the side, convey- ing function of auger and conveyor) prevent the engine from starting (start inhibit) when switched on or when set to "MANUAL"...
  • Page 86 D 10.18 4...
  • Page 87 Item Designation Brief description Lights up instrument panel A/B when the parking light Lights is switched on Press in an emergency (danger to persons, impending colli- sion, etc.)! Pressing the emergency stop button switches off the en- gine, the drives and the steering system. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents!
  • Page 88 D 10.18 6...
  • Page 89 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 but- ton again Starter / drive Run the starter continuously for a maximum of 20 sec- engine OFF onds, then take a break for 1 minute! All emergency stop buttons (on the operating panel and...
  • Page 90 D 10.18 8...
  • Page 91 Item Designation Brief description To activate the ignition voltage by turning the key. - Switch off by turning the key back to its starting position. On shutting off the vehicle, first switch off the ignition, then deactivate the main switch. Ignition lock Before the main battery switch is deactivated, a period of at least 10 seconds must elapse after switching off...
  • Page 92 D 10.18 10...
  • Page 93 Item Designation Brief description Pushbutton function: - Upper switch position: Close left hopper lid. Open / close - Lower switch position: left hopper Open left hopper lid. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - Upper switch position: Close right hopper lid.
  • Page 94 D 10.18 12...
  • Page 95 Item Designation Brief description Pushbutton function: - Left switch position: Extend left half of screed. Retract / extend - Right switch position: left screed Retract left half of screed. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - Left switch position: Retract right half of screed.
  • Page 96 D 10.18 14...
  • Page 97 Item Designation Brief description Pushbutton function: - Upper switch position: 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. Reversing switch The function can be triggered in all modes of Left conveyor the conveyor.
  • Page 98 D 10.18 16...
  • Page 99 Item Designation Brief description Pushbutton function: - Upper switch position: The conveying direction of the left half of the auger can be reversed in order to slightly reverse paving material for example. Reversing switch The function can be triggered in all modes of the auger. Left auger The main function switch locks the conveying function.
  • Page 100 D 10.18 18...
  • Page 101 Item Designation Brief description Detent switch function: - Upper switch position: Operating mode "AUTO": 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 switches. - Switch position, central: Left conveyor - Operating mode "OFF": The conveying function of the...
  • Page 102 D 10.18 20...
  • Page 103 Item Designation Brief description Detent switch function: - Upper switch position: Operating mode "AUTO": 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 position, central: Left auger - Operating mode "OFF": The conveying function of the...
  • Page 104 D 10.18 22...
  • Page 105 Item Designation Brief description Pushbutton/detent switch function - Upper switch position: Lift the screed. - Switch position, central: Screed stop (floating position OFF): Screed is hy- draulically blocked in position. - Lower switch position: Lower screed + floating position: Screed is lowered Screed and released in the floating position when the drive le- Raise / Lower...
  • Page 106 D 10.18 24...
  • Page 107 Item Designation Brief description Pushbutton function: - Upper switch position: Retract left levelling cylinder. Retract / extend left levelling - Lower switch position: cylinder Extend left levelling cylinder. On actuation, heed danger zones of moving parts of the vehicle! Pushbutton function: - Upper switch position: Retract right levelling cylinder.
  • Page 108 D 10.18 26...
  • Page 109 Item Designation Brief description Pushbutton function: - Upper switch position: Raise auger. - Lower switch position: Lower auger. Raising/lowering The height can be read off on the scale on the corre- auger (o) sponding hydraulic cylinder. Rule of thumb: Paving thickness plus 5 cm (2 inches) equals the auger crossbeam height.
  • Page 110 D 10.18 28...
  • Page 111 Item Designation Brief description Pushbutton function: - Filling function for the paving process. The conveying functions set to "automatic" (conveyor and auger) are switched on. Once the set material height is reached at the limit Fill vehicle for switches, the conveying functions are switched off. paving process On actuation, heed danger zones of moving parts of the vehicle!
  • Page 112 D 10.18 30...
  • Page 113 Item Designation Brief description Pushbutton function: - When the vehicle is stationary, this function enables all operating functions, which are only activated when the drive lever is swivelled out (vehicle driving), to be started up. The main function switch must be set to the OFF position.
  • Page 114 D 10.18 32...
  • Page 115 Item Designation Brief description Pushbutton function: - 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 The preset vehicle can be relocated and released at the switch...
  • Page 116 D 10.18 34...
  • Page 117 Item Designation Brief description Detent switch function: - Upper switch position: Operating mode "AUTO": The screed tamper is switched on when the drive lever is swivelled out. - Lower switch position: Tamper - Operating mode "OFF": The screed tamper is Operating mode switched off.
  • Page 118 D 10.18 36...
  • Page 119 Item Designation Brief description not used Detent switch function: - Upper switch position: Front working Front working lights ON. lights - Lower switch position: ON / OFF Front working lights OFF. Avoid dazzling other road users! Detent switch function: - Upper switch position: Rear working lights ON.
  • Page 120 D 10.18 38...
  • Page 121 Item Designation Brief description If a fault discovered on the drive engine is indicated by one of the warning lamps, a code assigned to a defined defect can be called up. Pushbutton function: - Upper switch position: Error / malfunction Call the error code.
  • Page 122 D 10.18 40...
  • Page 123 Item Designation Brief description Pushbutton function: - Upper switch position: To hydraulically extend the push roller crossbar. - Lower switch position: To hydraulically retract the push roller crossbar. Retract/extend push roller (o) If the push roller crossbar has been pressed into the home position by the counterpressure of the truck tyres, it has to be extended again.
  • Page 124 D 10.18 42...
  • Page 125 Item Designation Brief description Indicator lamp Lights up when the hydraulic filter needs replacing. hydraulic filter Replace filter element acc. to Maintenance Instructions! Lights up if the hydraulic oil temperature is too high. Indicator lamp Stop the paver finisher when if the temperature is too Hydraulic oil tem- high (drive lever in centre position), let the engine cool perature...
  • Page 126 D 10.18 44...
  • Page 127 Item Designation Brief description Battery charge Must go out after starting when the engine revs up. indicator (red) If the light does not go out, switch off the engine Indicates that there is fault in the vehicle control system. Each fault should be checked and rectified as soon as possible! Error message - Special equipment is needed to read out faults in the...
  • Page 128 D 10.18 46...
  • Page 129 Item Designation Brief description The operating hours are only counted while the engine Operating hours is running. counter Heed the maintenance intervals (see chapter F). Engine speed Shows the actual speed of the drive engine (rpm). not used D 10.18 47...

  • Page 130: Remote Control

    Remote control Depending on the side of the machine (left/right), the function switches only control the corresponding function on the particular side of the machine. Important! Do not disconnect remote controls with emergency stop button during op- eration! This causes the paver finisher to be shut down! D 10.18 48...
  • Page 131 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 stop longer possible! Danger of accidents! button...
  • Page 132 D 10.18 50...
  • Page 133 Item Designation Brief description Detent switch function: - Lower switch position: Operating mode "AUTO": The conveying function of the left / right conveyor is switched on when the drive lever is swivelled out and is continuously controlled via the material limit switches. Conveyor left/right - Switch position, central: Operating mode...
  • Page 134 D 10.18 52...

  • Page 135: D30.18 Operation

    D 30.18 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 136: Protective Roof (O)

    Protective roof (o) NOTE Caution! Possible collision of parts The following adjustments must be made before lowering the roof: - Both seat consoles pushed in. - Backrests and armrests of driver's seats tilted forwards. - Operating panel in lowest position and locked with the vandalism protection facility.
  • Page 137 Version The exhaust pipe is lowered or raised together with the roof. - Connect the pump lever (1) to the pump (2). - Tighten bolts (3) on both sides of the roof. - Set the adjustment lever (4) to the "Raise" or "Lower" position. - Operate the pump lever (1) until the roof has reached the upper or lower limit position.
  • Page 138 Version - Connect the pump lever (1) to the pump (2). - Tighten bolts (3) on both sides of the roof. - Set the adjustment lever (4) to the "Raise" or "Lower" position. - Operate the pump lever (1) until the roof has reached the upper or lower limit position.

  • Page 139: Control Platform, Telescoping Seat Consoles

    Control platform, telescoping seat consoles D 30.18 5...

  • Page 140: Operating Panel

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

  • Page 141: Seat Console

    Seat console The seat consoles left/right can be moved beyond the outer edge of the vehicle, pro- viding the driver with a better view of the paving area in this position. - There is a latch at both seat consoles. - Pull latch (10), extend left or right seat console and allow latch to engage again.

  • Page 142: Protective Roof (O)

    Protective roof (o) CAUTION Risk of crushing hands When closing the spring-loaded front window, 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 optionally with two side windows.

  • Page 143: Windscreen Wiper

    Windscreen wiper - Engage the windscreen wiper / screen wash on the operating panel if necessary. Ensure that the washer fluid tank (4) is always adequately filled. Replace worn wiper blades immediately. Sunshade A sliding sunshade (5) is available to the left and right of the protective roof to protect the driver, for example when the seat console is extended.

  • Page 144: Driver's Seat, Type I

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

  • Page 145: Driver's Seat, Type Ii

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

  • Page 146: Fuse Box

    Fuse box The terminal box, which contains all fus- es and relays, etc. is located beneath the central control platform floor panel. An assignment plan for fuses and relays can be found in chapter F8. D 30.18 12...

  • Page 147: Batteries

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

  • Page 148: Hopper Transport Safeguard

    Hopper transport safeguard Before parking or transporting the paver finisher, the hopper lids must be swung upwards and the transport safeguards for the hopper must be inserted. - Insert snap hook (1) in the corre- sponding shackle of the opposite hop- per lid.

  • Page 149: Paving Thickness Indicator

    Paving thickness indicator Two scales, on which the currently set paving thickness can be read off, are lo- cated on the left and right sides of the vehicle. - To change the reading position, the scale (1) can be raised and lowered again in one of the adjacent locating bores (2).

  • Page 150: Auger Lighting (O)

    Auger lighting (o) Two swivelling headlights (1) are located at the back of the vehicle for illuminating the auger compartment. - They are engaged together with the working lights. D 30.18 16...

  • Page 151: Led Working Light (O)

    LED working light (o) There are two LED spotlights (1) at the front and rear of the vehicle. Always align the working lights to avoid dazzling the operating personnel or oth- er road users! D 30.18 17...

  • Page 152: Mechanical Height Adjustment, Auger (O)

    Mechanical height adjustment, auger (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 alternatingly actuating the left and right ratchets.

  • Page 153: Sensor Rod / Sensor Rod Extension

    Sensor rod / sensor rod extension The sensor rod acts as an orientation aid for the vehicle driver during paving. Along the defined paving route, the vehicle driver can use the sensor rod to follow a tensioned reference wire or another marking. The sensor rod runs along the reference wire or over the marking.
  • Page 154 - Loosen the winged nut (3) to pull the sensor rod extension (4) out for adjustment to the required length. You can also change the angle by swivelling the joint (5). Tighten all assembly parts properly after setting up! During transportation, the sensor rod must be swivelled right back and fixed correctly. The max.

  • Page 155: Manual Separator Fluid Spray (O)

    Manual separator fluid spray (o) Used to spray the parts coming into con- tact 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 156: Separator Fluid Spraying System (O)

    Separator fluid spraying system (o) Used to spray the parts coming into con- tact with asphalt with a separator emulsion. - Connect the spray hose (1) with the hand piece (2). Only switch on the spraying system when the diesel engine is running; other- wise, the battery will be discharged.

  • Page 157: Conveyor Limit Switches

    Conveyor limit switches The mechanical conveyor limit switches (1) control the material flow on the rele- vant half of the conveyor. The conveyors should stop when the material has roughly reached the area below the auger tube. This requires that the auger height has been adjusted correctly (see chapter E).

  • Page 158: Ultrasonic Auger Limit Switches (Left And Right) - Plc Version

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

  • Page 159: (Left And Right) - Conventional Version

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

  • Page 160: Volt / 12 Volt Sockets (O)

    24 volt / 12 volt sockets (o) A socket (1) is located behind the left/ right seat consoles. Additional working lights can be con- nected here, for example. - Right seat console: 12V socket - Left seat console: 24V socket Voltage is present when the main switch is switched on.

  • Page 161: Central Lubrication System (O)

    Central lubrication system (o) The central lubrication system is located under the maintenance flap on the oper- ator's platform. The pumping interval adjusted in the facto- ry must be modified to the paving situation. Changing the duration of lubrication and breaks may be necessary when laying mineral or cement bound material mix.

  • Page 162: Pressure Control Valve For Paving Stop With Relief

    Pressure control valve for paving stop with relief Adjusts the pressure for the screen con- trol with paving stop - "floating stop with relief". Is engaged automatically with paving stop. - Pressure adjustment with valve (1). Lock the valve with the corresponding nut after making the adjustment! - For pressure indication, see mano- meter (2).

  • Page 163: Lane Clearer (O)

    Lane clearer (o) A swivelling lane clearer (1), which de- flects small obstacles away to one side, is located in front of both drive units. The lane clearers should only be swiv- elled down during paving. Swivelling the lane clearers: - Swivel the lane clearer (1) up and se- cure in the uppermost position with a shackle (2).

  • Page 164: Screed Eccentric Adjustment

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

  • Page 165: Push Roller Crossbar, Adjustable

    Push roller crossbar, adjustable 180° 180° For adaptation to various truck design types, the push roller crossbar (1) can be shift- ed to two positions. The adjustment travel is 60mm. - Close the hopper halves to lift the hopper flap (o). - After removing the bolts (3), remove the locking plate (2) on the lower side of the crossbar.

  • Page 166: Push Roller Damping, Hydraulic (O)

    Push roller damping, hydraulic (o) Push roller damping hydraulically absorbs the shocks between the material truck and paver finisher. - Activate the function on the operating panel as necessary. D 30.18 32...

  • Page 167: Fire Extinguisher (O)

    Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with operation of the fire extin- guisher (1). Observe the inspection interval for the fire extinguisher! First-aid kit (o) Any dressings that have been used must be replaced immediately! Heed the expiry date of the first-aid kit! D 30.18 33...

  • Page 168: Rotary Beacon (O)

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

  • Page 169: Illuminated Balloon (O)

    Illuminated balloon (o) D 30.18 35...
  • Page 170 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 171: Installation And Operation

    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 172: Decommissioning

    Decommissioning CAUTION Danger due to electric shock Electric shock can cause severe or fatal injuries - Do not start to dismantle the Powermoon until it has been disconnected from the power grid! - Switch off the illuminated balloon on the switch cabinet. - Disconnect the power plug from the socket (10).

  • Page 173: D40.18 Mode Of Operation

    D 40.18 Mode of operation Preparing for operation Required devices and aids To avoid delays on site, check before starting work whether or not the following de- vices and aids are present: - Wheel loader for transporting heavy extension parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separator fluids (emulsion) and manual injector...
  • Page 174 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 175: Before Starting Work (In The Morning Or When Starting Paving)

    Before starting work (in the morning or when starting paving) - Heed the safety instructions. - Check the personal protective equipment . - Take an inspection walk around the paver finisher and check for leaks and damages. - Install parts removed for transportation or for the night. - When screed is operated with the optional gas heating system, open the closing valves and the main shut-off valve.
  • Page 176 Check! How? For larger working widths, the walkway Auger coverings plates must be extended and the auger tunnels must be covered. Folding walkways must be present at the basic screed and all extension parts and folded down accordingly. Screed covers and walkways Check that the side shields, the side plates and the covers are securely seated.
  • Page 177 D 40.18 5...

  • Page 178: Starting The Paver Finisher

    Starting the paver finisher Before starting the paver finisher Before starting the diesel engine and beginning operation, the following steps must be performed: - Daily maintenance of the paver finisher (see chapter F). Check the operating hour counter to determine whether or not additional mainte- nance work (e.g.
  • Page 179 Do not use aerosol types such as ether as starting aid. This can cause an explosion and lead to personal injuries. D 40.18 7...
  • Page 180 D 40.18 8...

  • Page 181: External Starting (Starting Aid)

    External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24V system - Additional 24V battery - Start device that is suitable for external starting (24 V/90 A).
  • Page 182 - If necessary, start the engine of the vehicle supplying power and leave to run for a while. Now try to start the other vehicle: - Turn ignition key (3) to position 1 and wait for the preheat check (9) to go off. - Press the starter button (10) to start the engine.
  • Page 183 D 40.18 11...

  • Page 184: After Starting

    After starting To increase the engine speed: - Increase the engine speed with switch (1). The engine speed is increased to the preset value. Let the paver finisher warm up for approx. 5 minutes if the engine is cold. Observe indicator lamps The following indicator lamps must be observed under all circumstances: Battery charge indicator (2) Must go out after starting.
  • Page 185 D 40.18 13...

  • Page 186: Preparation For Transportation

    Preparation for transportation - Use switch (1) to close the hopper. - Engage both hopper transport safeguards. - Lift the screed completely using switch (2), set the crossbeam lock. - Turn the travel drive preselector (3) to zero. - Fully extend the levelling cylinders with the switch (5). To extend the levelling cylinders, levelling operating mode (6) must be switched to "MANUAL"...
  • Page 187 D 40.18 15...

  • Page 188: Driving And Stopping The Paver Finisher

    Driving and stopping the paver finisher - Set the travel drive to the desired speed level, fast/slow (1). - Upper switch position: transport speed (hare) - Lower switch position: operating speed (tortoise) - Turn the travel drive preselector (2) to medium speed. - For driving, carefully tilt the drive lever (3) forward or backward according to the drive direction desired.

  • Page 189: Preparations For Paving

    Preparations for paving Separator fluid Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator fluid. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). Screed heater system Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem- perature) before paving begins.

  • Page 190: Direction Marks

    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. - Adjust direction of travel indicator on the bumper.
  • Page 191 D 40.18 19...

  • Page 192: Loading/Conveying Material

    Loading/conveying material - Use switch (1) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (2) and the conveyor (3) to "auto". The conveying function starts by deflecting the drive lever. Check that the material is transferred properly.
  • Page 193 D 40.18 21...

  • Page 194: Starting For Paving

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

  • Page 195: Checks During Paving

    Checks during paving The following points must be constantly observed during paving: Paver function - Screed heater system - Tamper and vibration - Engine oil and hydraulic oil temperature - The screed parts must be retracted and extended in time when obstacles are in the way - Uniform material transport and distribution or supply to the screed;...
  • Page 196 D 40.18 24...

  • Page 197: Interrupting/Terminating Operation

    Interrupting/terminating operation During breaks in paving (e.g. delay due to material trucks) - Determine the approximate duration. - When cooling down of the material below the minimum paving temperature must be expected, run the paver finisher empty and create an edge like the end of a layer.
  • Page 198 D 40.18 26...

  • Page 199: When Work Is Finished

    When work is finished - Run the paver finisher empty and stop it. - Move the drive lever (1) to the central position, set preselector (2) to "0" and set the speed adjuster (3) to minimum. - Switch the auger (4), conveyor (5), tamper(o) (6), vibration (7) and levelling (8) functions to "OFF".

  • Page 200: Malfunctions

    Malfunctions Error code display and query for engine D 40.18 28...
  • Page 201 - If there is an error in the engine, a message appears with a flashing warning light (1). The corresponding error code (SPN/FMI) appears in the display (2). - The error code goes off again after a defined period of time. The flashing warning light (1) remains active.

  • Page 202: Error Code Display And Query For Travel Drive Computer

    Error code display and query for travel drive computer - If there is an error in the travel drive computer, a message appears with a flashing warning light (2). NOTE Service qualification necessary The error messages can only be read out by a qualified Dynapac service partner.

  • Page 203: Problems During Paving

    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 - grade control toggles between up and down Wavy surface...
  • Page 204 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 205: Malfunctions On The Paver Finisher Or Screed

    Malfunctions on the paver finisher or screed Malfunction Cause Remedy See operating instructions for At the diesel engine Various the engine See "External starting" (start Batteries empty Diesel engine assistance) does not start Various see "Towing" Tamper is obstructed by Properly heat the screed cold bitumen Hydraulic oil level in the...
  • Page 206 Malfunction Cause Remedy Engine speed is too low Increase the speed Hydraulic oil level is too low Top up oil Leak in the suction line Tighten the connections Flow rate regulator Replace Hopper cannot be defective swung open Leaking seals of the Replace hydraulic cylinder Control valve is defective...
  • Page 207 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 208 D 40.18 36...

  • Page 209: E10.18 Set-Up And Modification

    E 10.18 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 210 DANGER Danger due to changes at the vehicle Structural changes 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 211: Distribution Auger

    Distribution auger Height adjustment Depending on the material, the height of the auger – measured from its lower edge – should be at least 50 mm (2 inches) above the height of the material layer. Example: layer height 10 cm adjustment 15 cm from the ground An incorrect height setting can result in the following problems during paving: - Auger too high:...
  • Page 212 Mechanical height adjustment: - Set the ratchet direction lever (1) to the clockwise or anti-clockwise direction. - Adjust the required height by actuating the ratchet (2). - The current height can be read at the scale (3). Hydraulic height adjustment: - Adjust the required height by pressing the corresponding switch (operating panel).

  • Page 213: Auger Width Extension And Material Shaft With Protective Cover

    Auger width extension and material shaft with protective cover (optional equipment) To fit auger extensions, an additional auger segment (1) is fitted to the auger shaft. Assembly: - Remove outermost screw connection (2) from the basic auger. - Remove plug (3). - Fit the auger extension (1) to the corresponding side.

  • Page 214: Push Roller Crossbar, Adjustable

    Push roller crossbar, adjustable 180° 180° For adaptation to various truck design types, the push roller crossbar (1) can be shift- ed to two positions. The adjustment travel is 60mm. - Close the hopper halves to lift the hopper flap (o). - After removing the bolts (3), remove the locking plate (2) on the lower side of the crossbar.

  • Page 215: Hopper Scraper

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

  • Page 216: Crossbeam Guide

    Crossbeam guide To warrant correct guidance of the crossbeams, the guide plates (1) at both sides of the vehicle must be adjusted to prevailing paving conditions (e.g. positive or negative crowning, etc.). - Remove screws (2). - Move guide plate to the required size (basic setting 25mm).

  • Page 217: Screed

    Screed The Screed operating instructions cover all work required for mounting, setting up and extending the screed. Electrical connections Prepare or make the following electrical connections when the mechanical compo- nents have been mounted and set up: E 10.18 9...
  • Page 218 - Set remote control to holder (1). - Connect plug (2) with the remote control. If the remote control is not implemented, the plug (2) has to be set to the bridge socket (2a). - Connect the connection lead (3) of the side shield with the socket (4) of the screed. The cover of the extendable part must be removed to install the cables.

  • Page 219: Limit Switch

    Limit switch Auger limit switches (left and right) - mount PLC version The auger's ultrasonic limit switch is mounted on both sides on the side shield's handrail. - Place the sensor bracket (1) onto the handrail, align it and tighten with a wing bolt (2).

  • Page 220: Auger Limit Switches (Left And Right) - Mount Conventional Version

    Auger limit switches (left and right) - mount conventional version The ultrasonic sensor (1) is secured to the side shield via a bracket (2). - To adjust the sensor angle, loosen the clamps (3) and swivel the bracket. - To set the sensor height / the deacti- vation point, loosen the star handles (4) and adjust the linkage to the re- quired length.

  • Page 221: F10 Maintenance

    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 222 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 223: F20.18 Maintenance Review

    F 20.18 Maintenance review Maintenance review 82.18 50.18 60.18 31.18 40.18 70.18 F 20.18 1...
  • Page 224 Maintenance necessary after operating hours Assembly Chapter Conveyor F31.18 Auger F40.18 q q q Engine F50.18 q q q q q q q q q q Hydraulic system F60.18 q q q q q q Drive units F70.18 Electrical system F82.18 q q q q Lubrication points...

  • Page 225: F31.18 Maintenance - Conveyor

    F 31.18 Maintenance - conveyor Maintenance - conveyor F 31.18 1...
  • Page 226 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 227: Maintenance Intervals

    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 228: Points Of Maintenance

    Points of maintenance Chain tension, conveyor (1) Check chain tension: 170 mm 170 mm When the conveyor chain is tensioned correctly, the lower edges of both chain sags (before and after the chain guide) hangs approx. 170 mm above the ground. The conveyor chains should not be too tight or too slack.
  • Page 229 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 destruction of the drive wheels! If components have to be replaced as a result of wear, the following components...

  • Page 230: Conveyor Drive - Drive Chains (2)

    Conveyor drive - drive chains (2) To check the chain tension: There is a scale (A) on the chain guard to show the chain sag. - Move the chain: If the tension has been set properly, the chain must be able to move freely approx.

  • Page 231: Conveyor Deflectors / Conveyor Plates (3)

    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 232 F 31.18 8...

  • Page 233: F40.18 Maintenance - Auger Assembly

    F 40.18 Maintenance - auger assembly Maintenance - auger assembly F 40.18 1...
  • Page 234 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 235: Maintenance Intervals

    Maintenance intervals Interval Maintenance point Note Auger drive chains - Check tension Auger drive chains - Adjust tension Augur drive chains - Replace chains and chain sockets Augur box - Check grease fill Augur box - Top up with grease Augur box - Change grease Seals and sealing rings -...
  • Page 236 Interval Maintenance point Note 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 F 40.18 4...

  • Page 237: Points Of Maintenance

    Points of maintenance Auger drive chains (1) To check the chain tension: - Manually turn both augers to the right and left. In this case, movement clear- ance (C) at the augers' outer circumference should be 3-4 mm. Risk of injury due to sharp-edged parts! To re-tension the chains - Release the mounting screws (A).
  • Page 238 Check / replace chain: The drive chains (A) must be replaced at the latest when: - The sprockets (B) on the auger shaft or drive are worn. - The chains (A) have lengthened to such an extent that they can no longer be retightened.

  • Page 239: Auger Box (2)

    Auger box (2) Check grease fill To check the grease fill: - Remove side cover (A) No reduction in the quality and quantity of the grease fill is normally expected. However, the grease fill must always be replaced if there is a considerable change colour lumps...

  • Page 240: Seals And Sealing Rings (3)

    Seals and sealing rings (3) After reaching operating temperature, check the gearbox for leaks. In case of visible leaks, e.g. between the flange surfaces (A) of the drive, auger shaft (B) or at the side cover (C), re- placement of the seals and sealing rings is necessary.

  • Page 241: Outer Auger Bearing (4)

    Outer auger bearing (4) The grease nipples are located on each side at the top of the outer auger bearings. 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 242: Auger Blade (6)

    Auger blade (6) 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 243: F50.18 Maintenance - Engine Assembly

    F 50.18 Maintenance - engine assembly 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 50.18 1...
  • Page 244 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 245: Maintenance Intervals

    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 246 Interval Maintenance point Note - Engine air filter Check air filter - Engine air filter Emptying dust collector - Engine air filter Replaceair filter cartridge - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system Top up coolant...
  • Page 247 Interval Maintenance point Note - Engine drive belt Check drive belt - Engine drive belt Tighten drive belt - Engine drive belt Replace drive belt Maintenance Maintenance during the running-in period F 50.18 5...

  • Page 248: Points Of Maintenance

    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 249: Engine Lube Oil System (2)

    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! The sensor rod is located at the front end of the engine. Too much oil in engine damages gas- kets;...
  • Page 250 Oil change: The oil should be changed when at operating temperature. - Place the end of the oil drain port hose (C) in the collection container. - Remove the screw cap with a wrench and allow the oil to drain completely. - Replace the screw cap and tighten properly.

  • Page 251: Engine Fuel System (3)

    Engine fuel system (3) The fuel filter system consists of two filters: - Prefilter (A) with water separator - Main filter (B) Prefilter - draining of water Drain the collecting vessel at regular in- tervals, or in response to an error mes- sage from the engine control unit.
  • Page 252 Changing the prefilter: - Put a suitable drip pan underneath. - Disconnect the electrical connection/cable connection. - Loosen drain plug (C) and drain off liquid. - Untighten the filter cartridge (A) using a pair of oil filter tongs or oil filter strap and unscrew it.

  • Page 253: Engine Air Filter (4)

    Engine air filter (4) Empty dust collector - Empty the dust removal valve (B) on the air cleaner housing (A) by pressing the discharge port in the direction of the arrow. - Remove any baked on dust by press- ing together the upper valve section. Clean the discharge port from time to time.

  • Page 254: Engine Cooling System (5)

    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 opening, there is a danger of scalding! If necessary fill in a sufficient amount of coolant through the open port (A) of the...
  • Page 255 Checking and cleaning the radiator fins - If necessary, remove leaves, dust or sand from the radiator. Observe engine's operating instructions Checking coolant concentration - Check the concentration using a suitable tester (hydrometer). - Adjust the concentration if necessary. Observe engine's operating instructions F 50.18 13...

  • Page 256: Engine Drive Belt (6)

    Engine drive belt (6) 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 257: F60.18 Maintenance - Hydraulic System

    F 60.18 Maintenance - hydraulic system Maintenance - hydraulic system F 60.18 1...
  • Page 258 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 259 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: - Depressurise the hydraulic system for maintenance: 2. Open hopper. 3.

  • Page 260: Maintenance Intervals

    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 - Change ventilation filter - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank -...
  • Page 261 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 262: Points Of Maintenance

    Points of maintenance Hydraulic oil tank (1) - Check oil level at sight glass (A). The oil level must be up to the centre of the sight glass when the cylinders are retracted. If all the cylinders are extended, the level can fall below the sight glass.

  • Page 263: Ventilation Filter

    To change oil: - To drain the hydraulic oil unscrew the drain plug (D) at the bottom of the tank. - Collect the oil in a container using a funnel. - When returning the screw, make sure to use a new seal. When using the drainage hose (o): - Unscrew seal cap (E).
  • Page 264 Suction/return flow hydraulic filter (2) Replace the filter element when the indi- cator lamp in the operating panel or the service indicator (A) turns red at a hy- draulic oil temperature of more than 80°C or the interval has been reached. - Remove cover (A).

  • Page 265: High-Pressure Filter (3)

    High-pressure filter (3) The filter elements must be replaced when the maintenance indicator (A) turns red. The vehicle's hydraulic system contains 2 or 3 high-pressure filters. - Unscrew filter housing (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge.

  • Page 266: High-Pressure Filter (4)

    High-pressure filter (4) Replace the filter elements when the in- terval has been reached The filter (B) is in the engine compart- ment on the left of the vehicle. During the run-in time, the filter element can be cleaned with cleaning solvent, later it will have to be changed.

  • Page 267: Pump Distribution Gear (5)

    Pump distribution gear (5) - Check the oil level at the sight glass (A) side gear housing). The oil level must be up to the centre of the sight glass. For filling with oil: - Unscrew the filler screw (B). - Fill oil in through the filling port until the required filling level is achieved at the sight glass (A).

  • Page 268: Bleeder

    Bleeder - The functioning of the bleeder (A) must be ensured. If soiling has occurred, the bleeder should be cleaned. F 60.18 12...

  • Page 269: Hydraulic Hoses (6)

    Hydraulic hoses (6) - Specifically check the condition of the hydraulic hoses. - Immediately replace any damag- ed 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 270 Always comply with the following instructions when installing and removing hydrau- lic 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 271: Marking Hydraulic Hoses / Storage Period, Period Of Use

    Marking hydraulic hoses / storage pe- riod, 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 272: Auxiliary Flow Filter (6)

    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 273: F70.18 Maintenance - Drive Units

    F 70.18 Maintenance - drive units Maintenance - drive units F 70.18 1...
  • Page 274 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 275: Maintenance Intervals

    Maintenance intervals Interval Points of maintenance Note - Chain tension - Check - Chain tension - Adjust - Chains - Relieve - Bottom plates - Check wear - Bottom plates - Replace - Rollers - Check for leaks - Rollers - Check wear - Rollers - Replace...
  • Page 276 Interval Points of maintenance Note - Planetary gear - Check oil level - Planetary gear - Top up oil - Planetary gear - Change oil - Planetary gear - Check oil quality - Planetary gear - Check screw connections q - Planetary gear - Tighten screw connections Maintenance Maintenance during the running-in period...
  • Page 277 WARNING Danger from pretensioned springs Incorrectly performed maintenance and repair work can cause severe or fatal injuries! - Always observe the maintenance instructions. - Do not perform any unauthorised maintenance or repair work to pretensioned springs. - Comply with all further information in these instructions and in the safety manual.

  • Page 278: Points Of Maintenance

    Points of maintenance Chain tension (1) If the chains are not tensioned sufficient- ly, they can slip out of their guide formed by rollers, drive gear and idler wheel, thereby increasing wear levels. If the chains are tensioned too tightly, this increases wear on the idler wheel and drive unit mounting, and also increases wear on track bolts and bushes.
  • Page 279 1,000mm 500mm - Before checking/adjusting the chain tension, ensure that the position of the chain to the idler wheel is as shown in diagram (B). Correct if necessary by moving the vehicle a little. - Insert a measuring rule 1 m long between the sliding piece (C) and (D) of the track to determine the maximum slack: - Check the slack in the middle of the measuring rule (0.5 m).
  • Page 280 If a different level of slack is detected during the measurement process, proceed as follows: - Screw head section for flat nipple (toolbox) onto the grease gun. - Refill the chain tensioner with grease at the filler connection (A), then re- move the grease gun.

  • Page 281: Bottom Plates (2)

    Bottom plates (2) Always use new bolts and nuts when in- stalling new bottom plates! - After removing the worn bottom plates, the adhesions must be cleaned from the contact surfaces of the chain links and the nut seats. - Place the bottom plate with the front edge (A) over the chain links' bolt eye (B).

  • Page 282: Rollers (3)

    Rollers (3) Rollers with damaged surfaces or which are leaking should be replaced immedi- ately! - Relieving the caterpillar chain: - Raise the track chassis using suitable lifting equipment and remove adher- ing dirt. Observe the safety measures when rais- ing and securing loads! - Remove the defective roller.

  • Page 283: Planetary Gear (4)

    Planetary gear (4) Before checking the oil level, let the hot gear cool down for about 5 minutes. - Turn conveyor chain sprocket so that inspection bolt (A) is in the 9 o’clock position. - To check the oil level, unscrew the in- spection bolt (A) and the filler screw (B).

  • Page 284: Screw Connections

    Screw connections After approx. 250 hours of operation at full load, check that all gearbox mount- ing screws are firmly seated. Improperly tightened screws may lead to increased wear and to the destruction of components! - The correct torque for the gear/sprocket connecting screws (A) is: 255Nm...

  • Page 285: F82.18 Maintenance - Electrical System

    F 82.18 Maintenance - electrical system Maintenance - electrical system F 82.18 1...
  • Page 286 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 287: Maintenance Intervals

    Maintenance intervals Interval Maintenance point Note q Check batteries q Apply grease to battery terminals - Alternator Insulation monitoring, check electric system is functioning - Alternator Visual check for pollution or damage - Check the cooling air openings for pollution or clogging, clean if necessary.

  • Page 288: Points Of Maintenance

    Points of maintenance Batteries (1) Maintenance of batteries The batteries are factory-filled with the correct quantity of acid. The fluid level should come up to the top mark. If re- quired, top up the battery, but only use distilled water to do so! The battery terminal clips must be free of corrosion (oxide) and protected with a special grade of terminal grease.

  • Page 289: Recharging The Batteries

    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 290: Alternator (2)

    Alternator (2) Electrical system insulation monitoring The function of the protective insulation monitoring measure must be checked every day before starting work. This check only checks the function of the insulation monitor, not whether an insula- tion error has occurred on the heating sections or consumers. - Start the paver finisher's drive engine.
  • Page 291 If the test is conducted successfully, work may be undertaken with the screed and ex- ternal consumers may be used. If the "insulation fault" indicator lamp displays a fault even before the test button is pressed or if no fault is displayed during the simulation, work must not be undertaken with the screed or with connected, external equipment.

  • Page 292: Insulation Faults

    Insulation faults If an insulation fault occurs during operation, and the indicator lamp displays an insu- lation fault, the operator may proceed as follows: - Switch the switches of all external equipment and the heating system to OFF and press the reset button for at least 3 seconds to delete the fault. - If the indicator lamp does not go out, the fault lies in the alternator.

  • Page 293: Cleaning The Alternator

    Cleaning the alternator alternator must regularly checked for excessive dirt and must be cleaned if necessary. - The air intake (1) must be kept free of dirt. Cleaning with a high-pressure cleaner is not permissible! F 82.18 9...

  • Page 294: Drive Belts

    Drive belts Checking / adjusting belt tension: - The tension of the belt can only be adjusted using a pre-tensioning test device. Checking belt tension The tension of each belt must be inspected with pretension check- ing instrument. Specified tension: - In case of initial assembly:605-648N - After running-in period / maintenance interval: 518-561N...
  • Page 295 Replacing belt - Unfasten lock nut (A) from the clamping lock. - Turn and open clamping lock (B) until belts (C) can be replaced. Pre-tension the newly fitted belts using clamping lock (B). - Check / adjust belt tension. F 82.18 11...

  • Page 296: Electrical Fuses

    Electrical fuses Main fuses Main fuses (A) Main fuse Main fuse Preheating ignition system F 82.18 12...

  • Page 297: Fuses In Main Terminal Box

    Fuses in main terminal box Fuse carrier (B) Screed Screed Screed Starter Auger light Monitoring unit Monitoring unit Central lubrication Conveyor, auger 24V socket left 24V socket right Power supply A1 (master) 12V socket Rotary beacon F 82.18 13...
  • Page 298 Power supply A1 (master) Horn Diesel pump Power supply A2 (engine control unit) Ignition Instrument panel illumination Steering potentiometer, preselection potentiometer, GPS module Reverse buzzer Central lubrication Power supply A1 (master) Protective roof rear light Protective roof front light Interface - engine diagnosis - A2 Interface - engine diagnosis - A1 F 82.18 14...

  • Page 299: Relays In Main Terminal Box

    Relays in main terminal box Relays (C) Engine start Switched positive Engine start / stop Control unit voltage Emergency stop Front working lights Rear working lights Auger working light Horn Right conveyor Left conveyor Left auger Right auger Levelling - left Levelling - right Rotary beacon Reverse buzzer...
  • Page 300 F 82.18 16...

  • Page 301: F90.18 Maintenance - Lubricating Points

    F 90.18 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 90.18 1...

  • Page 302: Maintenance Intervals

    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 303: Points Of Maintenance

    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 safety valve installed! 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 304 Central lubrication system Check filling level The lubricant tank should always be filled sufficiently so that the system can- not "run dry", ensuring sufficient drive chain lubrication and eliminating the need for time-consuming bleeding of the system. - Always maintain a fill level above the "MIN"...
  • Page 305 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. - Disconnect the main lubrication line (A) at the distributor (B). - Start up the central lubrication sys- tem with the filled lubricant tank (C).
  • Page 306 Check the flow of lubricant at the consumers Each lubrication channel at the consu- mers must be checked as regards clear- ance. - Remove the lubrication line (A) and install normal lubricating nipple (B). - Connect the grease gun (C) included in the scope of supply to the lubricat- ing nipple (B).

  • Page 307: Bearing Points (2)

    Bearing points (2) One lubricating nipple (A) is located at each hydraulic cylinder bearing point (top and bottom). F 90.18 7...
  • Page 308 F 90.18 8...

  • Page 309: F100 Tests, Stopping

    F 100 Tests, stopping ... Tests, checks, cleaning, stopping F 100 1...

  • Page 310: Maintenance Intervals

    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 311 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 312: Inspection By An Expert

    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 313: Cleaning

    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 314: Cleaning The Hopper

    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 315: Cleaning Optical Or Acoustic Sensors

    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 316: Preserving The Paver Finisher

    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 317: Environmental Protection, Disposal

    Environmental protection, disposal Environmental protection Packaging materials, used operating substances, cleaning agents and machine ac- cessories must be correctly recycled. Always observe the local regulations! Disposal Correctly sorted disposal must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service (scrapped). The materials must be sorted correctly according to metal, plastic, electronic scrap, various operating substances etc.

  • Page 318: Bolts - Torques

    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 319: Fine Metric Threads - Strength Class 8.8 / 10.9 / 12.9

    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 320 F 100 12...

  • Page 321: F110.18 Lubricants And Operating Substances

    F 110.18 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 feeder failure.
  • Page 322 F 110.18 2...

  • Page 323: Capacities

    Capacities Substance Volume Diesel engine Engine oil litres (with oil filter change) Engine cooling system Cooling liquid 12,0 litres Fuel tank Diesel fuel 73,0 litres Hydraulic oil reservoir Hydraulic oil 80,0 litres Pump distribution gear Gearbox oil litres Pump distribution gear, Gearbox oil litres as of s/n 3309, 3510 ff.

  • Page 324: Operating Substance Specifications

    Operating substance specifications Notes on diesel fuel 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- tem! Keep fuel and fuel system free of water and impurities! Observe the instructions for fuel recommendations and the specification in the main- tenance instructions of the engine manufacturer! Drive engine TIER III (o) fuel specification...

  • Page 325: Engine - Lubricating Oil

    Engine - lubricating oil Esso / Dynapac Aral Fuchs Mobil Shell Exxon Engine Oil (* ) = recommended Observe the instructions for lubricant recommendations and the specification in the maintenance instructions of the engine manufacturer! Cooling system Dynapac Petronas Finke AGIP Chevron Caltex...

  • Page 326: Drive Unit Planetary Gear

    Drive unit planetary gear Esso / Dynapac Aral Fuchs Mobil Shell Exxon Gear Oil -Omala S2 GX 220 (*) = recommended 2.10 Auger box Esso / Dynapac Aral Fuchs Mobil Shell Exxon Auger -Gadus Grease V142W 00 (*) = recommended 2.11 Grease Esso /...

  • Page 327: Hydraulic Oil

    2.12 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 328 F 110.18 8...
  • Page 330 www.dynapac.com...

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