Page 1 OPERATION & MAINTENANCE Paver finisher F 121 C F 141 C Type 635 Keep this manual for future reference Order number for this manual: D900981342 01-0107 ......
Page 2 VALUE QUALITY THE ORIGINAL Your Authorized Dynapac Dealer:...
Page 3 Table of contents Preface ..................1 General safety instructions ................ 2 Acts, directives, accident prevention regulations ........2 Warning instructions .................. 2 Prohibitive signs ..................4 Protective gear ................... 5 Environmental protection ................6 Fire prevention ................... 6 Further instructions ..................7 Correct use and application ...........
Page 4 EN standards ................... 21 Continuous sound level F121C, Deutz TCD2013L04 ......21 Operating conditions during measurement ..........21 Measuring point configuration ..............21 Continuous sound level F141C, Deutz TCD2013L06 ......22 Operating conditions during measurement ..........22 Measuring point configuration ..............22 Vibration acting on the entire body ............
Page 5 D2.0 Operation ................. 1 Operation of the input and display terminal ..........1 Allocation of the keyboard of the display..........1 Working in the menu .................. 2 Menu structure of the setting and display options ......... 3 Main menu 00 ..................4 Display and function menu ..............
Page 6 D3.1 Operation ................. 1 Operating elements on the paver finisher ..........1 Batteries (71) ..................1 Battery main switch (72) ................ 1 Transport safeguards for the hopper (73) ..........2 Mechanical screed transport safeguard (to the left and the right beneath the driver’s seat) (74) ......3 Seat lock (behind the driver’s seat) (75) ..........
Page 7 D4.1 Operation ................. 1 Preparation of operation ................1 Required devices and aids ..............1 Before starting work (in the morning or when starting paving) ....1 Checklist for the machine operator ............2 Starting the paver finisher ................4 Before starting the paver finisher ............
Page 8 Set-up and modification ............1 Special notes on safety ................1 Auger ......................2 Height adjustment ..................2 Auger crossbeam installed in a fixed position ..........2 Mechanical adjustment with ratchet (optional) ........... 3 In case of hydraulic adjustment (option) ............ 3 Auger extension, auger type I ..............
Page 9 F5.1 Maintenance - Engine ............. 1 Maintenance - engine sub-unit ..............1 Maintenance intervals ................2 Points of maintenance ................4 Engine fuel tank (1) ................4 Engine lube-oil system (2) ..............5 Engine fuel system (3) ................7 Engine air filter (4) ................. 9 Coolant system of the engine (5) ............
Page 10 F8.1 Maintenance - Electronic System .......... 1 Maintenance - Electronic System .............. 1 Maintenance intervals ................2 Points of maintenance ................5 Batteries (1) ................... 5 Generator (2) ..................6 Adjustment of belt tightness ..............8 Replacement of belt ................9 Checking / adjusting belt tension: ............
Page 11 V Preface Safe operation of the machine requires specific knowledge that is imparted by the present operating instructions. The information is provided in a concise, clearly struc- tured form. The individual chapters are arranged in alphabetical order and every chapter starts with page 1. The individual pages are identified by the chapter letter and the page number.
Page 12 General safety instructions Acts, directives, accident prevention regulations The locally applicable acts, directives and accident prevention regulations shall be observed, even if the attention is not specifically directed to these. The operator himself shall be responsible for the observation and performance of the related regulations and actions! The following alerts, prohibitions and instructions refer to the risks to which people, machinery and environment are exposed.
Page 13 Attention: risk of hand injury! Attention: hot surfaces or hot liquids! Warning, risk of falling off! Attention: hazardous batteries! Attention: materials harmful to health and irritating substances! Attention: flammable materials! Attention: gas bottles!
Page 14 Prohibitive signs It is prohibited to open / step on / reach into / perform / adjust during operation or when the traction engine is running! Do not start the engine/drive! Maintenance and repair works can be carried out only with the Die- sel engine turned off! Do not sprinkle with water! Do not extinguish with water!
Page 15 Protective gear The applicable local regulations may define the use of different protective gear! Observe these specifications! Protect your eyes with googles! Wear appropriate head protection! Protect your hearing with appropriate ear mufflers! Protect your feet with safety footwear! Always wear tight, conforming working coveralls! Wear visibility vest for good visibility! In case of polluted air, wear respiratory mask!
Page 16 Environmental protection The locally applicable acts, directives and waste disposal regulations shall be ob- served, even if the attention is not specifically directed to these. During cleaning, maintenance and repair operation the materials polluting water e.g.: - lubricants (oils, grease) - hydraulic oil - gas oil - coolant...
Page 17 Further instructions Observe the manufacturer's and other instructions! e.g. the maintenance instructions of the engine manufacturer Description / figure in case of an electrically heated design! Description / figure in case of an electrically heated design!
Page 19 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 guide- lines are part of the present operating instructions and must always be heeded. Na- tional regulations are fully applicable.
Page 21 B Vehicle description Application The DYNAPAC F 121 C / F 141 C is a caterpillar paver finisher that is used for laying bituminous mixed material, roll-down or lean-mixed concrete, track-laying ballast and unbound mineral aggregates for foundations for paving.
Page 22 Description of assemblies and functions 635_ISO_DYN.bmp 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 Traction arm rail Paving thickness indicator Traction drive of the caterpillar drive Auger Screed...
Page 23 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 a high paving precision. The continuously adjustable hydrostatic traction drive allows the speed of the paver finisher to be matched to all work conditions.
Page 24 Traction drive: The continuously adjustable traction drive pumps are connected to the traction motors by means of high pressure hydraulic hoses. These oil motors drive the caterpillar chains via planetary gears that are mounted di- rectly inside the drive wheels of the caterpillar chains. Steering system/operator’s platform: The independent hydrostatic traction drives allow the finisher to be turned on the spot.
Page 25 Levelling system/slope control system: The slope control system (option) allows the traction point to be regulated at the left-hand or the right-hand side with a defined difference to the opposite side. To determine the actual value, the two traction arms are linked with a slope control rod.
Page 26 Danger zones In these areas of the machine there is a danger of pulling in or crushing due to the rotating, transporting or moving parts!
Page 27 Safety devices Safe operation is only possible when all operating and control elements are function- ing correctly and when all safety devices are in position. Check the function of these devices at regular intervals. (see chapter D, section 2.1). Emergency stop button - on the operating panel - on the two remote control units F0005_A1.EPS...
Page 28 Main switch (17) Mainswitch.tif/Mainswitch_SK.eps Hopper transport safeguards (18) Hopperlock2.tif/Hopperlock_SK.eps Screed transport safeguard (19) F0083_A1.TIF Latch for protective roof (20) F121Cb.Tif...
Page 29 635_side_Dyn.bmp/Feuerlöscher.bmp Item Designation 25 Fire fighting device 26 Engine hood 27 Lateral flaps 28 Walkway 29 Screed coverings 30 Hazard warning lights of the screed 31 Auger covers Accessories: - Wedges - Warning triangle - First-aid kit...
Page 30 Technical data, standard configuration Dimensions (all dimensions in mm) 1979 2900 6505* 1988 2550 3388 *VB510 T/TV 635_side_DYN.bmp,635_front_DYN.bmp For the technical data of the screed, see the operating instructions of the screed. B 10...
Page 31 Allowed angle of rise and slope max 15° max 15° max 15° 635_side_Dyn.bmp,635_front_Dyn.bmp Before operating your machine in an inclined position (gradient, slope, lateral inclina- tion) which is above the specified limit value, please, consult with the customer serv- ice for your machine! Allowed angle of driving up max 14°...
Page 32 Weights F 121 C (all weights in t) Paver finisher without screed about 16,3 Paver finisher with screed: - VB510 T/TV about 18,2 With extensions for max. working about 1,4 width additionally max. With filled hopper about 13,0 additionally max. For the weights of the screed and the screed attachments, see the operating instruc- tions for the screed.
Page 33 Performance data F 121 C VB 510 T/TV 2,55 2,00 5,10 8,10 VB 510 T/TV+ 2,55 2,00 5,10 VB 600 T/TV 3,00 2,45 6,00 8,20 VB 600 T/TV+ 3,00 2,45 6,00 SB 1250 T/TV 3,00 Travelling speed 0 - 4,5 km/h Working speed 0 - 23...
Page 34 Performance data F 141 C VB 510 T/TV 2,55 2,00 5,10 8,80 VB 510 T/TV+ 2,55 2,00 5,10 VB 600 T/TV 3,00 2,45 6,00 9,00 VB 600 T/TV+ 3,00 2,45 6,00 SB 1250 T/TV 3,00 9,00* Travelling speed 0 - 4,5 km/h Working speed 0 - 23...
Page 35 Traction drive/chassis Drive Hydrostatic drive, continuously controllable Two separately driven caterpillar drives with Caterpillar drive rubber grouser chains. Turning capacity Turning on the spot Speed See above Engine F 121 C Make/type Deutz TCD 2013 L04 2V Model 4-cylinder diesel engine (water-cooled) Performance 116 KW / 158 HP (at 2100 rpm) Volume of fuel tank...
Page 36 5.12 Material compartment (hopper) Volume about 6.0 m = about 13.0 t Minimum inlet height, center 520 mm Minimum inlet height, outside 595 mm 5.13 Material conveying Conveyors Left and right auger separately controllable Drive Hydrostatic, continuously controllable Conveying volume controller Fully automatic via configurable switching points 5.14 Material distribution...
Page 37 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 5.16 Electrical system...
Page 38 Location of instruction labels and identification plates B 18...
Page 39 Item Designation Label ”Filler neck for diesel fuel” * Label ”Filler neck for engine oil” * Label „Heed the operating instructions!“ Warning label ”Danger of squeezing!” ** Punched vehicle identification number Label ”Securing or fixing points for crane transportation”** Paver finisher identification label „CE + noise level“...
Page 40 Identification label for the paver finisher (6) Fertiger3.tif Item Designation Type of paver finisher Year of manufacture Serial number of the paver finisher series Max. permissible operating weight, incl. all attachments, in kg Max. permissible load on the front axle, in kg Max.
Page 41 EN standards Continuous sound level F121C, Deutz TCD2013L04 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 noise emission level of the finisher has been measured under free-field condi- tions according to prEN 500-6, dated March, 1997, and ISO 4872 at a normal engine speed of 2100 rpm.
Page 42 Continuous sound level F141C, Deutz TCD2013L06 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 noise emission level of the finisher has been measured under free-field condi- tions according to prEN 500-6, dated March, 1997, and ISO 4872 at a normal engine speed of 2100 rpm.
Page 43 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 prEN 1032-1995 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 according to prEN 1033-1995 are not exceeded.
Page 45 C 1.1 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 levelling device, auger limit switches, aprons, etc.).
Page 46 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 drive-on angle is included in Chapter „Technical Specifications“! Preparations - Prepare the paver finisher for transportation (see chapter D). - Remove all protruding or loose parts from the paver finisher and the screed (see also the operating instructions of the screed).
Page 47 Operation Switch Buttons - Disabling the interlocking of operation - Close the hopper halves. - Engage both hopper transport safe- guards. - Lift the screed. - Insert the transportation safeguards of the screed. - Turn the preselecting regulator to zero. - Move the drive lever forward.
Page 48 Driving onto the low-bed trailer Make sure that there are no persons in the danger area during loading. F0185_A1.TIF - Use the work gear and low engine speed to drive onto the low-bed trailer. - Lower the screed onto wooden blocks on the low-bed trailer. - Switch off the paver finisher.
Page 49 Secure the paver finisher in its position to the low-bed trailer: - Use only proper and permitted load fastening devices. - Use the four securing points provided (1, 2). Depending on the equipment of the machine there can be further support points (3) on the auger frame (3).
Page 50 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 protruding or loose parts from the paver finisher and the screed (see also the operating instructions of the screed).
Page 51 Operation Switch Buttons - Disabling the interlocking of operation - Close the hopper halves. - Engage both hopper transport safe- guards. - Lift the screed. - Insert the transportation safeguards of the screed. - Turn the preselecting regulator to zero. - Move the drive lever forward.
Page 52 Traction drive: Warning Marking Marking - Set the Fast/Slow switch to „Hare“. - Turn the preselecting regulator to maximum. - Use the drive lever to regulate the speed. Press the emergency stop button when a dangerous situation arises! C 1.1 8...
Page 53 Loading by crane Use only lifting gear that can bear the load. (See Chapter B for weights and dimensions). F0185_A1.TIF Four lifting eyes (1,2) are provided for loading the vehicle with a crane. - Park the paver finisher and render it safe. - Engage the transport safeguards.
Page 54 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 55 - Release lock nut (2), screw threaded dowel (3) into pump as far as possible and secure with lock nut. - Actuate lever (4) of hand pump until sufficient pressure has been built up and traction system brakes have been released.
Page 56 Following towing, unscrew the threaded dowel (3) a few turns again and lock with the lock nut (2). The high pressure cartridges (1) have to be fully screwed back in to make the ma- chine usable again. The brakes of the traction drive are now active again and the machine is secured against accidental rolling away.
Page 57 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 unauthorized 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 59 D 1.1 Operation Safety regulations Starting the engine, the traction drive, the conveyor, the auger, the screed or the lift- ing 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 60 Operating elements Operating panel Bedienpult_SPS_Kette_635_2.bmp,Element1_SPS_Kette_635.bmp,Element2_SPS_Kette_635.bmp,Element3_Kette_635.bmp D 1.1 2...
Page 61 General notes on the observation of CE regulations All functions of self-engaging buttons which might provoke a risk during start-up of the diesel engine (conveying function of auger and conveyor) are set to STOP in case of an emergency stop or a control restart. Changes of settings which are per- formed when the diesel engine is at a standstill („AUTO”...
Page 62 Element2_SPS_Kette_635.bmp D 1.1 4...
Page 63 Item Designation Brief description Positions: Ignition and light off Ignition on Parking/rear lights, instrument panel illumination, Ignition lock and il- working lights (if applicable) lumination switch Driving light High beam Not used In the case of an emergency (danger to persons, possible col- lision etc.), press in the button! - Pressing the emergency stop button switches off the en- gine, the drives and the steering system.
Page 64 Element2_SPS_Kette_635.bmp D 1.1 6...
Page 65 Item Designation Brief description For switching on the paver finisher functions and for continu- ously regulating the traction speed – forward or reverse. Zero position: starting is possible; engine at idling speed; no traction drive Drive lever Depending on the position of the drive lever, the following (forward - reverse) functions can be activated: Position 1: Conveyor and auger on.
Page 66 Element1_SPS_Kette_635.wmf D 1.1 8...
Page 67 Item Designation Brief description Push-button: Left: open left hopper half Right: open right hopper half Open hopper If both hoppers are hydraulically actuated at the same time (1 valve), either the left button or the right button can be used for operation.
Page 68 Element1_SPS_Kette_635.wmf D 1.1 10...
Page 69 Item Designation Brief description Self-engaging buttons with LED indication Hare: transport speed Traction drive Tortoise: operating speed for paving fast/slow When restarting, the buttons are set to working speed (tortoise). Self-engaging buttons with LED indication When restarting, the button is set to „Straight-ahead travel”.
Page 70 Element1_SPSC.cdr D 1.1 12...
Page 71 Item Designation Brief description Not used Vibration Operation and application: see button (20). Self-engaging buttons with LED indication Toggling between two switching conditions. Stop: Operational readiness Auger left/right Auto Reset to STOP in case of an emergency stop or a restart. Button 16 locks the conveying function.
Page 72 Element1_SPSC.cdr D 1.1 14...
Page 73 Item Designation Brief description Self-engaging button with LED indication Switched off by pressing the button again or by pressing but- ton 25 or 31. 1. „MANUAL” auger operation Requirements: button 24 must be set to „AUTO” „MANUAL” auger - Using the buttons in the pad (left) for the directions of move- operation and lift- ment (29), the conveying speed of the automatic function ing/lowering the...
Page 74 Element1_SPSC.cdr D 1.1 16...
Page 75 Item Designation Brief description Push-button function Lift screed If the drive lever is in its central position, the speed of the engine rises automatically when moving. Self-engaging button with LED indication Lower screed/screed in floating position The button 16 must be set to „OFF” Screed floating position: Pressing the button turns the LED ON and prepares the screed for „floating position”, which is activated by the actuated drive lever (9).
Page 76 Element3_SPS_Kette_635.wmf/Leuchtmodul_SPS_Kette_635.bmp D 1.1 18...
Page 77 Item Designation Brief description To query, set and save various operating status and functions Control setting and as well as for displaying messages related to machine and en- display terminal gine. Normal display up to 120 °C = 248 °F. Hydraulic oil ther- In case of higher temperature stop the machine, (set mometer...
Page 78 Element3_SPS_Kette_635.wmf/Leuchtmodul_SPS_Kette_635.bmp D 1.1 20...
Page 79 Item Designation Brief description This light is on, if the water separator of the fuel system has established a too high water level. In order to avoid the damage of the traction engine drain the separated water immediately according to the Alarm light (red) operation manual.
Page 80 Element3_SPS_Kette_635.wmf/Leuchtmodul_SPS_Kette_635.bmp D 1.1 22...
Page 81 Item Designation Brief description It is on, when the oil pressure is too low. Stop the engine again. See the further possible faults in the operating in- Oil pressure indica- tor for the Diesel en- structions for the engine gine (red) The fault is indicated together with the „Error mes- sage“...
Page 82 Remote control Warning! Do not isolate while operating by remote control provided with emergency stopping button (0). This will lead to stopping the machine! D 1.1 24...
Page 83 Item Designation Brief description Its function and use are similar to those of the emergency Emergency stop button (7) on the control panel. button (o) It is important in such dangerous situations, which cannot be overseen by the driver. Horn Its function is similar to the button (30) on the control panel.
Page 84 Warning! Do not isolate while operating by remote control provided with emergency stopping button (0). This will lead to stopping the machine! D 1.1 26...
Page 85 Item Designation Brief description Auger Its function is similar to the button (24) on the control panel. Conveying direction For the adjustment of the transport direction of the auger of the auger. - switch (61) must be set to „auto“. Transport capacity Plus / minus buttons for the modification of transport capaci- of the auger and...
Page 86 Bottom part Remote_SPS_neu2.bmp Item Designation Brief description Connection to the levelling automatic Connect the cable for the grade control unit here. system Connection to the end position switch of Connect the cable for the material limit switch here. the auger Cable for the remote Connect to the socket on the screed.
Page 87 D 2.0 Operation Operation of the input and display terminal TDM.cdr Allocation of the keyboard of the display. - (A) Encoder (Rotation and pressure): - For paging in the menu - For selecting various points within one menu - For the modification of parameters - For confirming the modified parameters - Buttons (B), (C), (D) F1 - F3: - To select the functions displayed on the screen...
Page 88 Working in the menu TDM.cdr Example: Emergency program (401) - Rotate (A) Encoder until the selection surface (1) appears. - Rotate Encoder (A) until the selection surface gets on the menu point required. - Press (A) Encoder or (B) F2 button to modify the selected menu point. - Adjust the required value by rotating Encoder (A).
Page 89 Menu structure of the setting and display options The following figure shows the menu structure and operation and it serves the simpli- fication of the procedures in case of various settings and displays. D 2.0 3...
Page 90 Main menu 00 Display and function menu - Speed - processing mode - Speed - Travel (2) - Engine speed (3) - Road length meter (4) - Fuel consumption (5) - Adjustment possibility „Stopping the screed with Terminal_SPS_Kette_635.wmf/Bild_000.bmp pretensioning“ (6) - 0=The function is inactive - 1=The function is active When the drive lever is in neutral position, the screed retains its position with the...
Page 91 Menu 01 - Engine speed Adjustment menu of engine speed (1) - Open the submenu: F3). - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_000.bmp Submenu 101 - Setting the engine speed - Saving, back to the main menu: (F3) - Resetting changes, back to the main menu: (F1) Setting is performed in steps of 50, the speed of the en-...
Page 92 Menu 02 - Measuring value of drive engine Menu to query the various measuring values of the drive engine. - Open the submenu: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_000.bmp Submenu 103 - Display of measuring value Drive en- gine Display following...
Page 93 Menu 03 - Trip meter and fuel gauge Menu to query the various op- erating data - Open the submenu: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_003.bmp Submenu 301 - Road sec- tion, fuel consumption dis- play/reset Display of the following serv- ice data: - Fuel consumed (calculated value) (1)
Page 94 Menu 04 - Emergency func- tion / stopping the screed and turning on the tamper In case of the loss of the specified target value or of the measuring of the actual value (e.g. faulty sensor, transducer), the capacity of the various functions can be set for the automatic opera- tion.
Page 95 Menu 05 - Layer thickness Menu for setting the type of layer to be processed - Open the submenu: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_005.bmp Submenu 501 - Preselec- tion of layer thickness The following types of layers can be selected: - Top layer: 3 parameters - Binder course 2 parame-...
Page 96 Submenu 502 - Setting the speed of auger The speed can be set in 8 stages. The actual speed se- lected for the applicable feed- er auger is shown on displays (1) and (2). Basic settings applicable to the specific layer types: - Top layer: 4 - Binder course 6 Terminal_SPS_Kette_635.wmf/Bild_502.bmp...
Page 97 Menu 06 - Screed charging Menu to set the starting load - Open the submenu: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_006.bmp Submenu 102 - Starting load setting Setting the duration of start- ing load - Saving, back to submenu 06: (F3) - Resetting changes, back to menu 06: (F1)
Page 98 Menu 07 - Screed type Menu for adjusting the screed type - Open the submenu: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_007.bmp Submenu 701 - Setting the screed type The following screed types can be set: - VB/EB-screed type: 0 pa- rameter - SB-screed: 1 parameter - Saving, back to submenu...
Page 99 Menu 08 - Service hour me- Menu to query the service hours - Back to the main menu: (F1) or (F3) Terminal_SPS_Kette_635.wmf/Bild_008.bmp D 2.0 13...
Page 100 Menu 09 - Service Password protected menu to perform the various service settings - Password prompt opening: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_009.bmp Submenu 201 - Password prompt Enter password: - The password can be con- firmed by pressing the En- coder - Back to menu 09: (F1) Terminal_SPS_Kette_635.wmf/Bild_201.bmp...
Page 101 Menu 10 - Error memory Menu for the repeated query of error messages - Display (0): There is no er- ror message - Display (1): Fault message can be displayed - Error message query: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_010.bmp Error message display:...
Page 102 Menu 11 - Error memory Computer of machine oper- ation Menu for the repeated query of error messages sent by the computer of machine op- eration - Display (0): There is no er- ror message - Display (1): Fault message can be displayed Terminal_SPS_Kette_635.wmf/Bild_011.bmp - Retrieval of error message:...
Page 103 Menu 12 - Program version Menu to query the version number of the installed pro- gram In case you use the help of Technical Support for your machine, always specify the version number of the pro- gram. - Back to the main menu: (F1) or (F3) Terminal_SPS_Kette_635.wmf/Bild_012.bmp D 2.0 17...
Page 104 Menu 13 - Terminal settings Menu for the various settings of the terminal - Open the submenu: (F3) - Back to the main menu: (F1) Terminal_SPS_Kette_635.wmf/Bild_013.bmp Submenu 104 - Terminal settings Setting of Contrast (1) brilliance of display (2) and the sensitivity of Encoder (3) - Saving, back to submenu 13: (F3)
Page 105 Further messages on the display Display No. / report Display message 646 Emergency stop button de- pressed - Back to the previous menu: (F3) message 647 Adjustment mode Displays: - Engine speed (1) - Trip covered (2) - Fuel consumed (calculated value) (3) - Back to the previous menu: (F3)
Page 106 Terminal error messages Each error message is assigned a number. If you use the help of the Technical Sup- port for your machine, please, provide this number and all information included in the error message. Fault No. / report Display 600.
Page 107 Fault No. / report Display 610. error message - „Drive lever forward“ locked Variable: - Drive / steering direction (1) 615. error message - Sensor of running gear faulty Variable: - LH-side sensor (1) - RH-side sensor (2) 617. error message - Broken line - drive lever pump control 619.
Page 108 Fault No. / report Display 621. error message - Setup fault of travel speed potentiometer in the service software. 622. error message - Drive lever potentiometer setup-fault in the service software. 623. error message - Short circuit / line fault - drive lever microswitch forward / reverse (parallel switch)
Page 109 Fault No. / report Display 626. error message - Warning signal of traction engine - SPN = part concerned - FMI = type of fault - OC = frequency of repetition see chapter „Fault codes of traction en- gine“. 628. error message - Communication interrupted Master drive engine 629.
Page 110 Fault No. / report Display 635. error message - Keyboard fault / Keyboard fuse faulty 636. error message - Remote control fault / Keyboard fuse faulty Variable: - LH-side remote control (1) - RH-side remote control (2) - Remote control fuse (3) 638.
Page 111 Fault No. / report Display 643. error message - Tamper target value potentiometer faulty 644. error message - Vibrator target value potentiometer faulty 645. error message - Communication interrupted Master display D 2.0 25...
Page 112 Instructions related to error messages 638. error message Communication interrupted Master drive automatic system. First check if the fuse F5.1 is good. If the cause of the interrupted data link is not the fuse, the Diesel engine can be started. - Switch on button (1) (LED comes on) - Press start button (2).
Page 113 Fault codes of the traction engine. If a fault occurs in the traction engine, this is indicated by the specific signal lamp (1) and simultaneously an explana- tion appears on the display. Leuchtmodul_SPS_Kette_635.bmp The error message displayed simultane- ously includes several error codes, the decoding of which clearly defines the fault.
Page 114 Example: Explanation: The flashing control lamp marks the serious failure of the traction engine and the en- gine will stop automatically or it has to be stopped. Display: SPN: FMI: Cause: Cable failure in the Rail pressure detector. Effect: The engine switches off. Frequency: The fault occures for the first time.
Page 115 Error messages D 2.0 29...
Page 116 D 2.0 30...
Page 117 D 2.0 31...
Page 118 D 2.0 32...
Page 119 D 2.0 33...
Page 120 FMI-codes D 2.0 34...
Page 121 Special functions Emergency operation program for the case of keyboard failure To ensure the pavers operating ability during a display failure, an emergency program will be started automatically. Following setting and functions will be max min adjusted and switched on: - Number of revolutions of the Diesel engine: 1800 min - Traction drive (1) slow (Tortoise)
Page 122 Accessory the following function can be switched by using the remote controls: - Press button (1) to close the hopper. - Press button (2) to open the hopper. - Lifting the screed: - Switch off the LED bar (3) of auger and conveyor completely by using the accompanying Minus-buttons (4).
Page 123 D 3.1 Operation Operating elements on the paver finisher Batteries (71) The batteries of the 24 V system are lo- cated under the left maintenance flap. For the specifications, refer to chapter B, ”Technical Data”. For servicing, see chapter F. Heed the instructions when starting the paver finisher externally.
Page 124 Transport safeguards for the hopper (73) Before parking or transporting the paver finisher, the hopper halves must be swung upwards and the transport safe- guards for the hopper must be inserted. Item: - (a) - outside on the two half-hoppers - (b) - in the feeding hopper (o) Do not enter the hopper while the engine is running! Danger of being caught by...
Page 125 Mechanical screed transport safe- guard (to the left and the right be- neath the driver’s seat) (74) Used to protect the lifted screed from in- advertent lowering. The screed transport safeguard must be inserted before trans- portation and when work is finished. Transportation with unsecured...
Page 126 Separator fluid spraying system (80) Used to spray the parts coming into con- tact with asphalt with a separator emul- sion. - The indicator lamp (A) lights up when the emulsion pump is running - On/off switch (B) for the emulsion pump - Quick-release coupling (C) for hose connection...
Page 127 Further switch options for optional equipment features may be located on the central panel: On / off switch for additional head- light in the roof (85): Actuate switch (a) to activate. On / off switch for fuel tank filler pump (85a) If the pump is actuated with the switch (a), the indicator lamp (b) lights up.
Page 128 On/Off switch of work headlights (85d): Actuate switch (a) to switch on. In the switch position „ON“ the control light (b) is on. On/Off switch of flasher (85e): Actuate switch (a) to switch on. In the switch position „ON“ the control light (b) is on. If the optionally available 230 V systems is installed, an additional switch cabinet is mounted on the paver finisher:...
Page 129 Hydraulic folding roof (87) (o) The hydraulically folding roof is secured by means of a latch (A) at the rear sus- pension on the left and right sides of the machine. This must be released prior to lowering and raising. Once it has reached its terminal position, the roof must be secured with the latch again.
Page 130 Electric setting of the transportation volume of the conveyor (o) (88) With this the transport volume of the conveyor can be adjusted when me- chanical limit switch or ultrasonic sensor is used. - The „0“ position of the scale corre- sponds to the smallest adjustable vol- ume.
Page 131 Conveyor limit switches (89) The mechanical conveyor limit switches (89) or the ultrasonic conveyor limit switches (89ao) control the material flow at the respective conveyor half. The conveyors should stop when the material has roughly reached the area below the auger tube. This requires that the auger height has been adjusted correctly (see chapter E).
Page 132 Ultrasonic auger limit switches (90) (left and right) The limit switches control the material flow at the respective auger half. The ultrasonic sensor is mounted by means of an appropriate leverage to the side plate. Loose clamping lever for ad- justment and modify angle / height of the sensor.
Page 133 Pressure control valve for screed charging/relieving (93) Used to adjust the pressure for addition- al charging/relieving of the screed. - See ”screed charging/relieving de- vice”. (Chapters „Operating Panel“, „Opera- tion“). - Pressure display: see pressure gauge (93b). Pressure control valve for screed stop with pretensioning (93a) This valve is located beneath the right- hand bottom flap of the operator´s plat-...
Page 134 Central lubrication unit (o) (100) The central lubrication unit turns on in automatic mode when the drive engine starts. - Pumping time: 12 min - Duration of the break: 2 h 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 135 Particle filter - control light (102) (o) The control light of the particle filter is found under the control track of the oper- ating panel. When observing the control light (a) it is essential: Partikellight.tif Indicator Operating condition Cause / action colour No counterpressure Check the yellow...
Page 136 Front and side window (o) (103) The front window can be folded up for the maintenance works performed at the tank. - Fold the front window by its handle (A) and lock it on the RH and LH sides with the two locks (B) in the upper po- sition.
Page 137 Adjustment of screed eccentric (o) (104) 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 screen by adjusting the eccentric.
Page 139 D4.1 Operation Preparation of operation Required devices and aids To avoid delays on site, check before starting work whether or not the following de- vices and aids are present: - Wheel loader for transporting heavy extendable parts - Diesel fuel - Engine oil and hydraulic oil, lubricants - Separating agents (emulsion) and manual injector - Two filled propane gas bottles...
Page 140 Checklist for the machine operator Check! How? Emergency stop button Push in the button. - on the operating panel The diesel engine and all running drives - on both remote control units o must stop immediately. The paver finisher must immediately fol- Steering low every steering wheel movement in a precise manner.
Page 141 Check! How? For larger working widths, the walkway Auger covers 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.
Page 142 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 (such as monthly or yearly maintenance) must be performed.
Page 143 External starting (starting aid) The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24 V system - Additional 24 V battery - Start device that is suitable for external starting (24 V/90 A).
Page 144 After starting To increase the engine speed: - Set the drive lever (9) to position 1 (slightly off the center position). - Increase the engine speed by press- ing button (21) on the operating panel. The engine speed will be increased to the preselected value.
Page 145 Oil pressure indicator lamp for the traction drive (46) - Must go out after starting. If the lamp does not go out: Do not switch on the traction drive! Otherwise, Leuchtmodul_SPS_Kette_635.bmp the entire hydraulic system could be damaged. When the hydraulic oil is cold: - Set the conveyor switch (32) to „man- ual”...
Page 146 Battery charge indicator (49). Must go out after starting when the en- gine revs up. Briefly rev up the engine when the lamp does not go out or lights up during oper- Leuchtmodul_SPS_Kette_635.bmp ation. Switch off the engine and determine the cause for the malfunction if the lamp does not go out.
Page 147 Operation in case of transportation Lifting and securing the screed - Button (16) has to be switched off - Switch off the buttons (34) and lift the screed full by using button (33). - Extend the levelling cylinders full by using the buttons (25) and (27).
Page 148 Driving and stopping the paver finisher - Set the Fast/Slow switch (17) to „Hare”. - Set the preselector traction drive (10) to mark 10 - For driving, carefully tilt the drive lever (9) forward or backward according to the drive direction desired. In case of an emergency, press the emergency stop button (7)! - To stop the paver finisher, set the...
Page 149 Preparations for paving Separating agent Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator emulsion. Do not use diesel fuel as it dissolves the bitumen (prohibited in Germany!). F0147_A1.TIF Screed heater Switch on the screed heater ca. 15–30 minutes (depending on the ambient tempera- ture) before paving begins.
Page 150 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- Stossstange.bmp ingly.
Page 151 - Switch the conveyors on. The limit switches for the conveyors (89) or (89ao) must switch off when the material has reached the area be- neath the auger crossbeam. - Check that the material is conveyed properly. Manually switch on or off the conveyor if the material is not conveyed properly until a sufficient amount of material lies in front of the screed.
Page 152 Starting for paving Element2_SPS_Kette_635.wmf/Element1_SPS_Kette_635.wmfr/Tamprev.cdr/Vibrev.cdr/Remote_SPS_neu1cdr D4.1 14...
Page 153 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 Switch Position Traction drive fast/slow Tortoise-operating speed Preselector traction drive Mark 6-7 Preparation for screed floating...
Page 154 Checks during paving The following points must be constantly observed during paving: paver finisher function - Screed heater - 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 155 Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Switch (34) has the following positions: A: Relieving (screed ‘lighter’) B: Charging (screed ‘heavier’) Switch positions „Screed charging/re- lieving” are only effective when the pav- er finisher moves.
Page 156 Screed stop with prestressing When „stopping the screed“ the relieving pressure and the counterpressure of the material will provide retention so that the sinking of the screed is avoided when a temporary stop occurs. - Automatic screed stop when the drive lever is in the center position Screedswitch2a.bmp - To lift the screed press button (33A).
Page 157 Adjusting the pressure (o) Pressure adjustments can only be made while the diesel engine is running. Therefore: - Start the diesel engine and set the traction controller (10) to zero (precau- tion against inadvertent advancing). - Set switch (33) to the floating position. Screed stop (with prestressing): - Set the drive lever (9) to the center po- sition.
Page 158 Interrupting/terminating operation During breaks: (e.g. the material supply truck is late) - Determine the approximate duration. - When cooling down of the material be- low the minimum paving temperature must be expected, run the paver fin- isher empty and create an edge like the end of a layer.
Page 159 - Insert the mechanic screed transport safeguard (74) on both screed lifting cylinders. - While operating the tampers at a low speed, let any material residues drop out. F0083_A1.Tif - Set the drive lever (9) to the center po- sition and the speed adjuster (10) to minimum - Switch off the ignition (5).
Page 160 - Read and check the oper- ating hour meter to deter- mine whether maintenance work must be performed (see chapter F). - Cover and lock the operat- ing panel. - Remove material residues from the screed and the paver finisher and spray all parts with separator fluid.
Page 161 Malfunctions Problems during paving Problem Cause: - change in the material temperature, demixing - wrong material composition - incorrect operation of the roller - incorrectly prepared foundation - long standstill times between loads - grade control reference line is not suitable - grade control jumps to the reference line - grade control toggles between up and down Wavy surface...
Page 162 Problem Cause: - temperature of the material - 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 - paver finisher speed is too high - temperature of the material - change in the material temperature - moisture on the foundation...
Page 163 Malfunctions on the paver finisher or screed Malfunction Cause: Remedy See operating instructions for At the diesel engine Diverse the engine See ”External starting” Batteries empty Diesel engine does (start assistance) not start Diverse see ”Towing” Tamper is obstructed by Properly heat the screed cold bitumen Hydraulic oil level in the...
Page 164 Malfunction Cause: Remedy Control valve is defective Replace Hoppers lowers Leaking seals of the inadvertently Replace hydraulic cylinder Oil pressure too low Increase the oil pressure Leaking seal Replace Screed cannot be Screed relieving or Switch must be in the center lifted charging is switched on position...
Page 165 Malfunction Cause: Remedy Replace Traction drive fuse (Fuse holder on the operating defective panel) Check potentiometer, cables, Power supply is interrupted connectors; replace if necessary Traction drive monitoring Replace (type-specific) defective Traction does not Electro-hydraulic servo unit work Replace the servo unit of the pump defective Check and adjust if necessary Check the suction filter;...
Page 166 Emergency device/steering, drive system In case of a malfunction in the electronic drive system it is possible to override the system by an emergency device. This emergency device is included in the tool set of every crawler machine. To install the emergency device all plugs of the drive pump servo valves have to be replaced by the plugs of the emergency device.
Page 167 Following functions are located in the steering unit: No. Denomination Mounting screws for holder plate Switch for preselection of the zero position and forward reverse movement Adjustment knob for speed control (Replace speed preselector) Steering knob Switch to turn the paver finisher on the spot Function If the emergency device is connected all functions like engine speed, conveyor, au- ger, tamper and vibration have to be controlled by the forward reverse lever.
Page 168 Gray Wiring harness for drive pump Black of left caterpillar drive Marked YELLOW! 24 V / Ground Steering unit D4.1 30...
Page 169 E 01 Set-up and modification Special notes on safety Danger to personnel by inadvertent starting of the engine, the traction drive, the con- veyor, the auger, the screed or the lifting units. Unless specified otherwise, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Set the drive lever to the center position and set the preselector to zero;...
Page 170 Auger Height adjustment Depending on the mix of materials, when working with layer thicknesses of up to 15 cm, the height of the distribution auger (1) – measured from its bottom edge – should around 5 cm (2 inches) above the material layer thick- ness (depending on its mix of materials).
Page 171 Mechanical adjustment with ratchet (optional) - Set the ratchet direction lever to clock- wise or anticlockwise direction. Turn- ing anticlockwise lowers the auger, turning clockwise lifts the auger. - Set the desired height by alternatingly adjusting the right-hand and the left- hand side.
Page 172 Equally press both switches/buttons (2) so that the auger beam does not get into inclined position. - Check whether the heights on the left and on the right are identical. Screedlift_konv.bmp/Screedlift_SPS.bmp The height indicating scales (3) may be optionally also along the climbing rungs on the LH/RH sides! Schnskal.wmf E 01 4...
Page 173 Auger extension, auger type I Auger_Dyn.bmp Depending on the type of screed, the most diversified working widths can be reached. Auger and screed extension must match. See the operating instructions of the appro- priate screed, chapter ”Set-up and modification”, especially: –...
Page 174 Mounting extension parts - Loosen the clamping screws (6) on the support tube. Then turn in the center expanding screw (5) to expand the clamping joint. F132_A1.TIF - Pull the telescopic tube out of the sup- port tube (7). - Mount the required extension parts. Observe the guide groove of the spline! Make sure that the shaft end is clean! - Slide in the telescopic tube.
Page 175 Mounting support tube extensions If the working width exceeds 7.25 m, an auger crossbeam extension must be mounted. The support tube extension of the auger crossbeam consists of two halves (8) and is attached to the existing support tube by using a total of 5 screws. After the two halves have been screwed to the support tube, they also must be linked to F0134_A1.TIF...
Page 176 Installing tunnel plates To ensure an optimum material flow – especially in the case of large paving widths – so-called tunnel plates (11) must be installed. They are located directly in front of the auger distributor and – in conjunction with the auger –...
Page 177 Installing additional braces When operating with width of more than 7.25 m the augers must be provided with an additional support. F0141_A1.TIF To do so, attach two braces on both the left-hand and the right-hand side, be- tween the tunnel plate support and the bracket provided on the paver finisher.
Page 178 2.10 Auger mounting chart for ø 310 mm auger * from working width of 6.75 m the machine can be operated only with appropriate braces (screed, auger, material pipeline). E 01 10...
Page 179 2.11 Auger mounting chart for ø 380 mm auger * from working width of 6.75 m the machine can be operated only with appropriate braces (screed, auger, material pipeline). E 01 11...
Page 180 Auger extension, auger type II Auger_DEM.bmp E 01 12...
Page 181 Mounting extension parts Sch_ver1.tif Sch_ver2.tif E 01 13...
Page 182 - Lock the material shaft (5) with bolts (6), washers (7) and nuts (8) to the basic de- vice. - The material shaft can be adjusted in order to match the existing shaft. - Loosen the nuts (9) for this and turn the sleeve (10) of bolt (6). - Mount the extension of the auger shaft (11) on the auger shaft of the basic device.
Page 183 Auger modification plan. Marking Meaning Basic auger Auger section to be mounted + material shaft 320mm Auger section to be mounted + material shaft 640mm Auger section to be mounted + material shaft 960mm Auger - outer bearing E 01 15...
Page 184 Paving Mountable parts / bearing Mountable parts / bearing width 2.5 m - 3.7 m 3.2 m - 4.4 m 4.1 m - 5.0 m 4.1 m - 5.0 m 4.8 m - 5.7 m 4.8 m - 5.7 m 5.4 m - 6.3 m 5.4 m...
Page 185 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 when the mechanical components have been mounted and set up: Remote controls to socket (15) (on the screed). Socket.bmp Grade control to socket (16) (on the remote control...
Page 187 F 1.0 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 center position and the speed preselector to zero. - Remove the traction drive fuse from the operating panel.
Page 189 F 2.4 Maintenance overview Maintenance review F 2.4 1...
Page 190 Maintenance required after the following service hours. Sub-units Chapter Feeder Auger F4.2 q q q q Drive engine F5.1 q q q Hydraulics F6.0 Track F7.1 q q q Electronics Lubrication points Checking/stopping Maintenance required This review also includes the maintenance intervals of the optional equipment of the machine! F 2.4 2...
Page 191 F 3.0 Maintenance - Conveyor Maintenance - Conveyor F 3.0 1...
Page 192 Maintenance intervals Interval Points of maintenance Remark - Checking the tightness of the conveyor chain - Adjustment of the tightness of the conveyor chain - Checking the oil level of the conveyor drive - Topping up the oil level of the conveyor drive: - Changing the oil of the conveyor drive...
Page 193 Points of maintenance Chain tightness of the conveyor (1) Checking the chain tightness: For daily inspection look straight through under the bumper. The chain must not hang below the bottom edge of the bumper. Should readjustment be necessary, measure the slack unladen from the bottom edge of the floor plate until the lower edge of the chain (see the figure).
Page 194 The drive of conveyor (to the left/to the right) (2) The drive unit of the conveyor is under the floorboard of the operating position. Checking the oil level Only before the work starts. The oil level must reach the upper notch of the dipstick (A). Filling in the oil: After removing cover lid (B) through fill-in stub (C).
Page 195 F 4.2 Maintenance - Auger Maintenance - Auger sub-unit I F 4.2 1...
Page 196 Maintenance intervals Interval Points of maintenance Remark - Auger - outer bearing Lubrication - Auger central bearing Lubrication - Auger drive neck bearing Lubrication - Auger bevel gear oil level check - Auger bevel gear topping up the oil - Auger bevel gear oil change Maintenance Maintenance during run-in period...
Page 197 Points of maintenance Auger - outer bearing (1) The grease nipples (A) are located on each side on the top of outer bearing. These nipples must be lubricated each time when work is finished. The outer bearings of the auger shall be lubricated when hot, so that the eventual bitumen residues are expelled.
Page 198 Auger - drive gear neck bearing (3) Remove the hexagonal screw plug (A) in the neck of the drive. Replace the screw under it with a grease nipple 10x1. Using a grease gun press in about 10 strokes of grease. Thereafter, unscrew the grease nipple and drive in both screws.
Page 199 Auger bevel gear (on the RH and LH sides) (4) - For checking the oil level unscrew the inspection / filling plug (A). In case of proper oil level, the oil is at the lower edge of the inspection port or a lit- tle oil flows from the hole.
Page 201 F 5.1 Maintenance - Engine Maintenance - engine sub-unit In addition to these Maintenance Instructions, the Maintenance Instructions of the en- gine manufacturer must always also be observed. All other maintenance work and in- tervals noted in these instructions are also binding. F 5.1 1...
Page 202 Maintenance intervals Interval Points of maintenance Remark - Fuel tank Check the filling level - Fuel tank Refill with fuel - Fuel tank Clean the tank and device - Engine lube-oil system oil level check - Engine lube-oil system topping up the oil - Engine lube-oil system oil change - Engine lube-oil system...
Page 203 Interval Points of maintenance Remark - Engine air filter checking of air filter - Engine air filter dust collecting bin emptying - Engine air filter Clean / Replace the filter car- tridge - Cooling system of the engine Inspection of radiator fins - Cooling system of the engine Cleaning of the radiator fins - Cooling system of the engine...
Page 204 Points of maintenance Engine fuel tank (1) - Check the filling level on the gauge on the operating panel. Fill the fuel tank before each start of work so that the fuel system cannot „run dry“ and this way the time consuming venting (bleeding) can be avoided.
Page 205 Engine lube-oil system (2) Checking the oil level In case of correct oil level, the oil is be- tween the two notches of the dipstick (A). Check the oil level with a paver finisher standing on a flat area! If there is too much oil in the engine, the gaskets and seals may get damaged, while too little oil can lead to the over- heating of the oil and the damage of the...
Page 206 Changing the oil filter: As part of the oil change mount the new filter after the used oil was drained. - Untighten the filter (D) and clean its resting surface. - Apply thin coat of oil to the seal of the new filter and fill the filter with oil before mounting.
Page 207 Engine fuel system (3) The fuel filter system consists of three fil- ters: - Pre-filter (A) with water separator - Two main filters (B) Depending on the machine, the pre-filter is in the engine compartment or under the tank lid! Pre-filter - draining of water Empty the collection bin by the specified intervals or when the engine electronic...
Page 208 Replacement of the main filter: - Untighten the filter (B) and clean its resting surface. - Apply a thin coat of oil to the gasket of the new filter. - Tighten the filter by hand. After mounting the filter check for proper tightness during the trial run. Venting the filter: - Release the bayonet-mount of the manual fuel pump (F) by pressing and twisting counter-clockwise at the same time.
Page 209 Engine air filter (4) Emptying the dust collection bin - Empty the dust collection valve (B) on the air cleaner housing (A) by pressing the discharge port in the direction of the arrow. - Discharge the eventually compacted dust by pressing together the upper part of the valve.
Page 210 Coolant system of the engine (5) Checking / topping up of coolant The coolant level is checked when the engine is cold. Make sure that the anti- freeze and anti-corrosive liquid us suffi- cient (-25 °C). When hot, the system is under pressure. When opening, there is a danger of scalding! - If necessary fill in sufficient amount of...
Page 211 Engine exhaust system (7) Cleaning of particle filter As considerable amount of soot is accu- mulated in the filter, the cleaning must be performed under appropriate exhaust system. Clean the filter element removed with oil-free and grease-free pressure air! - Marking the flow of direction of the ex- haust gas on the filter case.
Page 213 F 6.0 Maintenance - Hydraulic system Maintenance - hydraulic system F 6.0 1...
Page 214 Maintenance intervals Interval Points of maintenance Remark - Hydraulic oil tank Check the filling level - Hydraulic oil tank Top up with oil - Hydraulic oil tank oil change and cleaning - Hydraulic oil tank Checking of maintenance indica- - Hydraulic oil tank Intake / return change of hydraulic filter, venting - High pressure filter...
Page 215 Points of maintenance Hydraulic oil tank (1) - Oil level check on dipstick (A). In case of retracted cylinders the oil level shall be at the upper mark. For filling in the oil: - Remove cap (B). - Fill in oil through the filling port until the required filling level is achieved on the dipstick (A).
Page 216 Suction/return flow hydraulic filter (2) Change the filter by the intervals speci- fied or when the maintenance indicator (A) at a hydraulic oil temperature of 80°C comes to the red mark. The temperature of the hydraulic oil can be read on the hydraulic temperature in- dicator (O) at the operating position.
Page 217 Venting the filter: - Fill the open filter case with hydraulic oil to about 2 cm below the upper rim. - Should the oil level drop, top up with oil. The slow sinking of the oil level by about 1 cm/min is normal! - When the oil level remains steady, mount the assembled unit with the new filter car- tridge, carefully into the housing and tighten the locking screws of the lid (B).
Page 218 High pressure filter (3) Replace the filter cartridge when the maintenance indicator (A) turns red. - Unscrew filter house (B). - Remove the filter cartridge - Clean the filter house. - Insert the new filter cartidge. - Replace the seal ring of the filter hous- ing.
Page 219 Pump distribution gear (4) - Oil level checking on the viewing glass (A) (at the side of the distribution box). The oil level must be up to the center of the viewing glass. For filling in the oil: - Unscrew the filling in screw plug (B). - Fill in oil through the filling port until the required filling level is achieved on the viewing glass (A).
Page 220 Hydraulic hoses (5) - Check the condition of the hydraulic hoses specifically. - Immediately replace the injured hos- The aged hoses may become porous and burst! Risk of accident! The numbers stamped in the joints of the hoses state the date of manufacture (A) and the maximum pressure (B) allowed for that hose.
Page 221 F 7.1 Maintenance - running gear Maintenance - running gear 635_ISO_Dyn.bmp/LW_DYN_inter.bmp F 7.1 1...
Page 222 Maintenance intervals Interval Points of maintenance Remark - Chain tightness Inspection - Chain tightness setting - Planetary gear oil level check - Planetary gear topping up the oil - Planetary gear oil change Maintenance Maintenance during run-in period F 7.1 2...
Page 223 Points of maintenance Track tightness (1) Slack tracks may slip out of the guides of the rolls, drive and guide wheels and in- tensive wear may take place. Too tight tracks add to the wear of guide wheels and drive bearings, the pins and bushes of the tracks as well.
Page 224 Planetary gear (2) - For checking the oil level unscrew the inspection plug (A). In case of proper oil level, the oil is at the lower edge of the inspection port or a lit- tle oil flows from the hole. For filling in the oil: - Remove filling plug (A).
Page 225 F 8.1 Maintenance - Electronic System Maintenance - Electronic System F 8.1 1...
Page 226 Maintenance intervals Interval Points of maintenance Remark Check the level of battery electrolyte q Top up with ion exchanged water Coat the battery poles with grease Maintenance Maintenance during run-in period F 8.1 2...
Page 227 Interval Points of maintenance Remark Also see - Generator the opera- Checking of operation of the insu- tion manu- lation monitoring of electric equip- al of the ment screed - Generator Visual checking for pollution or damage - Check the cooling air openings for pollution or clogging, clean as required.
Page 228 Interval Points of maintenance Remark q Electric fuses Maintenance Maintenance during run-in period F 8.1 4...
Page 229 Points of maintenance Batteries (1) Maintenance of storage batteries The batteries are filled with the appropri- ate volume of electrolyte in the factory. The electrolyte level shall be up to the top mark. Top up with ion exchanged water only, when required! The shoes shall be free of oxyde and coated with special battery protection grease.
Page 230 Generator (2) Checking of operation of the insulation monitoring Check insulation daily with operating machine and switched on connection sockets. - Turn on the electrical equipment with switch (1), control light (2) comes on. - Press testing button (3) and the in- scription "Isolationsfehler - Insulation Fault"...
Page 231 Checking of ball bearings / Replace- ment of ball bearings Report the displayed fault code to the customer service of the paver finisher and they will discuss with you the steps to be taken. F 8.1 7...
Page 232 Drive belts (V-belt) Checking belt tension The tightness of each belt shall be in- spected with a tightness checking instru- ment. Specified tension: - in case of first assembly: 550 N - after run-in period / maintenance interval: 400N Riemensp.tif Instructions for checking of tightness in the description of the tightness measuring instrument.
Page 233 Drive belt (toothed belt) Replacement of belt - Unfasten both lock nuts (A) from the clamping lock. - Rotate and open clamping lock (B) un- til belt (C) can be replaced. Pre-tension newly fitted belt using clamping lock (B). - Checking / adjusting belt tension Riemenspann.jpg F 8.1 9...
Page 234 Checking / adjusting belt tension: The tension of the V-belt must be checked and set after the belt has been replaced. - The tension of the belt can only be ad- justed using a pre-tensioning test de- vice. Deflection Specified belt tension levels: (read from bottom to top) - Generator 17KVA:...
Page 235 Electric fuses (3) Type of machine: Conventional electronics Switch box Fuses_635_konv.eps Main fuses Fuses in the switching cabinet Relays in the switching cabinet Main fuses (A) Main fuses Reserve F 8.1 11...
Page 236 Fuses in the switching cabinet (B) F5.5 Machine drive Machine drive Temperature control, electric heating Gas heating Connection sockets with On-Off switch buttons Connection sockets with On-Off switch buttons Connection sockets with On-Off switch buttons Connection sockets with On-Off switch buttons Starting the engine Engine regulation Machine drive...
Page 237 Relays in the switching cabinet (C) Starting the engine 18.2 Retracting the screed on the right hand side 18.1 Retracting the screed on the right hand side Power supply, terminal 15 Engine regulation Complementary emergency stop free free Re-compressor Machine drive Engine regulation F 8.1 13...
Page 238 Fuses on the operating panel Bedienpult_konv_Kette_635_Fuse1/Fuse1.tif/Fuse.bmp Fuse carrier (A) Engine start, start button interlock, idling speed, re- verse indicator Interlocking relay, Bat 15+ relay, monitoring systems Levelling, screed stopping Conveyor, RH-side auger Conveyor, LH-side auger Tamper, vibration Hopper, screed lift and lowering, screed retraction/ex- tension, screed power supply, re-compression lift (o), cabin movement (o), auger lifting/lowering (o) Emergency stopping...
Page 239 Relays on the operating panel Bedienpult_konv_Rad_656_Fuse3.wmf Relays (A) Emergency stopping (VB805/1105, EB50,75) Screed functions Conveyor / LH-side auger Conveyor / RH-side auger Engine regulation free free F 8.1 15...
Page 240 Type of machine: PLC- electronics Switch box Fuses_635_konv.eps Main fuses Fuses in the switching cabinet Relays in the switching cabinet Main fuses (A) Main fuses Reserve F 8.1 16...
Page 241 Fuses in the switching cabinet F5.5 Machine drive Machine drive Temperature control, electric heating Gas heating Connection sockets with On-Off switch buttons Connection sockets with On-Off switch buttons Connection sockets with On-Off switch buttons Connection sockets with On-Off switch buttons Starting the engine Slave A51 Slave A52...
Page 242 Engine regulation Machine drive Spray equipment Emulsion spray appliance Diesel fuel pump Flasher Headlight (glass fibre reinforced roof) Working floodlights (o) Power supply Master A1 Particle filter (o) Exhaust equipment (o) Seat heating Windscreen wiper Reserve Power supply Master A1 F 8.1 18...
Page 243 Relays in the switching cabinet (C) Starting the engine Power supply, terminal 15 Engine regulation Reversing sound alert Starter button interlocking Machine drive Horn F 8.1 19...
Page 244 Fuses on the operating panel Bedienpult_SPS_Kette_635_Fuse1/Fuse1.tif/Fuse.bmp Fuse carrier (A) F1,1 F1,8 Emergency stopping Monitoring systems, Bat 15+ relay, motor sensors Display power supply, keyboard free free free Screed power supply,cabin movement (o) free Fuse carrier (B) free Horn, reversing alert Windscreen wiper (o), road profile adjustment Headlights on the left/right sides RH-side low beam headlight...
Page 245 F 9.0 Maintenance - Points of lubrication Maintenance- Points of lubrication The information related to the lubrication points of the various sub-units are included in the specific maintenance descriptions and additional reading is recommended as follows. In case of applying a central lubrication unit (o) the number of the lubrication points may differ from the data provided in the description.
Page 246 Maintenance intervals Interval Points of maintenance Remark - Check the filling level of the lubri- cant tank q - Fill up the lubricant tank - Vent the central lubrication unit - Check the pressure limiting valve - Check the leakage of the lubri- cant at the consumer unit - Bearings Maintenance...
Page 247 Points of maintenance Central lubrication (1) Danger of injuries! Do not reach into the tank when the pump is running. Operate the central lubrication system with a mounted safety valve only! During operation do not perform mainte- Handverl.jpg/Gefahr.jpg nance operations on the safety valve! The lubricant ejected may cause injuries as the equipment operates under high pres- sure! Make sure that the starting of the diesel engine should be prohibited while work is per-...
Page 248 Central lubrication unit Check the filling level The lubrication tank shall always be filled so that the system could not „run dry“ and the proper lubrication of the points of lubrication is ensured and there is no need for a time consuming venting operation.
Page 249 Vent the central lubrication unit The venting of the lubrication system be- comes necessary if the central lubrica- tion unit was operated with an empty lubrication tank. - Untighten the main line (a) of the lu- brication pump at the flow divider (b). - Start the operation of the central lu- brication unit with the refilled lubri- cant tank (c).
Page 250 Check the leakage of the lubricant at the consumer unit Check the continuity of all the lubrication canals at the consumers. - Disconnect the lubrication pipe (a) and fit a standard grease nipple (b). - Connect the grease gun (c) supplied with the machine to the grease nip- ple (b).
Page 251 Bearings (2) There are grease nipples on the bearing points of the hydraulic cylinder (one each, at the top and bottom) (a). Zylinder.bmp F 9.0 7...
Page 253 F 10.0 Checks, decommissioning Tests, check-up, cleaning, stopping F 10.0 1...
Page 254 Maintenance intervals Interval Points of maintenance Remark - General observation q - Checks by a specialist q - Cleaning q - Conservation of paver finisher Maintenance Maintenance during run-in period F 10.0 2...
Page 255 General observation The daily practice includes the walk around the machine with checking the following items: - Are there injuries on the parts or control elements? - Are there leaks on the engine, the hydraulics, the gear box, etc.? - Are all the locking points secure (conveyor, auger, screed)? Repair the detected faults immediately in order to avoid risks of accidents and envi- ronmental pollution! Checks by a specialist...
Page 256 Cleaning - Clean all parts which come into contact with the material to be laid. - Spray the polluted parts with the separating agent spray equipment (o). Before cleaning with high pressure jet, lubricate all the bearings with grease as spec- ified.
Page 257 Conservation of paver finisher Downtime up to 6 months - Stop the machine in a place protected from intensive sunshine, wind, moisture and frost. - Lubricate all the lubrication points with grease as specified, use the optional central lubrication unit as appropriate. - Change the oil in the Diesel engine - Tightly seal the muffler of the exhaust pipe.
Page 259 F 11.0 Lubricants and Fuels Lubricants and fuels Use only the lubricants listed or the equivalent quality products of prestigious produc- ers. Use only such vessels for filling in oil or fuel, which are clean both outside and inside. Take into account the filling volumes (see the section „Filling volumes“). Low quality oil or lubricant speeds up wear and the failure of the machine.
Page 260 Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic fluids based on ester, HEES Manufacturer ISO category of viscosity VG 46 Shell Naturelle HF-E46 Panolin HLP SYNTH 46 Esso HE 46 Total Fina Elf Total Biohydran SE 46 b) mineral oil pressure fluid Manufacturer ISO category of viscosity VG 46 Shell...
Page 261 Instructions referring to the oil types applied Shell Tivela 220 Transmission oil 220 - synthetic oil Caterpillar drive - planetary gear * Optimol Optigear 220 Transmission oil 220 - mineral oil * In case of crawler driven pavers only Filled in the factory with the fuel indicated. F 11.0 3...
Page 262 Filling volumes Fuel Volume Fuel tank gas oil liters Hydraulic oil tank hydraulic oil liters Pump distribution gear Transmission oil 90 liters Planetary gear Transmission oil 220 liters Caterpillar drive * Drive of the conveyor Transmission oil 220 liters (each side) Central lubrication unit (option) Grease Batteries Ion exchanged water...
Page 263 Engine - type Deutz TCD 2013 L06 2V Deutz_2013L06 Fuel Volume Diesel engine Engine oil 10W40 20,0 liters (with oil filter change) Cooling system of the Coolant 20,0 liters engine Engine - type Deutz TCD 2013 L04 2V Deutz_2013L06 Fuel Volume Diesel engine Engine oil 10W40...
Page 264 Engine type Deutz TCD 2012 L06 2V Deutz_2013L06 Operating substance Volume Diesel engine Engine oil 10W40 21,5 liters (with oil filter change) Cooling system of the Coolant 20,0 engine Engine type Cummins QSB 6.7 C190, C205, C220 Cummins_QSB6.7.tif Operating substance Volume Diesel engine Engine oil 10W40...
Page 265 Auger - Type I Auger_Dyn.bmp Fuel Volume Auger bevel gear Transmission oil 90 liters (each side) Auger - Type II Auger_DEM.bmp Fuel Volume Planetary gear Transmission oil 90 liters auger (each side) Auger drive case Transmission oil 460 liters Auger - outer bearing Heat resistant bearing grams (by bearings)**...
Page 266 Instructions to change from mineral oil to synthetic oil / from synthetic oil to mineral oil Caterpillar drive - planetary gear Mixing synthetic oils with mineral oils is strictly forbidden! - Completely drain the used oil. Change the oil when the engine is at op- erating temperature.
Page 267 TRAINING/EDU- CATION We offer our Customers various training programmes on DYNAPAC equipment in our specialised training centre in our factory. We hold train- ing sessions also for special arrange- ments in addition to courses and programs held on fixed dates SERVICE In case of operational failures and questions related to parts, please, contact one of our au-...
Page 268 Don’t hesitate to contact your local dealer for: service spare parts documentation accessories information about the complete Dynapac paving and planing range...

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Atlas Copco Dynapac F 121 C Operation & Maintenance Manual

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