Atlas Copco DYNAPAC F2500C Operation & Maintenance Manual
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Atlas Copco DYNAPAC F2500C Operation & Maintenance Manual

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OPERATION
&
MAINTENANCE
Paver Finisher
F2500C
F2500CS
Type 890 / 891
Keep for later use in document compartment
Article No. for this handbook: 4812037944 (A5) / 4812037949 (A4)
01-0111
Valid for:
_________________ to _________________
_________________ to _________________

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  • Page 1 OPERATION & MAINTENANCE Paver Finisher F2500C F2500CS Type 890 / 891 Keep for later use in document compartment Article No. for this handbook: 4812037944 (A5) / 4812037949 (A4) 01-0111 Valid for: _________________ to _________________ _________________ to _________________...
  • Page 2 Original spare parts only Everything from one source Your authorised Dynapac dealer:...

  • Page 3: Table Of Contents

    Table of contents Preface ..................1 General safety instructions ................ 2 Laws, guidelines, accident prevention regulations ........2 Warnings ....................2 Prohibitive symbols ..................4 Protective equipment ................. 5 Environmental protection ................6 Fire prevention ................... 6 Additional information ................7 CE identification and Declaration of Conformity ........
  • Page 4 Location of instruction labels and identification plates ......18 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) ........
  • Page 5 Operation ................. 1 Operating elements on the paver finisher ..........1 Control elements on the operator's control station ........1 Protective roof (o) .................. 1 Protective cabin (o) ................2 Windscreen wiper .................. 2 Control panel, rigid ................. 3 Operating panel, moveable ..............3 Control platform, moveable (o) ..............
  • Page 6 Storage box ..................34 Fire extinguisher (o) ................34 Rotary beacon (o) ................35 Fuelling pump (o) ................. 36 Power moon (o) ................... 37 Operation ................. 1 Preparing for operation ................1 Required devices and aids ..............1 Before starting work (in the morning or when starting paving) ....2 Check list for the vehicle operator ............
  • Page 7 Set-up and modification 1 ............Special notes on safety ................1 Distribution auger ..................2 Height adjustment ..................2 Grain sizes up to 16 mm ................ 2 Grain sizes > 16 mm ................2 Mechanical adjustment with ratchet (o) ................... 3 Hydraulic adjustment (o) ................
  • Page 8 Limit switch ....................43 Auger limit switches (left and right) - mounting the PLC version ................ 43 Auger limit switches (left and right) - mounting the conventional version ............44 Screed ...................... 45 Electrical connections ................45 10.1 Machine operation without remote control / side board ......46 Maintenance ................
  • Page 9 Maintenance - engine assembly ..........1 Maintenance - engine assembly ..............1 Maintenance intervals ................2 Points of maintenance ................5 Engine fuel tank (1) ................5 Engine lube oil system (2) ..............6 Engine fuel system (3) ................8 Engine air filter (4) ................
  • Page 10 Maintenance - lubricating points ........... 1 Maintenance - lubricating points ..............1 Maintenance intervals ................2 Points of maintenance ................3 Central lubrication system (1) ..............3 Bearing points (2) .................. 7 F100 Tests, stopping ..............1 Tests, checks, cleaning, stopping .............. 1 Maintenance intervals ................

  • 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 Warning on danger of crushing! There is a danger of crushing when certain components are operat- ed, or certain functions or vehicle movements are carried out. Always make sure that there are no persons within the endangered areas! Warning on hand injuries! Warning on hot surfaces or hot liquids! Warning on danger of falling! Warning on dangers posed by batteries!

  • Page 14: 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 15: 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 16: 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 17: 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-...

  • Page 18: 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 19: 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 20: 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 21: 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 23: B Vehicle Description

    B Vehicle description Application The Dynapac F2500C / F2500CS 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...

  • Page 24: Description Of Assemblies And Functions

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

  • Page 25: 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 26 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 27 Material compartment (hopper): The hopper inlet is equipped with a conveyor sys- tem that empties the hopper and transfers the material to the auger. The hopper can hold approx. 15.0 t. To facilitate emptying and to improve material transport, each of the lateral covers of the hopper can be hydraulically moved.
  • Page 28 Levelling/slope control system: The slope control system (o) can be used to reg- ulate the traction point on the left-hand or the right-hand side with a defined difference to the opposite side. To determine the actual value, the two traction crossbeams are linked with a slope control rod.

  • Page 29: Danger Zones

    Danger zones In these vehicle working areas, there may be a risk of drawing in or crushing during normal operation caused by rotating and conveying elements, or by components in motion. Danger of being pulled in! Danger of crushing!

  • Page 30: Safety Devices

    Safety devices 4 5 6 7...
  • Page 31 Item Designation Hopper transport safeguard Screed lock, mechanical / hydraulic (o) Main switch Emergency stop button Horn Ignition key Lights Protective roof latch (o) Fire extinguisher (o) Screed warning light (o) Covers, lateral flaps, coverings Rotary beacon (o) Located on both sides of the vehicle Safe operation is only possible if the control and safety devices are functioning perfectly and if the protective equipment is fitted correctly.

  • Page 32: Technical Data, Standard Configuration

    Technical data, standard configuration Dimensions (all dimensions in mm) 2125 2900 6120 6400 1995 2550 3500 3610 For screed technical data, refer to the screed operating instructions. B 10...

  • Page 33: 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 34: Weights F2500C (All Weights In T)

    Weights F2500C (all weights in t) Paver finisher without screed Approx. 14.5 Paver finisher with screed: - V5100 Approx. 18.2 With extension parts for max. Approx. xxx working width, additionally max.: With filled hopper Approx. 15.0 Additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.

  • Page 35: Performance Data F2500C

    Performance data F2500C V5100TV 2.55 2.00 5.10 8.10 Transport speed 0 - 4 km/h Operating speed 0 - 30 m/min Paving height -150 - 320 Max. grain size Theoretical paving performance B 13...

  • Page 36: Performance Data F2500Cs

    Performance data F2500CS V5100TV 2.55 2.00 5.10 8.10 V6000TV 3.00 2.00 6.00 9.00 Transport speed 0 - 4 km/h Operating speed 0 - 30 m/min Paving height -150 - 320 Max. grain size Theoretical paving performance B 14...

  • Page 37: Travel Drive/Traction Unit

    Travel drive/traction unit Drive Hydrostatic drive, continuously controllable Two separately driven caterpillar drives with rub- Drive unit ber grouser chains Turning capacity Turning on the spot Speed See above Engine F2500C Make/type Cummins QSB 6.7-C173 Version 6-cylinder diesel engine (water-cooled) Performance 110 kW / 150 hp (at 2200 rpm) Pollutant emissions in...

  • Page 38: Material Compartment (Hopper)

    5.12 Material compartment (hopper) Volume Approx. 6.5 m = approx. 15.0 t Minimum inlet height, centre 555 mm Minimum inlet height, outside 560 mm Hopper width, outside, open 3610 mm 5.13 Material transfer Type Dual conveyor belt Width 2 x 655 mm Conveyors Left and right auger separately controllable Drive...

  • Page 39: Screed Lifting Device

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

  • Page 40: Location Of Instruction Labels And Identification Plates

    Location of instruction labels and identification plates B 18...
  • Page 41 xxxxxxxxxxxxxxxxx B 19...

  • Page 42: Warning Signs

    Warning signs Pictogram Meaning Warning - Operating instructions! Danger due to improper operation. The machine personnel must have read and understood the safety, operating and maintenance instructions for the ma- chine before the machine is put into op- eration! Failure to comply with the operating and warning instructions can cause severe or fatal injuries.
  • Page 43 Pictogram Meaning Warning - Danger of crushing fingers and hands with moving, accessible machine parts! Crushing points can cause severe inju- ries with the loss of parts of the fingers or hand. Keep your hands at a safe distance from the danger area! Warning - Spring-loaded part! Performing work incorrectly can cause...
  • Page 44 Pictogram Meaning Warning - Hazard from hydraulic res- ervoir and from hydraulic oil under pressure! Escaping hydraulic oil under pressure can pierce the skin and enter into the body, causing severe or fatal injuries. Always observe the operating instruc- tions! Warning - Danger from tyres filled with water! Handling tyres filled with water incorrect-...

  • Page 45: Information Signs

    Information signs Pictogram Meaning Operating Instructions Position of the storage compartment. Lifting point Lifting the machine is only permitted at these lifting points! Lashing point Lashing the machine is only permitted at these points! Main battery switch Position of the main battery switch. Diesel fuel Position of the filling point.
  • Page 46 Pictogram Meaning Engine oil Position of the filling and control point. Engine coolant Position of the filling and control point. Hydraulic oil Position of the filling point. Hydraulic oil level Position of the control point. Engine oil drainage point Position of the drainage point. Gearbox oil Position of the filling and control point.

  • Page 47: Ce Marking

    Pictogram Meaning Tamper speed adjuster Position of the speed adjuster. Vibration, speed adjuster Position of the speed adjuster. CE marking No. Pictogram Meaning CE, sound output level B 25...

  • Page 48: Instructive Symbols, Prohibitive Symbols, Warning Symbols

    Instructive symbols, prohibitive symbols, warning symbols Pictogram Meaning Wear ear protection devices Do not enter the area! Do not spray the area or part with water! Warning on dangers posed by batteries! First aid kit B 26...

  • Page 49: Danger Symbols

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

  • Page 50: Further Warnings And Operating Instructions

    Further warnings and operating instructions Pictogram Meaning - Important! Let the engine reach operating tempera- ture for 5 minutes at half speed after cold- starting. - Move the traction lever slightly from its 0-position. - Possibly adjust switch gear to neu- tral position.
  • Page 51 Pictogram Meaning Overview "Tyre pressure / working width / speed preselection" Overview "Tyre pressure / working width / speed preselection" - Engine start - All switches in neutral! The engine cannot be started when func- tions are switched on. Always observe the operating instruc- tions! B 29...

  • Page 52: Identification Label For The Paver Finisher (41)

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

  • Page 53: En Standards

    EN standards Continuous sound pressure F2500C, Cummins QSB 6.7-C173 The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protection devices are used, hearing can be impaired. The sound emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6:2006 and ISO 4872.

  • Page 54: Continuous Sound Pressure F2500Cs, Cummins Qsb 6.7-C173

    Continuous sound pressure F2500CS, Cummins QSB 6.7-C173 The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB(A). If no ear protection devices are used, hearing can be impaired. The sound emission level of the paver finisher was measured under free-field condi- tions according to EN 500-6:2006 and ISO 4872.

  • Page 55: Vibration Acting On The Entire Body

    Vibration acting on the entire body When the machine is used properly, the weighted effective acceleration values at the driver’s seat of a = 0.5 m/s according to DIN EN 1032 are not exceeded. Vibrations acting on hands and arms When the machine is used properly, the weighted effective acceleration values at the driver’s seat of a = 2.5 m/s...
  • Page 56 B 34...

  • Page 57: C10 Transportation

    C 10 Transportation Safety regulations for transportation Accidents can happen when the paver finisher and the screed are not properly pre- pared for transportation or when transportation is carried out improperly! Reduce both the paver finisher and the screed to their basic widths. Remove all pro- truding parts (such as the automatic levelling system, auger limit switches, aprons, etc.).

  • Page 58: 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 59 Operation Travelling direction Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Engage screed transport safeguards. Extend levelling cylinders completely. Retract the screed parts until the screed matches the basic width of the paver finish- C 10 3...

  • Page 60: 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 61: Driving Onto The Low-Bed Trailer

    Driving onto the low-bed trailer Make sure that there are no persons in the danger area during loading. - Use the work gear and low engine speeds to drive onto the low-bed trailer. C 10 5...

  • Page 62: Lashing Equipment

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

  • Page 63: Loading

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

  • Page 64: Preparing The Machine

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

  • Page 65: Securing The Load

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

  • Page 66: Securing At The Rear - Screed With Side Board

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

  • Page 67: Securing At The Rear - Screed Without Side Board

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

  • Page 68: After Transportation

    After transportation - Remove the attachment devices. - Raise the protective roof (o): See section entitled "Protective roof" For a paver finisher without roof: - Mount the exhaust extension pipe. - Lift the screed to the transportation position. - Start the engine and drive from the trailer at a low engine/traction speed. - Park the paver finisher in a secure spot, lower the screed and switch off the engine.

  • Page 69: Protective Roof (O)

    Protective roof (o) The protective roof can be raised and lowered with a manual hydraulic pump. The exhaust pipe is lowered or raised to- gether with the roof. - Remove the lower section of the pump lever (1) from the storage compart- ment, and connect to the upper sec- tion using a pipe (2).

  • Page 70: Transportation

    Transportation Reduce the paver finisher and the screed to their basic widths; also remove any at- tached side plates. Preparations - Prepare the paver finisher for transportation (see chapter D). - Remove all overlaying or loose parts from finisher and screed (see also Operating instructions for the screed).
  • Page 71 Operation Travelling direction Close the hopper lids. Engage both hopper transport safeguards. Lift the screed. Engage screed transport safeguards. Extend levelling cylinders completely. Retract the screed parts until the screed matches the basic width of the paver finish- C 10 15...

  • Page 72: Driving Mode

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

  • Page 73: Loading By Crane

    Loading by crane Use only lifting gear that can bear the load. (See chapter B for weights and dimensions). Attachment and loading equipment must meet the conditions of the applicable acci- dent prevention regulations! The vehicle's centre of gravity is dependent on the screed which is mounted. Example: C 10 17...
  • Page 74 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 75: 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 76 Two high-pressure cartridges (6) are located on both of the travel drive pumps (5). The following activities must be carried out to activate the towing function: - Loosen lock nut (7) half a turn. - Screw in the bolt (8) until increased re- sistance occurs.

  • Page 77: 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 78 C 10 22...

  • Page 79: Operation

    D 10 Operation Safety regulations Starting the engine, the travel drive, the conveyor, the auger, the screed or the lifting devices can cause injuries or even the death of persons. Make sure before starting any of these devices that no-one is working at, in or be- neath the paver finisher or within its danger area! - Do not start the engine or do not actuate any controls when this is expressly forbid- den!

  • Page 80: Controls

    Controls Operating panel D 10 2...
  • Page 81 General notes on adherence to CE regulations All detent switch functions which may pose a risk on starting the diesel engine (auger and conveyor conveying function) are set to the STOP function in the case of EMER- GENCY STOP or restarting the control system. If settings are changed when the die- sel engine is stopped ("AUTO"...
  • Page 82 D 10 4...
  • Page 83 Item Designation Brief description Lights up instrument panel A/B when the parking light is Lights switched on In the case of an emergency (danger to persons, possible col- lision etc.), press in the button! Pressing the emergency stop button switches the engine, the drives and the steering system off.
  • Page 84 D 10 6...
  • Page 85 Item Designation Brief description Energizes starter motor while pressed. All emergency stop but- Starter tons (on the operating panel and the remote controls) must be pulled out. For switching on the paver finisher functions and for continu- ously regulating the road speed – forward or reverse. Zero position: engine at idling speed;...
  • Page 86 D 10 8...
  • Page 87 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 88 D 10 10...
  • Page 89 Item Designation Brief description Pushbutton function: - Upper switch position: Close left half of hopper. Open/close left - Lower switch position: hopper Open left half of hopper. On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - Upper switch position: Close right half of hopper.
  • Page 90 D 10 12...
  • Page 91 Item Designation Brief description Detent switch function: - Left switch position: "AUTO" operating mode: 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. Left auger - - Switch position, central: operating mode...
  • Page 92 D 10 14...
  • Page 93 Item Designation Brief description Pushbutton function: - Left switch position: Manual start of the conveying function, Conveying direction outwards. - Right switch position: Manual start of the conveying function, Left auger Conveying direction inwards. "MANUAL" For manual triggering, the auger function must be conveying direction switched to "AUTO"...
  • Page 94 D 10 16...
  • Page 95 Item Designation Brief description Pushbutton function: - Left switch position: Extend left half of screed. Left screed - Right switch position: extend / retract Retract left half of screed. On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - Left switch position: Retract right half of screed.
  • Page 96 D 10 18...
  • Page 97 Item Designation Brief description Detent switch function: - Left switch position: "AUTO" operating mode: 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. Left conveyor - - Switch position, central: operating mode...
  • Page 98 D 10 20...
  • Page 99 Item Designation Brief description Detent switch function: - Upper switch position: Screed stop (floating position OFF): Screed is hydraulically locked in position. - Lower switch position: Lower screed + floating position: Screed is lowered and held in the floating position when the drive lever Screed stop (float- is swivelled out.
  • Page 100 D 10 22...
  • Page 101 Item Designation Brief description Detent switch function: - Left switch position: "AUTO" operating mode: Screed vibration is switched Vibration - on when the drive lever is swivelled out. operating mode - Switch position, central: "AUTO" / "OFF" operating mode: Screed vibration is switched "OFF"...
  • Page 102 D 10 24...
  • Page 103 Item Designation Brief description Pushbutton function: - Upper switch position: Retract left levelling cylinder. Extend / retract left - Lower switch position: levelling cylinder Extend left levelling cylinder. On actuation, note danger zones of moving parts of the vehicle! Pushbutton function: - Upper switch position: Retract right levelling cylinder.
  • Page 104 D 10 26...
  • Page 105 Item Designation Brief description not used Detent switch function: - Upper switch position: Front working lights ON. Working lights, front - 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 106 D 10 28...
  • Page 107 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 fault code.
  • Page 108 D 10 30...
  • Page 109 Item Designation Brief description not used not used Lights up when a serious error has occurred on the engine. The engine is automatically shut down for safety. The error code can be called up using the switch Error message with "Call up error / malfunction".
  • Page 110 D 10 32...
  • Page 111 Item Designation Brief description Battery charge in- Must go out after starting when the engine revs up. dicator (red) If the light does not go out, switch off the engine not used Indicates that there is a drive engine fault. Depending on the type of fault, the vehicle can temporarily continue to be operat- ed or, in the case of serious faults, should be shut down imme- diately to prevent further damage from occurring.

  • Page 112: Remote Control

    Remote control Depending on the machine side left/right, the function switches steers only the appro- priate function on the respective machine side! Important! Do not disconnect remote controls with emergency stop button (O) during operation! This causes the paver finisher to be shut down! D 10 34...
  • Page 113 Item Designation Brief description In the case of an emergency (danger to persons, possible col- lision etc.), press in the button! Pressing the emergency stop button switches the engine, the drives and the steering system off. Making way, lifting the screed or other actions are then no Emergency stop longer possible! Danger of accidents! button...
  • Page 114 D 10 36...
  • Page 115 Item Designation Brief description Pushbutton function: - Upper switch position: Retract left / right levelling cylinder. Extend / retract levelling - Lower switch position: cylinder left / right Extend left / right levelling cylinder. On actuation, note danger zones of moving parts of the vehicle! Detent switch function: - Upper switch position:...
  • Page 116 D 10 38...

  • Page 117: Operation

    D 30 Operation Operating elements on the paver finisher Control elements on the operator's control station Protective roof (o) The protective roof can be raised and lowered with a manual hydraulic pump. The exhaust pipe is lowered or raised to- gether with the roof.

  • Page 118: Protective Cabin (O)

    Protective cabin (o) The protective roof is equipped with an additional front window and two side windows. - The side windows can be swivelled out to the side at the bracket (1). Press the lock (2) to unlock. Windscreen wiper - Activate the windscreen wiper (3) / screen wash on the operating panel if necessary.

  • Page 119: Control Panel, Rigid

    Control panel, rigid Operating panel, moveable The operating panel can be shifted to several positions on the left- and right-hand sides of the vehicle. - Loosen panel latch (1) and slide panel console to the desired position using the handle (2). - Insert panel latch (1) into one of the detent positions (3).

  • Page 120: Control Platform, Moveable (O)

    Control platform, moveable (o) The control platform can be hydraulically shifted beyond the left/right outer edge of the vehicle, providing the driver with a better view of the paving area in this position. - When the control platform has been moved, the windows (1) additionally offer a good view of the paving area.

  • Page 121: Operating Panel, Moveable

    Operating panel, moveable The operating panel can be shifted to several positions on the left- and right-hand sides of the vehicle. - Raise panel latch (2) and slide panel console to the desired position using the han- dle (3). - Insert panel latch (2) into one of the detent positions (4). Make sure it is latched properly! Only adjust the operating position whilst the vehicle is stationary! Operating panel, swivelling (o)

  • Page 122: Emergency Actuation Control

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

  • Page 123: Seat Console, Swivelling (O)

    Seat console, swivelling (o) The seat consoles can be swivelled for operation beyond the outer edge of the vehicle. - Press latch (1), swivel seat console to the desired position and allow latch to engage again. Make sure it is latched properly! Only adjust the operating position whilst the vehicle is stationary! Seat console storage compartment...

  • Page 124: 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 125 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 126: 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 10...

  • Page 127: 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 128: Hopper Transport Safeguard

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

  • Page 129: Screed Lock, Hydraulic (O)

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

  • Page 130: Paving Thickness Indicator

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

  • Page 131: Auger Lighting (O)

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

  • Page 132: Xenon Working Light (O)

    Xenon working light (o) Xenon working lights have a secondary high voltagesource. Only a qualified electrician may work on the lighting after the primary voltage has been switched off. Please contact a Dynapac dealer! Caution, environmentally harmful waste! Working lights with Xenon lamps have a gas discharge lamp containing mercury (Hg).

  • Page 133: Watt Spotlight (O)

    500 watt spotlight (o) There are two halogen spotlights (2) at the front of the machine and also at the back. - For machine without roof: clamping bolt (3) to change the height of the spotlights. Always align the working lights to avoid dazzling the operating personnel or other road users! Danger of burning! The working lights...

  • Page 134: Auger Height Adjustment Ratchet (O)

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

  • Page 135: 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 136 - Once the sensor rod has been set to the desired width, the clamping bolts (2) must be tightened again. - The inserted sensor rod extension is secured with the bolts (4). Depending on the side of the vehicle on which the sensor rod extension is used, the entire sensor rod may have to be removed and re-inserted on the other side of the vehicle! - After releasing the wing nuts (5), the end section of the sensor rod extension (6)

  • Page 137: Manual Separator Fluid Spray (O)

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

  • Page 138: Separator Fluid Spraying System (O)

    Separator fluid spraying system (o) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. - Connect the spray hose (1) with quick- action coupling (2). Only switch on the spraying system when the diesel engine is running; other- wise, the battery will be discharged.
  • Page 139 Conveyor limit switches - PLC ver- sion The mechanical conveyor limit switches (1) or the ultrasonic conveyor limit switches (2) control the material flow on the relevant half of the conveyor. The conveyors should stop when the materi- al has roughly reached the area below the auger tube.
  • Page 140 Conveyor limit switches - conven- tional version The mechanical conveyor limit switches (1) control the material flow on the rele- vant half of the conveyor. The conveyors should stop when the material has roughly reached the area below the au- ger tube.
  • Page 141 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 142 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 143: Volt / 12 Volt Sockets (O)

    24 volt / 12 volt sockets (o) A socket (1) is located beneath 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 144: Pressure Control Valve For Paving Stop With Relieving

    Pressure control valve for screed charging/relieving A valve (1) is used to set the pressure for additional screed charging/relieving. Switching on, see screed charging/re- lieving (chapter "Operating panel", "Op- eration"). - For pressure indication, see manome- ter (3). Pressure control valve for paving stop with relieving This is used to set the pressure for "Screed control with paver finisher stop - floating stop with relieving".

  • Page 145: Central Lubrication System (O)

    Central lubrication system (o) The central lubrication system is activat- ed in automatic mode as soon as the drive engine is started. - Pumping time: 4 min - Pause time: It is prohibited to change the factory-set durations of pumping and break without consulting the technical customer serv- ice! Changing the duration of lubrication and...

  • Page 146: 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 147: 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 148: Push Roller Crossbar

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

  • Page 149: Push Roller Crossbar

    Push roller crossbar, hydraulically extendable (o) For adaptation to various truck design types, the push roller crossbar (1) can be retracted and extended hydraulically. The max. adjustment travel is 90 mm. - Activate the function on the operating panel as necessary. Extending the push roller increases the transportation length of the paver finish- On actuation, ensure that nobody is in...

  • Page 150: Storage Box

    Storage box For storing the on-board tool kit, remote controls and other accessories. Lock the storage box at the end of work. Fire extinguisher (o) The paver finisher personnel must be fa- miliarised with fire extinguisher (2) oper- ation. Observe the inspection intervals for the fire extinguisher! D 30 34...

  • Page 151: 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). - Slide the rotary beacon with the tube (2) out to the desired height and se- cure with the clamping bolt (3).

  • Page 152: Fuelling Pump (O)

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

  • Page 153: Power Moon (O)

    Power moon (o) The power moon is a special, illuminated balloon with shadow-reducing and anti- dazzle light. Use of the power moon increases the height of the paver finisher. Note the passage height of bridges and tunnels. The power moon must not be used in the vicinity of highly flammable materials (e.g.
  • Page 154 - Secure the lower part of the tripod (3) to the preassembled bracket (5) using the relevant assembly parts (4). - Connect the tripod sections (6) and secure with stop screws (7). - Place the power moon's journal (8) onto the top part of the tripod and se- cure with the stop screws (9).

  • Page 155: Operation

    D 40 Operation Preparing for operation Required devices and aids To avoid delays on site, check before starting work whether or not the following devices and aids are present: - Wheel loader for transporting heavy extension parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separator fluids (emulsion) and manual injector - Two filled propane gas bottles...

  • Page 156: 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 157 Check! How? For larger working widths, the walkway Auger coverings plates must be extended and the auger tunnels must be covered. For larger working widths, the walkway plates must be extended. Hinged walkway plates must be swung Screed covers and walkways down.
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  • Page 159: 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.
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  • Page 161: 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 24 V system - Additional 24 V battery - Start device that is suitable for external starting (24 V/90 A).
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  • Page 163: After Starting

    After starting Let the paver finisher warm up for approx. 5 minutes if the engine is cold. D 40 9...
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  • Page 165: Observe Indicator Lamps

    Observe indicator lamps The following indicator lamps must be observed under all circumstances: For further possible faults, see Engine operating instructions. Engine coolant temperature check (1) Lights up when the engine temperature is outside of the permissible range. Stop the paver finisher (drive lever to the centre position), let the engine cool down while idling.
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  • Page 167: 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"...
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  • Page 169: 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 170: 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 171: 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. - Pull the direction indicator out of the bumper (arrow) and adjust it accord- ingly.
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  • Page 173: 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". - Set the corresponding switches for the auger and the conveyor on the remote con- trols (if applicable) to "auto".
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  • Page 175: 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 Travel drive speed - fast/slow slow ("Tortoise")

  • Page 176: 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 - Uniform material transport and distribution or supply to the screed;...

  • Page 177: General

    Paving with "screed control at paver finisher stop" and "screed charging/ relieving" General The screed hydraulics can be influenced in three different ways to attain optimum paving results: - floating stop with relief when the paver finisher is halting, - floating paving when the paver finisher is driving, - floating paving with screed charging or relieving when the paver finisher is driving.
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  • Page 179: Screed Control With Paver Finisher Stop / In Paving Operation

    Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Switch (1) has the following positions: A: relieving (screed 'lighter') B: function OFF C: charging (screed 'heavier') Switch positions "Screed charging/relieving" are only effective when the paver finish- er moves.
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  • Page 181: Screed Control With Paver Finisher Stop - Floating Stop With Relief

    Screed control with paver finisher stop - floating stop with relief As for charging/relieving, a pressure of 2-50 bar can be individually applied to the screed lifting cylinders. This pressure acts to combat the weight of the screed to pre- vent the screed from sinking into the freshly laid material.
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  • Page 183 Setting pressure for screed control with paver finisher stop - floating stop with relief - Set the drive lever (4) to the centre po- sition. - Set switch (2) to position C. - Set the pressure using pressure regu- lating valve (7); read the pressure off at the manometer (6).
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  • Page 185: Interrupting/Terminating Operation

    Interrupting/terminating operation During breaks (e.g. the material supply truck is late) - Determine the approximate duration. - When cooling down of the material below the minimum paving temperature must be expected, run the paver finisher empty and create an edge like the end of a lay- - Set the drive lever (1) to the centre position.
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  • Page 187: 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, conveyor, tamper and vibration functions "OFF". - Lift the screed: set switch (4) to centre position, switch (5) to the top position and switch (6) to lifting.

  • Page 188: Malfunctions

    Malfunctions Error code query for engine D 40 34...
  • Page 189 If a fault on the engine is detected and is signalled by one of the warning lamps (1) or (2), a code to which a defined fault is assigned can be displayed using the query switch (3). Output of the flash code is performed by the other warning lamp: if a fault is displayed by warning lamp (1), output is carried out via warning lamp (2) and vice-versa.

  • Page 190: Output Of Numerical Code

    Output of numerical code - Press switch (3) into display position until the three-digit code has been output via the warning lamp. While the switch for error queries is being actuated, the warning lamp which first signalled the fault which occurred goes out. Example: PAUSE PAUSE...
  • Page 191 Flash sequence: 4-Pause-2-Pause-5. Fault code: 425 If the output switch continues to be held in its upper position, the code is issued once again. Once the switch for error queries has returned to its 0 position, the warning lamp which signalled the fault lights up again. This continues until the corresponding error or malfunction has been rectified.

  • Page 192: Error Codes

    Error codes D 40 38...
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  • Page 199: Problems During Paving

    Problems during paving Problem Reason - change in the material temperature, demixing - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long standstill times between loads - grade control reference line is not suitable - grade control jumps to the reference line - grade control toggles between up and down Wavy surface...
  • Page 200 Problem Reason - material temperature Cracks in the layer - cold screed (centre strip) - bottom plates are worn or warped - wrong crowning - material temperature - screed extendable parts are incorrectly installed Cracks in the layer - limit switch is not correctly set (outer strip) - cold screed - bottom plates are worn or warped...

  • Page 201: Malfunctions On The Paver Finisher Or Screed

    Malfunctions on the paver finisher or screed Malfunction Reason Remedy See operating instructions for the At the diesel engine Various engine See "External starting" (start Batteries empty Diesel engine does assistance) not start Various see "Towing" Tamper is obstructed by Properly heat the screed cold bitumen Hydraulic oil level in the tank...
  • Page 202 Engine speed is too low Increase the speed Hydraulic oil level is too low Top up the oil Leak in the suction line Tighten the connections Flow rate regulator defec- Replace Hopper cannot be tive swung open Leaking seals of the hydrau- Replace lic cylinder Control valve is defective...
  • Page 203 Malfunction Reason Remedy Control valve is defective Replace Hoppers lowers inad- Leaking seals of the hydrau- vertently Replace lic cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot be Screed relieving or charging Switch must be in the centre lifted is switched on position...
  • Page 204 Malfunction Reason Remedy Replace (fuse strip on the oper- Travel drive fuse defective ating panel) Check potentiometer, cables, Power supply interrupted connectors; replace if necessary Travel drive monitoring Replace (type-specific) defective Traction does not Electro-hydraulic servo unit Replace the servo unit work of the pump defective Check and adjust if necessary...

  • Page 205: Set-Up And Modification

    E 10 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, au- ger, screed or screed lifting devices. Unless otherwise specified, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Move drive lever into centre position and turn preselector controller to zero, remove...

  • Page 206: Distribution Auger

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

  • Page 207: Mechanical Adjustment

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

  • Page 208: Height Adjustment For Large Working Widths / With Brace

    Height adjustment for large working widths / with brace Auger height adjustment for large working widths can be carried out with a hinged brace: Only adjust the height of the auger with the slewing bracket retaining pins removed! - Remove the slewing bracket (3) split pin (1) and retaining pin (2) on both sides of the vehicle.
  • Page 209 - Extend or shorten the braces by rotating the adjustment rods (5) until the retaining pins can be inserted. - Retighten the lock nuts (4). - Install the split pin (1) and retaining pin (2). Each time the height is adjusted, the auger must be realigned via the braces! See section "Aligning the auger"! E 10 5...

  • Page 210: Auger Extension

    Auger extension Auger_DEM.bmp Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. Refer to the appropriate chapter "Set-up and modification" in the Operating instruc- tions for the screed: – screed extension chart To attain the desired working width, the respective screed extensions, side plates, au- gers, tunnel plates or cut-off shoes must be mounted.

  • Page 211: Mounting Extension Parts

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

  • Page 212: Mounting The Outer Auger Bearing

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

  • Page 213: Mounting The Auger End Bearing

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

  • Page 214: Auger Extension Chart

    Auger extension chart Symbol Meaning - Auger blade 160 mm - (160L) left - Auger blade 160 mm 160L 160R - (160R) right - Auger extension part 320 mm - (320L) left - Auger extension part 320 mm 320L 320R - (320R) right - Auger extension part 640 mm...
  • Page 215 Symbol Meaning Outer auger bearing Auger end bearing E 10 11...

  • Page 216: Auger Upgrading, Working Width 3.14 M

    Auger upgrading, working width 3.14 m 320 L 320 R Auger upgrading, working width 3.78 m 640 L 640 R Auger upgrading, working width 4.42 m 640 L 320 R 320 L 640 R E 10 12...

  • Page 217: Auger Upgrading, Working Width 5.06 M

    Auger upgrading, working width 5.06 m 320 L 960 L 960 R 320 R Auger upgrading, working width 5.70 m 640 L 960 L 960 R 640 R E 10 13...

  • Page 218: Auger Upgrading, Working Width 6.34 M

    Auger upgrading, working width 6.34 m E 10 14...

  • Page 219: Auger Upgrading, Working Width 6.98 M

    Auger upgrading, working width 6.98 m E 10 15...

  • Page 220: Auger Upgrading, Working Width 7.62 M

    Auger upgrading, working width 7.62 m E 10 16...

  • Page 221: Auger Upgrading, Working Width 8.26 M

    Auger upgrading, working width 8.26 m E 10 17...

  • Page 222: Auger Upgrading, Working Width 8.90 M

    Auger upgrading, working width 8.90 m E 10 18...

  • Page 223: Mounting The Auger Brace

    Mounting the auger brace E 10 19...
  • Page 224 Before mounting the auger brace, the required auger height should already have been set on the basic auger! Note the section "Height adjustment for large operating widths / with brace"! - Mount the left/right guide plates (1) on the vehicle frame shackles with the relevant assembly parts (2).

  • Page 225: Aligning The Auger

    Aligning the auger - Loosen lock nuts (26). Note the left-hand thread (L) and right-hand thread (R) mark on the brace! - Extend or shorten the braces (17) by rotating both adjustment rods (21) until all mounted material shafts align with the auger. The adjustment rod (21) is equipped with a bore (27) on the left and right.

  • Page 226: Material Shaft, Hinged

    Material shaft, hinged To close the gap between auger box and side board of the screen, hinged material shafts can be fitted to both sides of the auger. The hinged material shafts swivel up due to the material pressure which is exerted and swivel in due to screed retraction.

  • Page 227: Hopper Scraper

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

  • Page 228: Offsetting The Screed

    Offsetting the screed Depending on the paving condition re- quirements, the crossbeam can be moved backwards or forwards. This adjustment enlarges the material space between the auger and screed. - Loosen the four mounting screws (1). - Remove the screws and move the ve- hicle forwards.

  • Page 229: Levelling

    Levelling Slope controller During operation, no work may be car- ried out on the slope control linkage or the slope controller! - Mount the slope control linkage (1) in the intended position between the two crossbeams. - Mount the slope controller (2) on the slope control linkage's retaining plate (3).

  • Page 230: Mounting The Sensor Arm

    Mounting the sensor arm - Position the sensor arm mounting (1) on the corresponding journal of the screed side board. - Tighten the pin (2) so that the sensor arm is just still able to swivel. The sensor arm can be secured on the side board with the lock (3).

  • Page 231: Setting Up The Sensor Arm

    Setting up the sensor arm Before starting paving, the sensor arm must be set, with the grade control sys- tem, to its reference (cable, kerb, etc.). Sensing should be carried out in the area of the auger. - Swivel the sensor arm (2) over the ref- erence.

  • Page 232: Big Ski 9 M, Big Ski 13 M

    Big ski 9 m, big ski 13 m MBS6.bmp The big ski is used for contactless sensing over a particularly large reference length. A total max. ski length of approx. 9.30 m can be achieved with the combination of 1 centre element and 2 module elements together with the sensor arm extensions. A total max.
  • Page 233 Assembly of the short version is described in the following, as the longer variant is achieved simply by adding further module elements. MBS11.bmp The distances between the sensors are ideally identical (X1 = X2). The centre sensor is mounted in the usual individual sensor position so that, if nec- essary, work can be carried out with just one sensor by switching over on the MOBA- matic (e.g.

  • Page 234: Mounting The Big Ski Bracket On The Crossbeam

    Mounting the big ski bracket on the crossbeam The entire big ski construction is mount- ed laterally on the crossbeams. To do so, the two crossbeam brackets must first be mounted. The crossbeam brack- et design differs slightly depending on the paver finisher which is used.

  • Page 235: Mounting The Swivel Arms

    Mounting the swivel arms - Slide a fixing ring (1) over the tube of the big ski bracket (2). The fixing ring's 45° chamfer must point upwards. - Then slide the two swivel arms (3) onto the tube of the big ski bracket. The rear swivel arm is positioned, rotat- ed by 180°, on the big ski bracket.

  • Page 236: Mounting The Centre Element

    Mounting the centre element MBS6b.bmp During assembly, it must be ensured that the round lug (1) for attaching the subse- quent modules points upwards. The centre element (2) is already fitted in the factory with 2 pre-assembled sliding parts (3) / (4), which are pushed over the two round mounting journals of the swivel arms.

  • Page 237: Extending The Big Ski

    Extending the big ski The big ski can be extended to both the 9 m and 13 m versions. Structure of the 9 m version: Extension part at the front/rear each. Structure of the 13 m version: Two extension parts at the front/rear each.

  • Page 238: Mounting The Sensor Bracket

    Mounting the sensor bracket A sensing system with 3 sensors is pro- vided over the entire length of the big ski. One sensor each on the centre element, and the front and rear end elements. The centre sensor should be mounted on the ski in precisely the location in which it would be found during normal operation (approx.

  • Page 239: Mounting And Aligning The Sensors

    Mounting and aligning the sensors - Insert the sensor mounting (1) into the bracket (2). - Align the sensor and secure with the relevant star handle bolts. - The sensing height can be adjusted by loosening the star handle bolts (3). At the two outer sensor brackets, the sensor can also be mounted on the swiv- elling sensor extension arm (4).

  • Page 240: Mounting The Distributor Box

    Mounting the distributor box The distributor box should be mounted in such a way that simple wiring to the controller and the sensors is possible. The connections for the sensors should always point down to prevent water from entering the distributor box. Inlets which are not required must be sealed with dust caps.

  • Page 241: Connection Diagram

    Connection diagram The three sensors are connected to the distributor box and the distributor to the machine according to the following scheme. - Sensors - Front (1) - Centre (2) - Rear (3) - Distributor box (4) - Machine interface (5) E 10 37...

  • Page 242: Automatic Steering Unit

    Automatic steering unit E 10 38...

  • Page 243: Mounting The Automatic Steering Unit On The Paver Finisher

    Mounting the automatic steering unit on the paver finisher During operation, no work may be carried out on the automatic steering unit! Depending on the desired sensing side on the vehicle, the sensor rod tube may have to be removed and re-inserted on the other side of the vehicle! - Pull the sensor rod tube (1) at the front of the vehicle out to the desired length and secure with the clamping bolts (2).

  • Page 244: Mounting And Aligning The Sensor

    Mounting and aligning the sensor - Insert the sensor mounting (13) into the bracket (14) and secure with a wing nut (15). - Align the angle between the sensor and reference and secure with the relevant clamping bolt (16). The sensor and reference must be at right angles to each other! - The sensing height can be set by loosening the fixing screw (17).
  • Page 245 Automatic steering unit operating in- structions - When the automatic steering unit is activated, the steering potentiometer is deactivated. Steering is carried out automatically via ski cable sensing. - Activate the function on the operating panel as necessary. - The automatic steering unit can be overridden by actuating the steering potentiometer.

  • Page 246: Emergency Stop During Feeder

    Emergency stop during feeder operation If the function is not in use, the bridge connector must be fitted to the corres- ponding socket, as otherwise the travel drive is blocked! E 10 42...

  • Page 247: Limit Switch

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

  • Page 248: Auger Limit Switches (Left And Right)

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

  • Page 249: Screed

    Screed The Operating instructions for the screed cover all work required for mounting, setting up and extending the screed. Electrical connections Establish the following connections on the rear of the remote control brackets (1) when the mechanical assemblies have been mounted and set up: PLC version: - Auger limit switches (2) - Remote control (3)

  • Page 250: Machine Operation Without Remote Control / Side Board

    10.1 Machine operation without remote control / side board The machine can only be driven without connected remote control corresponding bridge connectors have been fitted on both sides of the machine. Side board with mounted remote bracket: - Fit bridge connector (1) in the socket of the remote control and secure with cap.

  • Page 251: F10 Maintenance

    F 10 Maintenance Notes regarding safety Maintenance work: Maintenance work may only be carried out when the engine is at a standstill. Secure the paver finisher and the attachments against inadvertent starting before be- ginning any maintenance work: - Set the drive lever to the centre position and the speed preselector to zero. - Pull out the ignition key and the battery main switch.
  • Page 252 F 10 2...

  • Page 253: F20 Maintenance Review

    F 20 Maintenance review Maintenance review 90 100 F 20 1...
  • Page 254 Maintenance required after the following service hours Assembly Chapter Conveyor q q q q Auger q q q q Engine q q q Hydraulics q q q q q q Drive units Electronics Lubrication points Checking/stopping F100 Maintenance required In this overview, you will find the maintenance intervals for optional machine equip- ment! F 20 2...

  • Page 255: F30 Maintenance - Conveyor

    F 30 Maintenance - conveyor Maintenance - conveyor F 30 1...

  • Page 256: 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 257: Points Of Maintenance

    Points of maintenance Chain tension, conveyor (1) Check chain tension: When the conveyor chain is correctly tensioned, the lower edge of the chain is approx. 20-25mm over the lower edge of the chassis. The conveyor chains should not be too tight or too slack.

  • Page 258: Conveyor Deflectors

    Check / replace chain: At the latest, the conveyor chains (A) must be replaced when their elongation has progressed so far that they can no longer be re-tensioned. Chain links must not be removed to shorten the chain! Incorrectly dividing the chains would lead to the destruction of the drive wheels! If components have to be replaced as a...
  • Page 259 Conveyor drive - drive chains (2) To check the chain tension: - If the tension has been set properly, the chain must be able to move freely approx. 10 - 15 mm. To re-tension the chains - Unfasten mounting screws (A) and lock nut (B) slightly.
  • Page 260 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 261: F40 Maintenance - Auger Assembly

    F 40 Maintenance - auger assembly Maintenance - auger assembly F 40 1...
  • Page 262 Maintenance intervals Interval Maintenance point Note Outer auger bearing - Lubricate Auger planetary gear - Check oil level Auger planetary gear - Top up oil Auger planetary gear - Change oil Auger drive chains - Check tension Auger drive chains - Adjust tension Auger box - Check oil level...
  • Page 263 Interval Maintenance point Note Gearbox bolts - Check tightening Gearbox bolts - Tighten to correct torque Outer bearing bolts - Check tightening Outer bearing bolts - Tighten to correct torque Auger blade - Check wear Auger blade - Replace auger blade Maintenance Maintenance during the running-in period...

  • Page 264: Points Of Maintenance

    Points of maintenance Outer auger bearing (1) The grease nipples are located on each side at the top of the outer auger bear- ings. These nipples must be lubricated at the end of work to force out any bitumen res- idues which may have entered and to supply the bearings with fresh grease when warm.

  • Page 265: Auger Planetary Gear (2)

    Auger planetary gear (2) - For oil level check unscrew and re- move the inspection bolt (A). When oil level is correct, the oil comes up to the lower edge of the inspection bore or a small amount of oil escapes through the aperture.

  • Page 266: Drive Chains Of The

    Drive chains of the augers (3) To check the chain tension: - Manually turn both augers to the right and left. In this case, movement clearance (C) at the augers' outer circumference should be 13-15 mm. Risk of injury due to sharp-edged parts! To re-tension the chains - Release the mounting screws (A).

  • Page 267: Auger Box (4)

    Auger box (4) Check oil level In case of correct oil level, the oil is between the two notches of the dipstick (A). For filling in the oil: - Unscrew screws (B) from the top cov- er of the auger box. - Take off the cover (C).

  • Page 268: Seals And Sealing Rings (5)

    Seals and sealing rings (5) After reaching operating temperature, check the gearbox for leaks. In case of visible leaks, e.g. between the flange surfaces (A) of the gearbox, re- placement of the seals and sealing rings is necessary. F 40 8...

  • Page 269: Gearbox Bolts

    Gearbox bolts Check tightening (6) Following the running-in period, the tightening torques of the outer gearbox bolts must be checked. - Tighten to the following torques if nec- essary: - (A): 86 Nm - (B): 83 Nm - (C): 49 Nm - (D): 49 Nm - (E): 86 Nm Check that each bolt has attained the full...

  • Page 270: Auger Blade (8)

    Auger blade (8) If the surface of the auger blade (A) be- comes sharp-edged, the diameter of the auger is reduced and the blades (B) have to be replaced. - Remove the bolts (C), washers (D), nuts (E) and auger blade (B). Risk of injury due to sharp-edged parts! Auger blades must be installed play- free;...

  • Page 271: F50 Maintenance - Engine Assembly

    F 50 Maintenance - engine assembly Maintenance - engine assembly In addition to these maintenance instructions, the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances. All mainte- nance work and service intervals itemised here are binding in nature. F 50 1...

  • Page 272: 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 273 Interval Maintenance point Note - Engine air filter Check air filter - Engine air filter Dust collector Emptying - Engine air filter Air filter cartridge Replace - Engine cooling system Check radiator fins - Engine cooling system Clean radiator fins - Engine cooling system Check level of the coolant - Engine cooling system...
  • Page 274 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 4...

  • Page 275: 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 276: Engine Lube Oil System (2)

    Engine lube oil system (2) Check oil level In case of correct oil level, the oil is between the two notches of the dipstick (A). Only check the oil level when the finisher is in a horizontal position! Too much oil in engine damages gas- kets;...
  • Page 277 - Position a collecting container be- neath the oil pan oil drain screw (E). - Remove the oil drain screw (E) and al- low the oil to drain completely. - Reinstall the oil drain screw (E) with a new seal and tighten properly. - Fill in the specified quality of oil through the filler opening (B) on the engine until the oil level rises to the...

  • Page 278: Engine Fuel System (3)

    Engine fuel system (3) All filters are accessed via the service flap (A) on the vehicle's centre wall: - Remove the screws (B) from the inner side of the frame and remove the serv- ice flap (A). - After completing the maintenance work, reinstall the service flap (A) properly.
  • Page 279 Changing the prefilter: - Drain off separated water at the cock (E) and collect, then close the cock again. - Pull off the water sensor (F) connector. - Loosen the filter cartridge (C) using a filter wrench or filter strap and unscrew. - Clean sealing surface of filter bracket.

  • Page 280: Engine Air Filter (4)

    Engine air filter (4) Empty dust collector - Empty the dust removal valve (A) on the air filter housing by compressing the discharge slot. - Remove any baked on dust by press- ing together the upper valve section. Clean the dust removal valve from time to time.
  • Page 281 Replace air filter insert Maintenance of the filter becomes nec- essary if: - Engine electronics service indicator - Open the air filter housing (B) at the clips (C). - Move filter element (D) to the side a lit- tle and then pull it out of the housing. - Pull out the safety element (E) and check for signs of damage.

  • Page 282: 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 it is opened, there is danger of scalding! - If necessary fill in a sufficient amount of coolant through the open port (A) of...
  • Page 283 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 13...

  • Page 284: Engine Drive Belt (6)

    Engine drive belt (6) Check drive belts - Check the drive belt for damage. Small transverse cracks in the belt are acceptable. In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces, belt re- placement is necessary. Observe engine's operating instructions Replace drive belt Observe engine's operating instructions...

  • Page 285: F60 Maintenance - Hydraulic System

    F 60 Maintenance - hydraulic system Maintenance - hydraulic system F 60 1...
  • Page 286 Maintenance intervals Interval Maintenance point Note - Hydraulic oil tank - Check fill level - Hydraulic oil tank - Top up with oil - Hydraulic oil tank - Change oil and clean - Hydraulic oil tank - Check maintenance indicator - Hydraulic oil tank - Intake / return hydraulic filter;...
  • Page 287 Interval Maintenance point Note - Hydraulic hoses - Visual inspection - Hydraulic system Leak test - Hydraulic system Retighten screw connections - Hydraulic hoses - Replace hoses - Auxiliary flow filter- Replace filter element Maintenance Maintenance during the running-in period F 60 3...

  • Page 288: Points Of Maintenance

    Points of maintenance Hydraulic oil tank (1) - Check oil level on sight glass (A). The oil level must be up to the centre of the sight glass when the cylinders are re- tracted. If all the cylinders are extended, the level can fall below the sight glass.
  • Page 289 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. The oil should be changed when at oper- ating temperature.

  • Page 290: Suction/Return Flow Hydraulic Filter (2)

    Suction/return flow hydraulic filter (2) Carry out filter replacement according to the interval or the indicator lamp in the operating panel! - Remove cover mounting screws (A) and lift off cover. - Disassemble the removed unit into: - Cover (B) - Separating plate (C) - Filter (D) - Dirt trap (E)

  • Page 291: Bleeding The Filter

    Bleeding the filter - Fill the opened filter housing with hy- draulic oil up to approx. 2 cm below the top edge. - If the oil level drops, replenish oil again. Slow oil level reduction of approx. 1 cm / min.

  • Page 292: 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 3 high-pressure filters. - Unscrew filter housing (B). - Remove the filter cartridge. - Clean the filter housing. - Insert the new filter cartridge. - Replace the seal ring of the filter hous- ing.

  • Page 293: Pump Distribution Gear (4)

    Pump distribution gear (4) - Oil level check on dipstick (A). The oil level must lie between the upper and lower marks. For filling in the oil: - Pull out the dipstick (A) completely. - Add new oil through the dipstick open- ing (B).

  • Page 294: Bleeder

    Bleeder The bleeder (A) can be found on the rear of the pump distribution gear housing. - The functioning of the bleeder must be ensured. If soiling has occurred, the bleeder should be cleaned. F 60 10...

  • Page 295: Hydraulic Hoses (5)

    Hydraulic hoses (5) - Specifically check the condition of the hydraulic hoses. - Immediately replace any damaged hoses. Replace hydraulic hoses if the following criteria are found on inspection: - damage of the outer layer to the inlay (e.g. chafing, cuts, cracks). - brittleness of the outer layer (cracking of the hose material).
  • Page 296 Always comply with the following instructions when installing and removing hydraulic hoses: - Always only use original Dynapac hydraulic hoses! - Always observe high standards of cleanliness! - Hydraulic hoses must always be fitted to ensure that in all operating statuses, - there is no tensile load apart from dead weight.
  • Page 297 Marking hydraulic hoses / storage pe- riod, period of use A number stamped onto the threaded connection provides information about the date of manufacture (A) (month / year)and the maximum pressure permit- ted for this hose (B). Never install hoses on top of one anoth- er and always ensure that they are at the correct pressure.

  • Page 298: 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 neces- sary! Replacing filter element: - Release the threaded cover connection (A) then open the non-return valve briefly to lower the oil level in the filter, then close the non-return valve again.

  • Page 299: F70 Maintenance - Drive Units

    F 70 Maintenance – drive units Maintenance – drive units F 70 1...

  • Page 300: Maintenance Intervals

    Maintenance intervals Interval Maintenance point Note - Chain tension - Check - Chain tension - Adjust - Chains - Relieve - Bottom plates - Check wear - Bottom plates - Replace - Rollers - Check for leaks - Rollers - Check wear - Rollers - Replace...

  • Page 301: Planetary Gear (4)

    Interval Maintenance point Note - Planetary gear - Check oil level - Planetary gear - Top up oil - Planetary gear - Change oil - Planetary gear - Check oil quality - Planetary gear - Screw connections Check - Planetary gear - Screw connections Tighten Maintenance...
  • Page 302 Any work on the pretensioned spring element must only be carried out by trained, specialist personnel! The spring elements must only be removed by a specialist workshop! The following applies to all spring elements in the event of a necessary repair: replace the complete unit only! Repairing the spring elements involves significant safety measures and should only be carried out by a specialist workshop!
  • Page 303 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 304 - Drive the vehicle forwards slightly, to relieve strain on the upper track section. - Remove the cover (D). - Screw head section for flat nipple (toolbox) onto the grease gun. - Refill the chain tensioner with grease at the filler connection (A), then remove the grease gun.
  • Page 305 Relieving the chain: The grease in the tensioning element is under pressure. Carefully and slowly un- screw the filling valve, but not too far. - Remove the cover (D). - Unscrew the lubricating nipple (A) on the grease tensioner using a tool until the grease is able to emerge from the nipple's lateral hole.
  • Page 306 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 307 Rollers (3) Rollers with damaged surfaces or which are leaking should be replaced immedi- ately! - Relieving the caterpillar chain: - Raise the track chassis using suitable lifting equipment and remove adhering dirt. Observe the safety measures when rais- ing and securing loads! - Remove the defective roller.
  • Page 308 Planetary gear (4) - Turn the conveyor chain sprocket so that the drain plug (B) is located at the bottom. - For oil level check unscrew and re- move the inspection bolt (A). When oil level is correct, the oil comes up to the lower edge of the inspection bore or a small amount of oil escapes through the aperture.
  • Page 309 Alternatively, the oil level can be checked and the oil changed at the rear of the gear- box: - Remove protective cover (A) - The following are located at the rear of the gearbox: - Oil inlet (B) - Oil level check (C) - Oil drain (D) Carry out the oil level check and oil change as per the description above.
  • Page 310 Screw connections After approx. 250 hours of operation at full load, check that all gearbox mount- ing screws are firmly seated. Improperly tightened screws may lead to increased wear and to the destruction of components! - The correct tightening torque for the connecting screws for the gearbox - chain sprocket (A) is: 295 Nm...

  • Page 311: F80 Maintenance - Electrical System

    F 80 Maintenance - electrical system Maintenance - electrical system F 80 1...

  • Page 312: Maintenance Intervals

    Maintenance intervals Interval Maintenance point Note Filling level of battery electrolyte - check q Top up with distilled water Apply grease to battery terminals q Electrical fuses Maintenance Maintenance during the running-in period F 80 2...

  • Page 313: 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 oxide and protected with a special termi- nal grease.

  • Page 314: Electrical Fuses / Relays (2)

    Electrical fuses / relays (2) Main fuses Fuses in terminal box Relays in terminal box Main fuses (A) F1.1 Main fuse F1.2 Main fuse F 80 4...
  • Page 315 Fuses in terminal box (B) F 80 5...
  • Page 316 Screed Screed Levelling Engine start / emergency stop Tamper (o) / vibration Screed on / off not used Indicator lamps Emulsion spraying system (o) Travel drive sensors not used Conveyor sensors 12V sockets (o) Levelling not used 24V sockets Indicator displays Auger not used Rotary beacon (o)
  • Page 317 Relays in terminal box (C) F 80 7...
  • Page 318 Ignition Travel drive computer voltage supply not used Engine start Travel drive computer outputs Ignition Front working lights Rear working lights Horn Start inhibit, emergency stop Start inhibit Rotary beacon (o) not used not used not used Reverse buzzer (o) not used not used not used...

  • Page 319: Relays In Operating Panel (D)

    Relays in operating panel (D) Floating position Screed start (auto) Screed hazard warning flashers, left-hand Screed hazard warning flashers, right-hand Lock screed extend / retract l.h. Lock screed extend / retract r.h. F 80 9...

  • Page 320: Relays In The Engine Compartment (E)

    Relays in the engine compartment (E) Engine start F 80 10...

  • Page 321: F90 Maintenance - Lubricating Points

    F 90 Maintenance - lubricating points Maintenance - lubricating points The information on the lubricating points for the various assemblies is assigned to the specific maintenance descriptions and must be read there! F 90 1...
  • Page 322 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 323: 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 the safety valve in- stalled! Handverl.jpg/Gefahr.jpg Do not undertake any work on the pres- sure relief valve during operation! Risk of injury due to escaping lubricant, as the system operates at high pressures! Ensure that the diesel engine cannot be started when working on the system!

  • Page 324: Central Lubrication System (1)

    Central lubrication system Check filling level The lubricant tank should always be filled sufficiently to ensure that the sys- tem does not "run dry", that adequate lu- bricating point supply is ensured and that time-consuming bleeding does not become necessary. - Always maintain a fill level above the "MIN"...
  • Page 325 Bleed central lubrication system Bleeding the lubrication system is nec- essary if the central lubrication system has been operated with an empty lubri- cant tank. - Release the main lubrication line (a) at the distributor (b). - Start up the central lubrication sys- tem with the filled lubricant tank (c).
  • Page 326 Check the flow of lubricant at the con- sumers Each lubrication channel at the consum- ers must be checked as regards clear- ance. - Remove the lubrication line (a) and install a normal lubricating nipple (b). - Connect the grease gun (c) en- closed on delivery to the lubricating nipple (b).

  • Page 327: Bearing Points (2)

    Bearing points (2) One lubricating nipple (A) is located at each hydraulic cylinder bearing point (top and bottom). One lubricating nipple (B) is located at each push roller bearing point. F 90 7...
  • Page 328 F 90 8...

  • Page 329: F100 Tests, Stopping

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

  • Page 330: Maintenance Intervals

    Maintenance intervals Interval Maintenance point Note - General visual inspection q - Inspection by an expert q - Cleaning q - Preserving the paver finisher Maintenance Maintenance during the running-in period F 100 2...

  • Page 331: General Visual Inspection

    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? Immediately take actions to correct any detected malfunction to avoid damages, dan- gers or environmental hazards!

  • Page 332: 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 333: 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 334: 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 335: Lubricants And Operating Substances

    F 110 Lubricants and operating substances Lubricants and operating substances Use only the lubricants listed below or comparable qualities of well-known brands. Only use containers which are clean on inside and outside for filling oil or fuel. Note capacities (see section "Capacities"). Incorrect oil or lubricant levels promote rapid wear and paver finisher failure.
  • Page 336 F 110 2...

  • Page 337: Capacities

    Capacities Substance Volume Diesel engine Engine oil litres (with oil filter change) Engine cooling system Cooling liquid 20.0 litres Fuel tank Diesel fuel litres Hydraulic oil reservoir Hydraulic oil litres Pump distribution gear Gearbox oil litres Planetary gear Gearbox oil litres drive unit Planetary gear...

  • Page 338: Lubricant Specifications

    Lubricant specifications Engine Atlas Copco Aral Esso / Exxon Fuchs Mobil Shell Engine Oil -Rimula R6LM 10W-40 (*) = recommended Cooling system Atlas Copco AGIP Chevron Caltex Delo Mobil Shell Coolant -Antifreeze Extended Extended Extended Spezial Life Coolant Life Coolant...

  • Page 339: Drive Unit Planetary Gear

    Drive unit planetary gear Atlas Copco Aral Esso / Exxon Fuchs Mobil Shell Traction -Omala Gear 100 Oil F 220 (*) = recommended Auger drive planetary gear Atlas Copco Aral Esso / Exxon Fuchs Mobil Shell Traction -Omala Gear 100...
  • Page 340 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic liquids based on ester, HEES Manufacturer ISO viscosity class VG 46 Atlas Copco Hydraulic 120 (*) Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso Univis HEES 46 Total Total Biohydran SE 46...
  • Page 341 TRAINING/ INSTRUCTIONS We offer our customers training cours- es on DYNAPAC equipment in our ded- icated factory training centre. We hold regular training courses in this training centre as well as courses out- side the scheduled hours. SERVICE Please contact one of our responsible service outlets if you encounter any operational prob- lems or have enquiries about spare parts.
  • Page 342 Don't hesitate to contact your local dealer for: service, spare parts / wearing parts, additional documentation, accessories the complete Dynapac paver finisher range.

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