Atlas Copco DYNAPAC Svedala Demag DF 115 C, Operation & Maintenance Manual

Page 1: ...35 02 0107 OPERATION MAINTENANCE Paver finisher Svedala Demag DF 115 C DF 135 C Type 35 Keep this manual for future reference Order number for this manual D900981370...

Page 2: ...VALUE QUALITY THE ORIGINAL Your Authorized Dynapac Dealer...

Page 3: ...ch 17 8 4 6 Hopper transport safeguards 18 8 4 7 Screed transport safeguard 19 8 4 8 Latch for protective roof 20 8 5 Technical data standard configuration 10 5 1 Dimensions all dimensions in mm 10 5...

Page 4: ...ions acting on hands and arms 23 7 9 Electromagnetic compatibility EMC 23 C1 1 Transportation 1 1 Safety regulations for transportation 1 2 Transportation on low bed trailers 2 2 1 Preparations 2 2 2...

Page 5: ...headlights 85d 6 On Off switch of flasher 85e 6 230 V On Off switch Connection sockets 85f 6 Locking of the collapsible roof LH and RH on the roofs console 86 6 Hydraulic folding roof 87 o 7 Electric...

Page 6: ...r finisher and screed loading unloading 14 General 14 Screed charging relieving 15 Screed control with the paver finisher standing still Floating position with and without prestressing 15 Screed contr...

Page 7: ...1 3 Auger extension auger type II 12 3 1 Mounting extension parts 13 3 2 Auger modification plan 15 4 Screed 17 5 Electrical connections 17 5 1 Remote controls 17 5 2 Grade control 17 5 3 Auger limit...

Page 8: ...gine drive belt 6 10 Engine exhaust system 7 11 F6 0 Maintenance Hydraulic system 1 1 Maintenance hydraulic system 1 1 1 Maintenance intervals 2 1 2 Points of maintenance 3 Hydraulic oil tank 1 3 Suct...

Page 9: ...t 17 Relays in the switching cabinet C 19 Fuses on the operating panel 20 F9 0 Maintenance Points of lubrication 1 1 Maintenance Points of lubrication 1 1 1 Maintenance intervals 2 1 2 Points of maint...

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Page 11: ...option is used Safety instructions and important notes are identified by the following pictograms f Precedes safety instructions that must be observed in order to prevent danger to per sonnel m Prece...

Page 12: ...e correct and specified appli cation of pavers shall also be observed 1 2 Warning instructions Warning pointing to hazardous place or danger Not observing the warning instructions may lead to injuries...

Page 13: ...k 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 mat...

Page 14: ...art 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 Do it yourself maintenance is prohi...

Page 15: ...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 tigh...

Page 16: ...polluting water e g lubricants oils grease hydraulic oil gas oil coolant detergents may not enter the soil or the sewer system These materials shall be collected stored transported in the correct con...

Page 17: ...m Observe the manufacturer s and other instructions A e g the maintenance instructions of the engine manufacturer m Description figure in case of an electrically heated design m Description figure in...

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Page 19: ...thin the meaning of the present operating instructions is defined as any natural or legal person who either uses the paver finisher himself or on whose behalf it is used In special cases e g leasing o...

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Page 21: ...pplication The Svedala Demag DF 115C DF 135 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 minera...

Page 22: ...aving thickness 6 t Traction roller 7 t Traction arm rail 8 t Paving thickness indicator 9 t Arm 10 t Traction drive of the caterpillar drive 11 t Auger 12 t Screed 13 t Operator s platform 14 t Opera...

Page 23: ...oof o Further equipment and upgrade options on request Engine The paver is driven by a water cooled Diesel engine For further details see the technical data and the engine s instruction manual The par...

Page 24: ...ed option The hydraulic front hopper lids o ensure that no material remains at the front of the feeding hoppers Material transfer The paver finisher is equipped with two conveyors driven sepa rately t...

Page 25: ...ulic cylinders on the arms and is controlled by means of toggle switches on the operating panel Automatic screed stop and screed charging relieving device The automatic screed stop prevents the screed...

Page 26: ...B 6 B 635_DEM D 6 24 01 01 07 3 Danger zones m 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: ...1 4 1 Emergency stop button on the operating panel on the two remote control units op tion m Pressing the emergency stop button switches off the engine the drives and the steer ing system Corrective m...

Page 28: ...4 5 Main switch 17 4 6 Hopper transport safeguards 18 4 7 Screed transport safeguard 19 4 8 Latch for protective roof 20 Mainswitch tif Mainswitch_SK eps 17 o Hopperlock2 tif Hopperlock_SK eps 18 o F...

Page 29: ...s Warning triangle First aid kit 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 635_side...

Page 30: ...ata standard configuration 5 1 Dimensions all dimensions in mm A For the technical data of the screed see the operating instructions of the screed 635_side_DEM bmp 635_front_DEM bmp 6505 2606 1962 160...

Page 31: ...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 5 3 Allowed angle of driving up 635_sid...

Page 32: ...nts see the operating instruc tions for the screed Paver finisher without screed about 16 3 Paver finisher with screed EB51 about 18 2 Including mounted accessories for max paving width additionally m...

Page 33: ...cut off shoe continuously hydraulically adjustable up to Maximum paving widths with attachments EB 51 2 55 2 00 5 10 8 10 m EB 51 2 55 2 00 5 10 m EB 60 3 00 2 45 6 00 8 20 m EB 60 3 00 2 45 6 00 m Tr...

Page 34: ...hoe continuously hydraulically adjustable up to Maximum paving widths with attachments EB 51 2 55 2 00 5 10 8 80 m EB 51 2 55 2 00 5 10 m EB 60 3 00 2 45 6 00 9 00 m EB 60 3 00 2 45 6 00 m SB 30 3 00...

Page 35: ...16 KW 158 HP at 2100 rpm Volume of fuel tank see chapter F Make type Deutz TCD 2013 L06 2V Model 6 cylinder diesel engine water cooled Performance 140 KW 190 HP at 1800 rpm Volume of fuel tank see cha...

Page 36: ...trollable Conveying volume controller Fully automatic via configurable switching points Augers Left and right side separately controllable Drive Hydrostatic external drive continuously controllable in...

Page 37: ...tions At standstill Screed stop Screed stop with pretensioning max pressure 50 bar During paving Screed charging Screed relieving max pressure 50 bar Levelling system Mechanical grade control optional...

Page 38: ...B 18 B 635_DEM D 18 24 01 01 07 6 Location of instruction labels and identification plates o 10 1 2 4 7 6 3 12 14 11 13 15 16 8 9 5 5 10 18 17...

Page 39: ...ctions 4 Warning label Danger of squeezing 5 Punched vehicle identification number 6 Label Securing or fixing points for crane transportation 7 Paver finisher identification label 8 CE noise level pla...

Page 40: ...ntification number 8 No Denomination 1 Type of paver finisher 2 Year of manufacture 3 Serial number of the paver finisher series 4 Max permissible operating weight incl all attachments in kg 5 Max per...

Page 41: ...und capacity level LWA 108 0 dB A Sound pressure level at the machine 7 2 Operating conditions during measurement The diesel engine was running at maximum speed The screed was in working posi tion low...

Page 42: ...city level LWA 109 0 dB A Sound pressure level at the machine 7 5 Operating conditions during measurement The diesel engine was running at maximum speed The screed was in working posi tion lowered to...

Page 43: ...ations of the EMC di rective 89 336 EEC 08 95 Interference emission according to DIN EN 50081 1 03 93 40 dB V m for frequencies of 30 MHz 230 MHz measured at a distance of 3 m 47 db V m for frequencie...

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Page 45: ...d into the hopper Close all coverings and check that they are securely seated In Germany gas bottles must not be transported on the paver finisher or on the screed Disconnect the gas bottles from the...

Page 46: ...see chapter D Remove all protruding or loose parts from the paver finisher and the screed see also the operating instructions of the screed Store these parts in a safe place f When screed is operated...

Page 47: ...t safe guards Lift the screed Insert the transportation safeguards of the screed A Only when remote control is not connected Turn the preselecting regulator to zero Move the drive lever forward The le...

Page 48: ...ow bed trailer Lower the screed onto wooden blocks on the low bed trailer Switch off the paver finisher Attach and secure the protective hood to protect the operating panel If necessary swing down the...

Page 49: ...it and store it 2 4 After transportation Remove the attachment devices Swing up the protective roof take out the bolts push the protective roof forward to raise it and insert the bolts to lock it agai...

Page 50: ...rts from the paver finisher and the screed see also the operating instructions of the screed Store these parts in a safe place f When screed is operated with the optional gas heating system Remove the...

Page 51: ...t safe guards Lift the screed Insert the transportation safeguards of the screed A Only when remote control is not connected Turn the preselecting regulator to zero Move the drive lever forward The le...

Page 52: ...3 2 Traction drive f Press the emergency stop button when a dangerous situation arises Warning Marking Marking Set the Fast Slow switch to Hare Turn the preselecting regulator to maximum Use the drive...

Page 53: ...fe Engage the transport safeguards Remove any attachments and accessories from the paver finisher and the screed until the basic width has been attained Take off all protruding or loose parts and the...

Page 54: ...he screed until the basic width has been attained The engine compartment holds a hand pump on the LH side which must be actuated to permit the towing of the machine Pressure for releasing the traction...

Page 55: ...pump until sufficient pressure has been built up and traction system brakes have been released Attach the tow bar to the coupling 5 located in the bumper A Now carefully and slowly tow the paver fini...

Page 56: ...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...

Page 57: ...de them somewhere on the ma chine m Do not turn off main switch 1 until 15 seconds after the ignition has been turned off A The engine electronics need this length of time to back up data Protect the...

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Page 59: ...o life and limb Always make sure during operation that no one is endangered by the machine Ensure that all protective covers and hoods are fitted and secured accordingly When damages are detected elim...

Page 60: ...1 4 2 D_1 4_01_GB fm 2 22 2 Operating elements 2 1 Operating panel 3 2 B 1 A 4 C B A Bedienpult_konv_Kette_635_2 bmp Element3_konv_Kette_635 bmp Element1_konv_Kette_635 bmp Element2_konv_Kette_635 bmp...

Page 61: ...her height Turn the knurled screw at the desired location into the designated notch and secure with the knurled nut f When not secured the operating panel can move Danger of accidents during transport...

Page 62: ...D 1 4 4 D_1 4_01_GB fm 4 22 Element2_konv_Kette_635 bmp 9 12 9a 5 8 14 A 6 7 13...

Page 63: ...A The scale approximately corresponds to the speed in m min when laying 9 Drive lever forward For switching on the paver finisher functions and for continu ously regulating the traction speed forward...

Page 64: ...D 1 4 6 D_1 4_01_GB fm 6 22 Element2_konv_Kette_635 bmp 9 12 9a 5 8 14 A 6 7 13...

Page 65: ...can be queried from the machine which means a specific fault Keep pressing the button until a three digit error message is displayed A See Chapter Operating Failures for querying the error code 14 Eme...

Page 66: ...D 1 4 8 D_1 4_01_GB fm 8 22 Element2_konv_Kette_635 bmp 27 19 18 17 28 29 B 16 25 26 22 21 20 23 24...

Page 67: ...urned on and the material end posi tion switch provides continuous regulation in the tunnel B stop turned off C manual continuously turned on full delivery capacity without material regulation If the...

Page 68: ...D 1 4 10 D_1 4_01_GB fm 10 22 Element2_konv_Kette_635 bmp 27 19 18 17 28 29 B 16 25 26 22 21 20 23 24...

Page 69: ...the drivearm 9 is in central position in case of stopping the paver finisher the screed is only main tained in floating position controlled f In case of transportation or maintenance operations al way...

Page 70: ...D 1 4 12 D_1 4_01_GB fm 12 22 Element2_konv_Kette_635 bmp 27 19 18 17 28 29 B 16 25 26 22 21 20 23 24...

Page 71: ...limit switch and the o ultrasonic sensor both switches must be in auto position 26 Adjustment of au ger beams on the LH RH sides o In case of hydraulically adjustable auger beams this is the way to ch...

Page 72: ...D 1 4 14 D_1 4_01_GB fm 14 22 Element1_konv_Kette_635 bmp Leuchtmodul_KONV_Kette_635 bmp 33 31 32 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C...

Page 73: ...tiometer Set steering to 0 position then adjust the potentiometer to drive the paver finisher straight ahead A This function is only active if the machine is not equipped with automatic synchronisatio...

Page 74: ...D 1 4 16 D_1 4_01_GB fm 16 22 Element1_konv_Kette_635 bmp Leuchtmodul_KONV_Kette_635 bmp 33 31 32 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C...

Page 75: ...opped immediately to prevent further faults All the faults shall be eliminated as soon as possible A The error message can be queried using button 13 A After the ignition is turned on the light is on...

Page 76: ...D 1 4 18 D_1 4_01_GB fm 18 22 Element1_konv_Kette_635 bmp Leuchtmodul_KONV_Kette_635 bmp 33 31 32 36 30 49 50 51 52 54 53 45 46 42 43 44 40 41 38 39 37 C...

Page 77: ...gine A The fault is indicated together with the Error mes sage light 45 has no function 46 Battery charge indi cator red Must go out after starting when the engine revs up Switch off the engine 47 Not...

Page 78: ...2 3 Remote control A With the help of the two remote controls on the RH and LH sides of the screed the functions available on the specific side of the paver finisher can be controlled 58 56 Remote_kon...

Page 79: ...to the function of the switch 17 on the control panel The switch must be set to auto 59 Auger Its function and use are similar to the function of the switch 25 on the control panel The switch must be...

Page 80: ...tomatic system Connect the cable for the grade control unit here 67 Connection to the end position switch of the auger Connect the cable for the material limit switch here 68 Cable for the remote cont...

Page 81: ...the paver finisher externally see section Starting the paver finisher External starting starting aid Battery main switch 72 The main switch interrupting the circuit between the battery and the main fu...

Page 82: ...the transport safe guards for the hopper must be inserted Item a outside on the two half hoppers or b in the feeding hopper o f Do not enter the hopper while the engine is running Danger of being caug...

Page 83: ...ment zero Screed lock only for transportation Use the interlocking of the main girder for transportation only Do not enter or work under screed only secured with screed lock for transportation Danger...

Page 84: ...ery will be discharged Switch off after use A A permanent installed hose guide D for the fluid spraying system is available as an option Pull hose out of the guide till there is an audible creak The h...

Page 85: ...losed spaces Danger to health Have a fire extinguisher ready On off switch special lighting 85b If the machine is equipped with addition al headlights these are actuated by means of the switch a When...

Page 86: ...t is mounted on the paver finisher 230 V On Off switch Connection sockets 85f In case of being equipped with 230 V ac cessories the connection sockets can be powered through switches a In the switch p...

Page 87: ...crushing Ensure that nobody inserts their fingers or hands into the joint areas or are placed at risk by the lowering roof during the folding proce dure In order to raise the roof again turn the key...

Page 88: ...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 adjusta...

Page 89: ...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 A This...

Page 90: ...modify angle height of the sensor The cables must be connected to the re mote control units located at the sides of the screed socket 62 A We recommend to adjust the limit switch positions while the...

Page 91: ...at form It is used to adjust the pressure for screed stop with pretensioning Activation see screed charging re lieving device 34 Pressure display see pressure gauge 93b Pressure gauge for screed charg...

Page 92: ...al mix Manual start of lubrication pumping time Remove the cover lid a Keep the starting button b depressed for at least 2 sec Replace the cover lid a A Observe the instructions of chapter Maintenance...

Page 93: ...ee chapter Maintenance for cleaning the particle filter Indicator colour Operating condition Cause action yellow No counterpressure No counterpressure Check the tightness of the system green Within th...

Page 94: ...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 Additional functions If necessary turn on the windscreen wipers on the RH...

Page 95: ...en lock nuts B for eccentric adjustment Swivel screed into desired position using lever C then engage the locking knob once again A If the levelling unit is connected to a height controller this has t...

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Page 97: ...parts Diesel fuel Engine oil and hydraulic oil lubricants Separating agents emulsion and manual injector Two filled propane gas bottles Shovel and broom Scraper spatula for cleaning the auger and the...

Page 98: ...ives must stop immediately Steering The paver finisher must immediately fol low every steering wheel movement in a precise manner Check straight running Horn on the operating panel on both remote cont...

Page 99: ...uard When the screed is lifted it must be possible to push the locking rods side ways into the recesses in the cross beams using the lever beneath the seat Hopper transport safeguard When the hopper i...

Page 100: ...er 1 to the center posi tion and the speed adjuster 2 to mini mum Insert the ignition key 3 in position 0 The lights should be switched off during starting to reduce the current drain on the battery A...

Page 101: ...cannot be used for external starting To externally start the engine Set the drive lever 1 to mid position and the speed regulator 2 to mini mum Insert ignition switch 3 to position 0 to turn on the ig...

Page 102: ...rge indicator 1 Must go out after starting when the en gine revs up m Briefly rev up the engine when the lamp does not go out or lights up during oper ation Switch off the engine and determine the cau...

Page 103: ...lator 5 to medium RPM and move the drive lever 6 un til the conveyor belt and the auger start operating Let the hydraulics warm up until the in dicator lamp goes out A The lamp goes out when the press...

Page 104: ...r Switch on the screed heater ca 15 30 minutes depending on the ambient tempera ture before paving begins Warming up prevents the material from sticking to the screed plates Direction marks To ensure...

Page 105: ...auger and the switch 3 of the feeder to auto posi tion Set the appropriate auger switch on the remote control and conveyor switch if applicable to auto position Set the engine speed regulator 4 to di...

Page 106: ...st 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 pr...

Page 107: ...D 4 6 11 D_4 6_01_GB fm 11 38 1 3 Starting for paving Element2_konv_Kette_635 bmp Element1_konv_Kette_635 bmp Tamprev cdr Vibrev cdr Remote_konv_neu1 bmp 3 14 2 1 9 8 6 7 5 4 12 13 B A...

Page 108: ...he check in the area of the drive chains or wheels as the screed tends to level an uneven ground The reference points for the layer thickness are the drive chains or wheels The basic setting of the sc...

Page 109: ...the way Uniform material transport and distribution or supply to the screed may require cor rections to settings of the material switches for conveyor and auger A See the section Malfunctions when pa...

Page 110: ...tain optimum paving re sults Screed stop with and without pretensioning with the paver finisher halted Screed charging or relieving with the paver finisher driving A Relieving reduces the screed weigh...

Page 111: ...ng 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 tem porary stop occurs Using the switch 2 the fo...

Page 112: ...the first stops until the lower edge of the screed no longer leaves any marks when the paver finisher moves on again A pressure greater than 10 15 bar neutralizes the screed weight thus preventing the...

Page 113: ...rade and or slope transducer the compacting perform ance will be modified layer thickness A Pressure can be adjusted and corrected during paving max 50 bar Screed control pressure with the pav er fini...

Page 114: ...ke the end of a layer Set the drive lever 1 to the center po sition During extended interruptions e g lunch break Drive lever 1 into centre position RPM speed adjustment 2 to mini mum position Switch...

Page 115: ...pers at a low speed let any material residues drop out Set the drive lever 5 to the center po sition and the speed adjuster 6 to minimum Switch off the ignition Switch off screed heater system When sc...

Page 116: ...need this length of time to back up data Read and check the operating hour meter 8 to determine whether main tenance work must be performed see chapter F Cover and lock the operating panel Remove mate...

Page 117: ...sage can be queried from the ma chine using the diagnostic button 2 which represents a specific fault The flashing code is also displayed by the control light 1 Display of the number code Set the diag...

Page 118: ...sition 0 the warning light which indicated the fault will come on again will flash or will be lit up continuously This will be as long as the fault or problem is eliminated A In order to check if no s...

Page 119: ...2 2 3 Diagnostics according to the error message list Charging air pressure Faulty sen sor input e g short circuit or broken cable t 800ms t 400ms BREAK t 2000ms t 400ms t 400ms t 800ms t 800ms t 400...

Page 120: ...D 4 6 24 D_4 6_01_GB fm 24 38 2 2 Error messages...

Page 121: ...D 4 6 25 D_4 6_01_GB fm 25 38...

Page 122: ...D 4 6 26 D_4 6_01_GB fm 26 38...

Page 123: ...D 4 6 27 D_4 6_01_GB fm 27 38...

Page 124: ...D 4 6 28 D_4 6_01_GB fm 28 38...

Page 125: ...D 4 6 29 D_4 6_01_GB fm 29 38 2 3 FMI codes...

Page 126: ...ng roller has stopped on the hot material roller has turned or roller speed has been changed too fast incorrect operation of the roller incorrectly prepared foundation truck brake is applied too tight...

Page 127: ...alled cold screed bottom plates are worn or warped screed does not work in the floating position paver finisher speed is too high auger is overloaded changing material pressure against the screed Mark...

Page 128: ...eyor or augers run too slowly Hydraulic oil level in the tank is too low Top up the oil Power supply is interrupted Check fuses and cables replace if necessary Switch is defective Replace the switch O...

Page 129: ...ower supply is interrupted Check fuse and cables replace if necessary Crossbeams cannot be lifted or lowered Switch on the remote con trol is set to auto Set the switch to manual Power supply is inter...

Page 130: ...ace the servo unit Insufficient supply pressure Check and adjust if necessary Check the suction filter replace the supply pump and the filter if necessary Drive shaft of hydraulic pumps or engines bro...

Page 131: ...drive pump servo valves have to be replaced by the plugs of the emergency device short screw driver is necessary The cable shoe is connected to power supply of 24 Volts and the cable eye is con necte...

Page 132: ...ch 2 to the recommended direction and engage the forward reverse le ver to forward direction If the recommended direction is reverse push switch in reverse but still the forward reverse lever should b...

Page 133: ...D 4 6 37 D_4 6_01_GB fm 37 38 24 V Ground Black Gray Wiring harness for drive pump of left caterpillar drive marked YELLOW Steering unit...

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Page 135: ...e battery main switch Secure lifted machine parts e g screed or hopper against lowering by means of mechanical supports Replace parts or have them replaced as stipulated f When connecting or disconnec...

Page 136: ...ixing and traction problems may occur Auger too low Not enough material that can be precompacted by the auger Irregularities resulting from this cannot be completely compensated for by the screed wavy...

Page 137: ...rning clockwise lifts the auger Set the desired height by alternatingly adjusting the right hand and the left hand side The actual height can be read on scale 1 in cm or inch LH side column inch RH si...

Page 138: ...e auger beam does not get into inclined position Check whether the heights on the left and on the right are identical A The height indicating scales 3 may be optionally also along the climbing rungs o...

Page 139: ...cation especially Screed extension chart Auger 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 F...

Page 140: ...the drive of the auger gear is slid all the way over the shaft end of the auger extension part and that the threads of the augers match Remove the expansion screw 5 Then tighten the clamping screws 6...

Page 141: ...urs by tightening the screwed connections 9 linking the support tube extension If the working width exceeds 7 50 m the hydraulic hoses 10 for the auger mo tors must be replaced with longer ones These...

Page 142: ...or more combined tun nel plates 13 must be used In this case additional stabilizing sup ports 12 must be attached to the tele scopic tube The tunnel plates must be directly screwed to the receptacles...

Page 143: ...e augers must be provided with an additional support 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 fi...

Page 144: ...E 01 10 E_01_GB fm 10 18 2 10 Auger mounting chart for 310 mm auger from working width of 6 75 m the machine can be operated only with appropriate braces screed auger material pipeline...

Page 145: ...E 01 11 E_01_GB fm 11 18 2 11 Auger mounting chart for 380 mm auger from working width of 6 75 m the machine can be operated only with appropriate braces screed auger material pipeline...

Page 146: ...E 01 12 E_01_GB fm 12 18 3 Auger extension auger type II Auger_DEM bmp...

Page 147: ...E 01 13 E_01_GB fm 13 18 3 1 Mounting extension parts Sch_ver1 tif Sch_ver2 tif 16 5 9 10 8 7 6 14 15 12 11 12 5...

Page 148: ...ing bolts 13 washers 14 and nuts 15 for the extension of the auger and simultaneously bolt the auger shafts firmly together A If the application conditions on the job site allow or demand auger extens...

Page 149: ...3 2 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 96...

Page 150: ...Mountable parts bearing Mountable parts bearing 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 6 3 m 6 0 m 6 9 m 6 0 m 6 9 m 6 7 m 7 6 m 6 7 m 7 6 m 7 3 m 8...

Page 151: ...Establish the following connections when the mechanical components have been mounted and set up 5 1 Remote controls to socket 15 on the screed 5 2 Grade control to socket 16 on the remote control uni...

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Page 153: ...ng to the specifica tions If in doubt contact the manufacturer f Re commissioning Mount all protective devices before re commissioning the paver finisher f Cleaning Cleaning must not be carried out wh...

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Page 155: ...F_2 3_01_GB fm 1 2 F 2 3 1 F 2 3 Maintenance overview 1 Maintenance review 7 2 4 1 3 5 1 6 8 9 10...

Page 156: ...intenance required after the following service hours 10 50 100 250 500 1000 year 2000 2 years 5000 20000 as required Feeder F3 q q q q Auger F4 1 q q q q q Drive engine F5 1 q q q q q q Hydraulics F6...

Page 157: ...F 3 0 1 F_3 0_01_GB fm 1 4 F 3 0 Maintenance Conveyor 1 Maintenance Conveyor...

Page 158: ...ear 2000 2 years as required 1 q Checking the tightness of the conveyor chain q Adjustment of the tightness of the conveyor chain 2 q Checking the oil level of the conveyor drive q Topping up the oil...

Page 159: ...of the floor plate until the lower edge of the chain see the figure m The chains should not be too tight or too slack Material between the chains and the sprocket wheel can lead to stoppage or breakag...

Page 160: ...hrough fill in stub C A On the dipstick about 10 cm corre sponds to about 0 25 l oil to be added The drive of the conveyor is filled in the factory with Optimol Optigear 220 oil Owing to the excellent...

Page 161: ...F 4 1 1 F_4 1_01_GB fm 1 8 F 4 1 Maintenance Auger 1 Maintenance auger sub unit...

Page 162: ...Lubrication 2 q Auger planetary gear oil level check q Auger planetary gear topping up the oil q Auger planetary gear oil change 3 q Auger drive chain checking of tightness q Auger drive chain adjustm...

Page 163: ...A In case of auger extension slightly un tighten the outer rings for the first lubri cation of the outer bearings ensuring better venting Following the lubrication the outer rings shall be retightened...

Page 164: ...rature Unscrew filling plug B and the drain plug C Drain the oil Drive in the oil drain plug C again Remove the inspection plug A Fill oil of the correct specification through the filling hole B until...

Page 165: ...ease locking bolts A Adjust the proper chain tightness with the threaded pins B Tighten the threaded pins to 20 Nm using a torque wrench Thereafter ease back the threaded pins by one full turn Retight...

Page 166: ...F 4 1 6 F_4 1_01_GB fm 6 8 Auger case 4 Checking the oil level A In case of correct oil level the oil is be tween the two notches of the dipstick A...

Page 167: ...ature Place a suitable dish under the auger cases to catch the oil Untighten bolts D on the perimeter of the auger shaft flange A The oil flows out between the flange and the auger housing Fully drain...

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Page 169: ...1 Maintenance engine sub unit m 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 t...

Page 170: ...and device 2 q Engine lube oil system oil level check q Engine lube oil system topping up the oil q Engine lube oil system oil change q Engine lube oil system oil filter change 3 q Engine fuel system...

Page 171: ...stem of the engine Cleaning of the radiator fins q Cooling system of the engine Check the level of the coolant q Cooling system of the engine topping up the coolant q Cooling system of the engine chan...

Page 172: ...way the time consuming venting bleeding can be avoided For filling in the fuel Unscrew cap A under the tank cov er Fill in fuel through the filling port until the required filling is achieved Replace...

Page 173: ...ve cap B Fill in oil until the correct level is achieved Return cap B Check the oil level once again using the dipstick Oil change A Change the oil when the engine is at op erating temperature Remove...

Page 174: ...ined 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 Tighten the filter by hand A After mounting...

Page 175: ...r Drain the separated water at the tap C collect it and close the tap again Pull down the connection of the water detector D Untighten the filter cartridge A with the collection sump using a pair of o...

Page 176: ...mount of the manual fuel pump F by pressing and twisting counter clockwise at the same time The pump piston now can be displaced by a spring Until strong resistance is felt and the pump moves already...

Page 177: ...field C is fully visible when the engine is stopped When the engine electronic unit indi cates service need Open the air filter lid Withdraw the filter cartridge C and the safety cartridge D A Clean...

Page 178: ...e system is under pressure When opening there is a danger of scalding If necessary fill in sufficient amount of coolant through the open port A of the compensating tank Changing the coolant A See oper...

Page 179: ...r to the filter edge than 10 cm Carefully blow out all the filter passag es Turn around the filter element and re peat the process on the other side as well Repeat the process until no more carbon res...

Page 180: ......

Page 181: ...F 6 0 1 F_6 0_01_GB fm 1 8 F 6 0 Maintenance Hydraulic system 1 Maintenance hydraulic system...

Page 182: ...ydraulic oil tank Checking of maintenance indica tor q q Hydraulic oil tank Intake return change of hydraulic filter venting 3 q High pressure filter Checking of maintenance indica tor q High pressure...

Page 183: ...arly clean the vent port of the oil tank from dust and pollution Clean the surfaces of the oil cooler m Use only the recommended hydraulic oils see section Recommended hy draulic oils For changing the...

Page 184: ...tor O at the operating position m When changing the hydraulic oil also change the filter Remove the lid fastening screws B and remove the lid Disassemble the withdrawn unit into the following parts li...

Page 185: ...into the housing and tighten the locking screws of the lid B Open the vent screw H Mount a transparent hose l on the vent screw and lead it into an appropriate con tainer Start the traction engine at...

Page 186: ...he new filter cartidge Replace the seal ring of the filter hous ing Turn on the filter housing by hand and tighten it using a wrench Start the trial operation and check the tightness of the filter A R...

Page 187: ...rew plug B m Take care of cleanliness Oil change Change the oil when the engine is at op erating temperature Remove the cover cap of the oil drain port C and screw on the hose provid ed as an accessor...

Page 188: ...red hos es f The aged hoses may become porous and burst Risk of accident A The numbers stamped in the joints of the hoses state the date of manufacture A and the maximum pressure B allowed for that ho...

Page 189: ...F 7 2 1 F_7 2_01_GB fm 1 4 F 7 2 Maintenance Running gear 1 Maintenance running gear 635_ISO_Dyn bmp LW_DEM_inter bmp 43...

Page 190: ...maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 q Track tightness checking q Track tightness setting 2 q Planetary gear oil level check q Planetary gear topping up the oil q...

Page 191: ...slack F of 2 3 cm must be present This applies in linear fashion if the free length L is less than or equal to 1 1 5 m at least 4 track links The extent of slack in the track is estab lished using a...

Page 192: ...reaches the lower edge of the fill ing hole Replace the cap A Oil change A Change the oil when the engine is at op erating temperature m Make sure that no pollution or foreign matter gets into the dr...

Page 193: ...F 8 1 1 F_8 1_01_GB fm 1 20 F 8 1 Maintenance Electronic System 1 Maintenance Electronic System...

Page 194: ...o Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 q Check the level of battery electrolyte q Top up with ion exchanged water q Coat the battery poles with...

Page 195: ...ion or damage Check the cooling air openings for pollution or clogging clean as required o q Generator Check the ball bearings by lis tening and replace them as re quired o q q Generator Replacement o...

Page 196: ...F 8 1 4 F_8 1_01_GB fm 4 20 No Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 3 q Electric fuses Maintenance q Maintenance during run in period g...

Page 197: ...me 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 p...

Page 198: ...eady before pressing the control button then work cannot pro ceed with the electrical system and the external consumers In case of insula tion fault the connection sockets are au tomatically turned of...

Page 199: ...F_8 1_01_GB fm 7 20 Checking of ball bearings Replace ment of ball bearings A Report the displayed fault code to the customer service of the paver finisher and they will discuss with you the steps to...

Page 200: ...screw A that the bracket B of the tightening roller comes to position zero scale C 0 For the adjustment of the locking de vice loosen or turn the appropriate nut D or counter nut E until the tight en...

Page 201: ...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 A Pre tension newly fitted belt using clamping lock B Checking a...

Page 202: ...28KVA Deflection force min 92 2N Deflection force max 100 5N A Belt deflection approx 5 4mm If necessary adjust the belt tension Set belt to correct tension using clamping lock B Retighten both lock n...

Page 203: ...20 Electric fuses 3 Type of machine Conventional electronics Switch box Main fuses A A Main fuses B Fuses in the switching cabinet C Relays in the switching cabinet F A 3 1 Main fuses 50 3 2 Reserve 5...

Page 204: ...witch buttons 10 5 7 Connection sockets with On Off switch buttons 10 5 8 Connection sockets with On Off switch buttons 10 5 9 Starting the engine 10 41 Engine regulation 25 44 Machine drive 1 51 Spra...

Page 205: ...arting the engine 18 2 Retracting the screed on the right hand side 18 1 Retracting the screed on the right hand side 94 Power supply terminal 15 145 Engine regulation 88 Complementary emergency stop...

Page 206: ...3 7 1 7 Hopper screed lift and lowering screed retraction ex tension screed power supply re compression lift o cabin movement o auger lifting lowering o 10 8 1 8 Emergency stopping 7 5 No F A 1 2 1 f...

Page 207: ...20 Relays on the operating panel Relays A K 31 Emergency stopping VB805 1105 EB50 75 17 Screed functions 12 Conveyor LH side auger 13 Conveyor RH side auger 33 Engine regulation 81 free 82 free Bedien...

Page 208: ..._01_GB fm 16 20 Type of machine PLC electronics Switch box Main fuses A A Main fuses B Fuses in the switching cabinet C Relays in the switching cabinet F A 3 1 Main fuses 50 3 2 Reserve 50 Fuses_635_k...

Page 209: ...Gas heating 10 5 5 Connection sockets with On Off switch buttons 10 5 6 Connection sockets with On Off switch buttons 10 5 7 Connection sockets with On Off switch buttons 10 5 8 Connection sockets wit...

Page 210: ...Emulsion spray appliance 3 53 Diesel fuel pump 5 54 Flasher 3 55 Headlight glass fibre reinforced roof 10 59 Working floodlights o 15 80 Power supply Master A1 7 5 82 Particle filter o 3 83 Exhaust e...

Page 211: ..._8 1_01_GB fm 19 20 Relays in the switching cabinet C K 15 Starting the engine 94 Power supply terminal 15 145 Engine regulation 49 Reversing sound alert 47 Starter button interlocking 42 Machine driv...

Page 212: ...7 Screed power supply cabin movement o 5 8 1 8 free 7 5 No F A 1 2 1 free 2 2 2 Horn reversing alert 3 3 2 3 Windscreen wiper o road profile adjustment 7 5 4 2 4 Headlights on the left right sides 7 5...

Page 213: ...ormation related to the lubrication points of the various sub units are included in the specific maintenance descriptions and additional reading is recommended as follows A In case of applying a centr...

Page 214: ...0 year 2000 2 years as required 1 q Check the filling level of the lubri cant tank o q Fill up the lubricant tank o q Vent the central lubrication unit o q Check the pressure limiting valve o q Check...

Page 215: ...ries as the equipment operates under high pres sure f Make sure that the starting of the diesel engine should be prohibited while work is per formed on the equipment f Observe the rules applicable to...

Page 216: ...Always keep the filling level above the MIN mark of the tank a Fill up the lubricant tank A grease nipple b is mounted for filling on the lubricant tank a Connect the grease gun c supplied with the ma...

Page 217: ...ck the tightness of all the connections and lines Check the pressure limiting valve m If lubricant is discharged at the pressure limiting valve a this refers to failure in the system The consumers rec...

Page 218: ...n pipe a and fit a standard grease nipple b Connect the grease gun c supplied with the machine to the grease nip ple b Keep on operating the grease gun until lubricant is visibly discharged If necessa...

Page 219: ...F 9 0 7 F_9 0_01_GB fm 7 8 Bearings 2 There are grease nipples on the bearing points of the hydraulic cylinder one each at the top and bottom a Zylinder bmp 2x a...

Page 220: ......

Page 221: ...F 10 0 1 F_10 0_01_GB fm 1 6 F 10 0 Checks decommissioning 1 Tests check up cleaning stopping...

Page 222: ...rvals No Interval Points of maintenance Remark 10 50 100 250 500 1000 year 2000 2 years as required 1 q General observation 2 q q Checks by a specialist 3 q Cleaning 4 q Conservation of paver finisher...

Page 223: ...locking points secure conveyor auger screed m Repair the detected faults immediately in order to avoid risks of accidents and envi ronmental pollution 3 Checks by a specialist A Subject the paver fini...

Page 224: ...the bearings with grease as spec ified Clean the machine with water after laying mineral mixes lean concrete etc m Do not spray water on the bearings electric or electronic parts Remove the residue of...

Page 225: ...smounted batteries every 2nd month Protect all shiny metal surfaces e g piston rods of the hydraulic cylinder against corrosion using an appropriate agent If the machine cannot be halted in a closed h...

Page 226: ......

Page 227: ...oil Refer to operating instructions for the engine The machine is filled with Shell Rimula Super FE 10 W 40 in the factory hydraulic oil See see chapter 1 1 The machine is filled with Shell Tellus Oi...

Page 228: ...ally decomposing pressure liquid please contact our advisory service in the factory A Use only such vessels for filling in oil or fuel which are clean both outside and inside Manufacturer ISO category...

Page 229: ...ng to the oil types applied In case of crawler driven pavers only A Filled in the factory with the fuel indicated Caterpillar drive planetary gear Shell Tivela 220 Transmission oil 220 synthetic oil O...

Page 230: ...raulic oil tank hydraulic oil 175 liters Pump distribution gear Transmission oil 90 4 5 liters Planetary gear Caterpillar drive Transmission oil 220 4 0 liters Drive of the conveyor each side Transmis...

Page 231: ...D 2013 L04 2V Fuel Volume Diesel engine with oil filter change Engine oil 10W40 20 0 liters Cooling system of the engine Coolant 20 0 liters Fuel Volume Diesel engine with oil filter change Engine oil...

Page 232: ...C220 Operating substance Volume Diesel engine with oil filter change Engine oil 10W40 21 5 liters Cooling system of the engine Coolant 20 0 Operating substance Volume Diesel engine with oil filter cha...

Page 233: ...Volume Auger bevel gear each side Transmission oil 90 0 6 liters Fuel Volume Planetary gear auger each side Transmission oil 90 0 5 liters Auger drive case Transmission oil 460 2 5 liters Auger outer...

Page 234: ...etary gear m Mixing synthetic oils with mineral oils is strictly forbidden Completely drain the used oil A Change the oil when the engine is at op erating temperature Rinse the subunit with the new ty...

Page 235: ...OPERATING ADVICE Anytime when our dealers cannot help you please feel free to contact us directly The team of our Technical Advisors is at your disposal TRAINING EDU CATION We offer our Customers vari...

Page 236: ...Don t hesitate to contact your local dealer for service spare parts documentation accessories and information about the complete Dynapac paving and planing range...