Dynapac F1200C, Operation & Maintenance Manual

Page 1: ...MAINTENANCE Paver Finisher Dynapac F1200C F1200CS Typ 456 457 Keep for later use in document compartment 4812023636 A5 02 0416 Valid for _________________ _________________ _________________ ________...

Page 2: ...www dynapac com...

Page 3: ...e and application 1 B Vehicle description 1 1 Application 1 2 Description of assemblies and functions 2 2 1 Vehicle 3 Construction 3 3 Danger zones 6 4 Safety devices 7 5 Technical data standard confi...

Page 4: ...EMC 27 C10 12 Transportation 1 1 Safety regulations for transportation 1 2 Transportation on low bed trailers 2 2 1 Preparations 2 3 Securing the load 4 3 1 Prepare the low bed trailer 4 3 2 Driving...

Page 5: ...LED working light o 9 Auger height adjustment ratchet o 10 Auger height displays 10 Sensor rod sensor rod extension 11 Manual separator fluid spray o 13 Separator fluid spraying system o 14 Conveyor l...

Page 6: ...ems during paving 28 1 8 Malfunctions on the paver finisher or screed 30 E10 12 Set up and modification 1 1 Special safety instructions 1 2 Distribution auger 3 2 1 Height adjustment 3 2 2 Auger width...

Page 7: ...nance engine assembly 1 1 Maintenance engine assembly 1 1 1 Maintenance intervals 3 1 2 Maintenance points 6 Engine fuel tank 1 6 Engine lube oil system 2 7 Engine fuel system 3 9 Engine air filter 4...

Page 8: ...e intervals 3 1 2 Maintenance points 4 Batteries 1 4 Recharging the batteries 5 Alternator 2 6 Insulation faults 8 Cleaning the alternator 9 2 Electrical fuses 10 2 1 Main fuses 1 10 2 2 Fuses in main...

Page 9: ...he hopper 5 5 2 Cleaning the conveyor and auger 5 6 Preserving the paver finisher 6 6 1 Shutdowns for up to 6 months 6 6 2 Shutdowns lasting from 6 months to 1 year 6 6 3 Recommissioning the machine 6...

Page 10: ...8...

Page 11: ...xample Page B 2 is the second page of chapter B These operating instructions cover various vehicle options Make sure that during op eration and maintenance work the description appropriate to the vehi...

Page 12: ...sible for compliance with the resulting regulations and measures A The following warnings prohibitive symbols and instructive symbols indicate dangers for persons the vehicle and the environment due t...

Page 13: ...esult in fatal or se vere injuries unless the corresponding actions are taken Caution Indication of a possible danger that result in moderate or mi nor injuries unless the corresponding actions are ta...

Page 14: ...tched off Warning on dangerous electrical voltage m All maintenance and repair work on the screed s electrical system must always be carried out by an electrician Warning on suspended loads m Never st...

Page 15: ...V 5 Warning on danger of falling Warning on dangers posed by batteries Warning on hazardous or irritating substances Warning on substances which constitute a fire hazard Warning on gas bottles...

Page 16: ...tart engine drive Maintenance and repair work may only be carried out with the diesel engine shut down Spraying with water is prohibited Extinguishing with water is prohibited Unauthorised maintenance...

Page 17: ...ggles to protect your eyes Wear suitable head protection Wear suitable hearing protection to protect your hearing Wear suitable safety gloves to protect your hands Wear safety shoes to protect your fe...

Page 18: ...Hydraulic oil Diesel fuel Coolant Cleaning liquids must not get into the soil or sewer system during cleaning maintenance and repair work Substances must be caught stored transported and brought to pr...

Page 19: ...c umentation A For example the maintenance instructions of the engine manufac turer m Description depiction applicable when equipped with gas heater m Description depiction applicable when equipped wi...

Page 20: ...cified in the valid regulations and amend ments together with harmonised standards and other valid provisions 3 Guarantee conditions A The guarantee conditions are included in the scope of supply of t...

Page 21: ...ting range of the machine caused by wrong or improper use of the machine defective or missing safety devices use of the machine by untrained uninstructed staff defective or damaged parts incorrect tra...

Page 22: ...he machine includes presence in the danger zone of the machine transporting persons leaving the operator s platform while the machine is operating removing protection or safety devices starting and us...

Page 23: ...e meaning of these 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 or renting the...

Page 24: ...A 2...

Page 25: ...ication The Dynapac F1200C CS paver finisher is a paver finisher with a caterpillar drive which is used for laying bituminous mixed material roll down or lean mixed concrete and unbound mineral aggreg...

Page 26: ...on indicator holder 4 t Caterpillar drive 5 t Levelling cylinder for paving thickness 6 t Paving thickness indicator 7 t Crossbeam 8 t Travel drive of the caterpillar drive 9 t Conveyor 10 t Auger 11...

Page 27: ...trols The following extra equipment option is available o Hydraulic front hopper flap o Material chute hinged material chute o Remote control o Additional headlights warning lamps o Emulsion spraying...

Page 28: ...hopper can be swivelled up together to reduce the transport width Material compartment hopper The hopper inlet is equipped with a conveyor sys tem that empties the hopper and transfers the material to...

Page 29: ...ystem always operates in conjunction with the levelling cylinders on the opposite side By adjusting the height of the traction point of the crossbeam the paving thickness of the material or the laying...

Page 30: ...nd the screed personnel are allowed on the vehicle or in the danger zone The vehicle operator and screed personnel must keep to the respective driver s seats Make sure that there is no one in the dang...

Page 31: ...B 7 4 Safety devices 4 5 6 7 8 8 2 1 9 3 10...

Page 32: ...Check the function of these devices at regular intervals A Functional descriptions for the individual safety facilities can be found in the following chapters Item Designation 1 Hopper transport safeg...

Page 33: ...B 9 5 Technical data standard configuration 5 1 Dimensions all dimensions in mm 4360 1390 3880 1900 1310 2830 1200 940 205 3850...

Page 34: ...B 10 5 2 Permissible approach angle max 15 max 10...

Page 35: ...hts of the screed and the screed attachments see the operating instruc tions for the screed Paver finisher without screed approx 4 85 Paver finisher with screed V240V V240V E approx 5 8 approx 5 8 Wit...

Page 36: ...0 3 10 m Transport speed 0 3 3 km h Operating speed 0 27 m min Paving thickness 150 200 mm Theoretical paving performance 300 t h Screed used Basic width without cut off shoes Minimum paving width wit...

Page 37: ...load Fuel consumption 2 3 load 14 l h 9 3 l h Fuel tank capacity See chapter F Make type Deutz TD 2 9 L4 Version 4 cylinder diesel engine Performance 49 KW 66 PS at 2200 rpm Fuel consumption full loa...

Page 38: ...620 mm Conveyor operation Automatic by means of mechanical limit switches Augers 320 mm Drive Left and right auger separately controllable Hydrostatic central drive continuously controllable Conveying...

Page 39: ...of injuries Never remove any warnings or information signs from the vehicle Damaged or lost warning or information signs must be replaced immediately Make yourself familiar with the meaning and posit...

Page 40: ...B 16 8 6 3 5 7 41 24 14 10 20 15 19 3 6 8 14 18 17 16 21 13 11 23 22 41 5 4 14 12 60 1 40 2 42 o...

Page 41: ...B 17 xxxxxxxxxxxxxxxxx 32 30 31...

Page 42: ...ve the ignition key before per forming any maintenance and repair work If the drive engine is left running or func tions are switched on this can cause se vere or fatal injuries Switch the engine off...

Page 43: ...aution Danger from incorrect towing Movements of the machine can cause severe or fatal injuries The traction system brakes must be re leased before towing Always observe the operating instruc tions 8...

Page 44: ...ing point 11 Diesel fuel sulphur level 15 ppm Position of the filling point specification 12 Lifting point Lifting the machine is only permitted at these lifting points 13 Main battery switch Position...

Page 45: ...tion of the drainage point 18 Gear oil drainage point Position of the drainage point 19 Gearbox oil Position of the filling and control point 20 Hydraulic oil drainage point Position of the drainage p...

Page 46: ...3 CE marking No Pictogram Meaning 23 Vibration speed adjuster Position of the speed adjuster 24 Auger and conveyor speed adjuster Position of the speed adjuster No Pictogram Meaning 30 CE sound output...

Page 47: ...tions No Pictogram Meaning 40 Wear ear protection devices 41 Warning on dangers posed by batteries 42 Do not spray the area or part with water No Pictogram Meaning 60 Engine start All switches in neut...

Page 48: ...ignation 1 Paver finisher type 2 Year of construction 3 Operating weight incl all extension parts in kg 4 Maximum permitted total weight in kg 5 Max permissible load on the front axle in kg o 6 Max pe...

Page 49: ...B 25 6 7 Explanation of 17PIN serial number A Manufacturer B Family Model C Check letter F Serial number 10002014JHG002076 A B C F...

Page 50: ...or s position at the height of the head LAF 83 6 dB A Sound capacity level LWA 104 0 dB A Sound pressure level at the vehicle 7 2 Operating conditions during measurement The diesel engine ran at maxim...

Page 51: ...of the EMC Directive 2004 108 EC Interference emission according to DIN EN 13309 35 dB V m for frequencies of 30 MHz 1GHz measured at a distance of 10 m 45 db V m for frequencies of 30 MHz 1 GHz meas...

Page 52: ...B 28...

Page 53: ...rmany gas bottles must not be transported on the paver finisher or on the screed Disconnect the gas bottles from the gas system and protect them with their caps Use a separate vehicle to transport the...

Page 54: ...isher must be taken into consideration when selecting the attachment and loading equipment 2 1 Preparations Prepare the paver finisher for transportation see chapter D Remove all overlaying or loose p...

Page 55: ...se the hopper lids Insert hopper transport safeguard Lift the screed Insert screed transport safeguard Extend levelling cylinders completely Retract the screed parts until the screed matches the basic...

Page 56: ...e for securing loads positive fit force connection diagonal lashing etc in accordance with the specific transport ve hicle m The low bed trailer must have the necessary number of lashing points with l...

Page 57: ...C 10 12 5 3 2 Driving onto the low bed trailer f Make sure that there are no persons in the danger area during loading Use the work gear and low engine speeds to drive onto the low bed trailer...

Page 58: ...g equipment m Always comply with the stated values for permitted lashing force and load rating m Always tighten the lashing chains and straps handtight 100 150daN m Lashing equipment must be checked b...

Page 59: ...oading In some vehicles the kingpin load is too low so that the load has to be positioned fur ther to the back of the vehicle A Always heed the details regarding load distribution stipulated for the v...

Page 60: ...ollowing prepara tions must be carried out Close hopper set hopper transport safeguards 1 Position the non slip mats under the screed across the whole width of the vehicle 2 and lower the screed Switc...

Page 61: ...t the front m Diagonal lashing secures the paver finisher at the front using the lashing points on the paver finisher and on the low load trailer Fasten the lashing chains as shown m The lashing angle...

Page 62: ...2 Securing at the rear screed with side board m Diagonal lashing secures the paver finisher at the rear using the lashing points on the paver finisher and on the low load trailer Fasten the lashing ch...

Page 63: ...ed to the transportation position Start the engine and drive from the trailer at a low engine traction speed Park the paver finisher in a secure spot lower the screed and switch off the engine Remove...

Page 64: ...ing or loose parts from finisher and screed see also Screed op erating instructions Store these parts in a safe place f When the screed is operated with the optional gas heat ing system Remove the gas...

Page 65: ...ose the hopper lids Insert hopper transport safeguard Lift the screed Insert screed transport safeguard Extend levelling cylinders completely Retract the screed parts until the screed matches the basi...

Page 66: ...ety switch A The safety switch must always be pressed when the drive lever is moved out of the neutral position Otherwise the travel drive is blocked Swivel the drive lever to maximum f The vehicle al...

Page 67: ...ty is dependent on the screed which is mounted Danger from suspended loads Crane and or lifted vehicle can tip when lifted and cause injuries The vehicle may only be raised at the marked lifting point...

Page 68: ...ny attachments and extension parts from the paver finisher and the screed until the basic width has been attained Take off all protruding or loose parts and the gas bottles of the screed heater see ch...

Page 69: ...ompartment left side it must be actuated to be able to tow the machine Pressure for releasing the traction system brakes is built up with the hand pump Release lock nut 2 screw threaded dowel 3 into p...

Page 70: ...hten the lock nut 7 to a torque of 22 Nm m On completion of the towing process re store the initial status Attach the tow bar to the coupling 9 located in the bumper A Now carefully and slowly tow the...

Page 71: ...e secured in such a way that unauthorised persons or playing children cannot dam age the vehicle Pull off the ignition key and the main switch 1 and take it with you do not hide them somewhere on the...

Page 72: ...ace for the hydraulic lift f Make sure that the hydraulic lift is securely and correctly positioned f The hydraulic lift is only intended to lift a load and not as a support Work should only be perfor...

Page 73: ...ehicle while it is being lifted f All raising and lowering work must be carried out uniformly with all hydraulic lifts in use Always check and observe horizontal alignment of the load f Always carry o...

Page 74: ...C 10 12 22...

Page 75: ...nning Danger to life Always make sure during work that no one is endangered by the vehicle Ensure that all protective covers and hoods are fitted and secured accordingly Immediately rectify damage whi...

Page 76: ...by rotating or conveying vehi cle parts Rotating or conveying vehicle parts can cause severe or fatal injuries Do not enter the danger zone Do not reach into rotating or conveying parts Only wear clo...

Page 77: ...ons that can pose a hazard when the diesel engine starts up turning to the side conveying function of auger and conveyor prevent the engine from starting start inhibit when switched on or when set to...

Page 78: ...D 10 12 4 15 16 18 14 13 17 12 11 10 10 19...

Page 79: ...ne speed setting if drive lever is extended Min setting Idling speed Max position Nominal speed A For paving select the rated speed reduce the speed for transportation A The automatic speed control ke...

Page 80: ...D 10 12 6 15 16 18 14 13 17 12 11 10 10 19...

Page 81: ...it will go A As well as pushing the drive lever out the safety switch in the running board of the operator s control station must be pressed Otherwise the travel drive is blocked A Use the preselecto...

Page 82: ...D 10 12 8 15 16 18 14 13 17 12 11 10 10 19...

Page 83: ...with deflect ed drive lever even if the travel drive preselector is set to zero 18 Steering potentiometer The steering wheel movement is transferred electrohydrauli cally A For precise adjustments pos...

Page 84: ...D 10 12 10 21 20 23 22...

Page 85: ...ht half of screed Right switch position Extend right half of screed f On actuation heed danger zones of moving parts of the vehicle 22 Left hopper open close Pushbutton function Upper switch position...

Page 86: ...D 10 12 12 25 24 27 26...

Page 87: ...apacity with out material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 25 Right auger Operating mode AUTO OFF MANUAL Detent switch function Operating...

Page 88: ...D 10 12 14 25 24 27 26...

Page 89: ...function can be triggered in all modes of the auger f On actuation heed danger zones of moving parts of the vehicle 27 Reversing switch for right auger Pushbutton function Left switch position The con...

Page 90: ...D 10 12 16 29 30...

Page 91: ...of the conveyor is switched on con stantly without material control via the limit switches f On actuation heed danger zones of moving parts of the vehicle 30 Reversing switch for conveyor Pushbutton...

Page 92: ...D 10 12 18 32 31...

Page 93: ...n Filling function for the paving process The conveying functions set to automatic conveyor and auger are switched on A Once the set material height is reached at the limit switches the conveying func...

Page 94: ...D 10 12 20 33...

Page 95: ...n position Lower switch position Lower screed floating position Screed is lowered and released in the floating position when the drive le ver is swivelled out A To prevent the screed from lowering dur...

Page 96: ...D 10 12 22 35 34...

Page 97: ...out Operating mode OFF The screed tamper is switched off Operating mode MANUAL The screed tamper is switched on constantly 35 Vibration Operating mode AUTO OFF MANUAL Detent switch function Operating...

Page 98: ...D 10 12 24 36 38 37...

Page 99: ...utton function Upper switch position Retract left levelling cylinder Lower switch position Extend left levelling cylinder A The AUTO and OFF mode are overriden when actu ated f On actuation heed dange...

Page 100: ...D 10 12 26 40 39...

Page 101: ...nisher turns on the spot the caterpillar chains run in opposite directions when the steering is turned to 10 Steering turned to the left vehicle turns to the left Steering turned to the right vehicle...

Page 102: ...D 10 12 28 42 41...

Page 103: ...itch position Rotary beacon ON Lower switch position Rotary beacon OFF A Switch on for safety on roads and in the construction site area 42 Working lights ON OFF o Detent switch function Upper switch...

Page 104: ...D 10 12 30 44 43...

Page 105: ...switch position Spray system ON Lower switch position Hopper function OFF 44 Changeover Remote control operator s plat form o Detent switch function Lower switch position Machine control takes place...

Page 106: ...D 10 12 32 45...

Page 107: ...engine is indicated by one of the warning lamps a code assigned to a defined defect can be called up Pushbutton function Upper switch position Call the fault code A Press the switch until the three d...

Page 108: ...D 10 12 34 51 56 58 57 59...

Page 109: ...d to read out faults in the vehicle control system A Please contact the technical customer serv ice for your vehicle 52 Error message drive engine yellow Lights up when there is a fault in the drive e...

Page 110: ...D 10 12 36 51 56 58 57 59...

Page 111: ...finished 55 Indicator lamp Air filter yellow Lights up if the air filter needs replacing A Replace filter element acc to maintenance instructions 56 Fuel reserve yel low Lights up when the fuel in th...

Page 112: ...D 10 12 38 Flame monitoring o 73 71 72 70...

Page 113: ...cator lamps light up A Please comply with further instructions for the flame monitoring function in the corre sponding Operating Instructions for the screed Pos Designation Brief description 70 Malfun...

Page 114: ...D 10 12 40 77 74 75 76...

Page 115: ...rts of the screed heater A When the temperature is adjusted the nominal temper ature is displayed for a few seconds before the display reverts to the actual temperature 75 Plus button Pressing the but...

Page 116: ...D 10 12 42 3 Remote control A Depending on the side of the machine left right the function switches only control the corresponding function on the particular side of the machine 80 81 82 83 84...

Page 117: ...g the external levelling system to the left of the vehicle A When not needed close the socket with the corre sponding protective cap 83 Socket Right levelling system for connecting the external levell...

Page 118: ...D 10 12 44 95 90 91 92 93 94...

Page 119: ...92 Auger left right Operating mode AUTO OFF MANUAL Detent switch function Left switch position Operating mode AUTO The conveying function of the left right half of the auger is switched on when the dr...

Page 120: ...D 10 12 46 95 90 91 92 93 94...

Page 121: ...end retract Pushbutton function Switch position in the corresponding direction extend or retract left right screed half f On actuation heed danger zones of moving parts of the vehicle 95 Screed warnin...

Page 122: ...D 10 12 48 4 Remote control 103 104 101 106 100 102 105 107 108 109...

Page 123: ...e the main shut off valve and the valves on the bottles by hand To restart the engine the button must be unlocked again 101 Steering potenti ometer The steering wheel movement is transferred electrohy...

Page 124: ...D 10 12 50 103 104 101 106 100 102 105 107 108 109...

Page 125: ...drive lever out the safety switch in the running board of the operator s control station must be pressed Otherwise the travel drive is blocked A Use the preselector to set the maximum speed f The vehi...

Page 126: ...D 10 12 52 103 104 101 106 100 102 105 107 108 109...

Page 127: ...mergencies and to indicate when the ve hicle starts to move A The horn can also be used to communicate acoustical ly with the truck driver for material loading 107 Left hopper open close Pushbutton fu...

Page 128: ...D 10 12 54 103 104 101 106 100 102 105 107 108 109...

Page 129: ...ited to work with the re mote control without fastening the safety cut out belt to the operator Fasten the safety switch belt 110 to the operator A If the safety switch is pulled the travel drive shut...

Page 130: ...D 10 12 56 5 Malfunctions 5 1 Error code query for engine 3 1 2...

Page 131: ...query switch 3 The flash code is issued by the other warning lamp 1 Output of numerical code Press switch 3 into display position until the three digit code has been output via the warning lamp While...

Page 132: ...A If several errors occur at the same time the various flash codes are displayed next to one another by pressing the output switch m Notify customer service of the fault number displayed on your paver...

Page 133: ...danger of falling from the vehicle which can cause severe to fatal injuries The operator must be at the intended driver s seat during operation Never jump onto or off a moving vehicle Keep accessible...

Page 134: ...ired side of the vehi cle Loosen the screws 5 and pull the handrail out of the holding tubes Then insert the handrail again and tighten the screws 5 properly In the running board there is a safety swi...

Page 135: ...f Ensure that nobody or nothing is in the danger area f Only adjust the operating position whilst the vehicle is stationary Danger due to damaged or missing operating instructions Failure to comply w...

Page 136: ...D 30 12 4 Fuse box The terminal box which contains all fus es and relays etc is located beneath the operating panel A An assignment plan for fuses and relays can be found in chapter F8...

Page 137: ...t according to the instructions see section Starting the paver finisher ex ternal starting starting aid Main battery switch The main battery switch separates the current circuit from the battery to th...

Page 138: ...uards inserted the hopper halves will slowly open dan ger during transportation Screed transport safeguard It is used to protect the lifted screed from inadvertent sinking The screed trans port safegu...

Page 139: ...trokes per minute is set fully variable using the rotary regulator A Speed regulation for vibration B The vibration frequency number of vi brations per minute is set fully variable using the rotary re...

Page 140: ...Turn to the left lower conveying speed Paving thickness indicator Two scales A on which the currently set paving thickness can be read off are located on the left and right sides of the vehicle Point...

Page 141: ...A They are engaged together with the working lights LED working light o The working lights are fitted in any posi tion on the machine using the magnetic foot Connect the lead with the 24V socket on t...

Page 142: ...the ratchet lever 2 Set the desired height by alternatingly actuating the left and right ratchets A The current height can be read on both auger height indicators A Observe the notes on adjusting the...

Page 143: ...rod extension are used ensure that there is no one in the vehicle s danger area A The sensor rod is adjusted when the vehicle is positioned with its set working width on the paving route and the refe...

Page 144: ...D 30 12 12 m Tighten all assembly parts properly after setting up...

Page 145: ...phalt with a separator emul sion m Only use approved separator emulsion in the spray 1 Build up pressure by actuating the pump lever 2 The pressure is indicated on the ma nometer 3 Actuate the manual...

Page 146: ...discharged Switch off after use Pull the hose out of the device until a click is audible When released the hose automatically engages here The hose is automatically retracted into the guide after pul...

Page 147: ...et the deactivation point Loosen the screw 3 and turn the paddle 1 2 on the shaft until the required switching point is reached or Loosen the screw 4 and turn the switching cam 5 on the shaft until th...

Page 148: ...s 3 to ensure that they are not damaged on extending and retracting the screed Align the ultrasound sensor 3 towards the mixed materials in front of the auger The sound waves should impact on the mixe...

Page 149: ...volt sockets o There is one socket 1 on each side of the operating panel console Additional working lights can be con nected here for example 24V socket A Voltage is present when the main switch is s...

Page 150: ...nel must be fa miliarised with operation of the fire extin guisher 2 A Observe the inspection interval for the fire extinguisher First aid kit o f Any dressings that have been used must be replaced im...

Page 151: ...y beacon onto the plug in contact and secure with a wing bolt 1 Slide the rotary beacon with the tube 2 out to the desired height and se cure with the clamping bolt 4 Activate the function on the oper...

Page 152: ...D 30 12 20...

Page 153: ...Diesel fuel Engine oil and hydraulic oil lubricants Separator fluids emulsion and manual injector Two filled propane gas bottles Shovel and broom Scraper spatula for cleaning the auger and the hopper...

Page 154: ...lighting must be provided when working at night Comply with all further information in these instructions and in the safety manual Danger of falling from the vehicle Entering and leaving the vehicle...

Page 155: ...op immediately Steering The paver finisher must immediately fol low every steering wheel movement in a precise manner Check straight ahead travel Horn On the operating panel on both remote controls Br...

Page 156: ...ansport safeguard When the hopper is closed it must be possible to insert the safety chain between the two hopper lids Miscellaneous Engine panels Lateral flaps Check that the hoods and flaps are secu...

Page 157: ...D 40 12 5 1 3 7 8 6 6 7 7 6 2 4 9 5...

Page 158: ...5 indicator lamps are on The Start inhibit indicator lamps shows that the following states are present on the operating panel or remote control Emergency stop button 6 pressed Auger function 7 switch...

Page 159: ...D 40 12 7 f Do not use aerosol types such as ether as starting aid This can cause an explosion and lead to personal injuries...

Page 160: ...D 40 12 8 1 3 7 8 6 6 7 7 6 2 4 9 5...

Page 161: ...battery with the positive terminal 2 of the vehicle battery Then connect the negative terminal 3 of the start aid battery to ground of the discharged vehicle e g to the en gine block or to a bolt 4 on...

Page 162: ...the starter run permanently for more than 20 seconds then allow for a break of one minute A If the engine does not start and the Error message 5 indicator lamp flashes then the electronic engine contr...

Page 163: ...D 40 12 11 1 2...

Page 164: ...gine speed can be increased by switching on a conveying function If the lamp remains on turn the engine off and ascertain the fault For further possible malfunctions refer to the section Malfunctions...

Page 165: ...D 40 12 13 6 1 2 3 4 5...

Page 166: ...ard Turn the travel drive preselector 3 to zero Fully extend the levelling cylinders with the switch 4 Use switch 5 to adjust the screed to the basic width of the paver finisher m Lift the auger if ne...

Page 167: ...D 40 12 15 4 6 6 6 1 2 5 3...

Page 168: ...rd or backward according to the drive direction desired Adjust the speed with the preselector 2 Carry out steering movements by actuating the steering potentiometer 5 f In emergency situations press t...

Page 169: ...creed auger push roller with a separator fluid m Do not use diesel fuel as it dissolves the bitumen prohibited in Germany Screed heater Switch on the screed heater approx 15 30 minutes depending on th...

Page 170: ...18 Direction marks To ensure straight paving a direction mark must be present or established road edge chalk lines or similar Pull the direction indicator out of the bumper arrow and adjust it accord...

Page 171: ...D 40 12 19 2 3 2 2 1 4...

Page 172: ...st the conveyor limit switches with the vehicle turned off until sufficient material is conveyed in front of the screed Filling function A The filling function can additionally be used to convey the m...

Page 173: ...D 40 12 21 1 8 9 8 8 6 4 2 3 5 7 10 13 11 12...

Page 174: ...y Check the area of the caterpillar chains as uneven ground is levelled by the screed The caterpillar chains act as reference points for the layer thickness The basic setting of the screed must be cor...

Page 175: ...Uniform material transfer 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 paver finis...

Page 176: ...D 40 12 24 1 2...

Page 177: ...create an edge like the end of a layer Set the drive lever 1 to the centre position During longer breaks e g lunch break Set the drive lever 1 to the centre position and the speed adjuster 2 to minim...

Page 178: ...D 40 12 26 1 4 5 10 10 7 3 2 9 6 8 12 10 13 14 16 15 11 4 4 11 11...

Page 179: ...h tampers o 6 OFF Switch off screed heater 13 Switch the working and warning lights 14 to OFF Read and check the operating hour meter 15 to determine whether maintenance work must be performed see cha...

Page 180: ...ong waves change in the material temperature demixing roller has stopped on the hot material roller has turned or roller speed has been changed too fast incorrect operation of the roller incorrectly p...

Page 181: ...low screed extendable parts are incorrectly installed 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 ch...

Page 182: ...he suction line of the pump Seal or replace the connections Tighten or replace the hose clamps Oil filter is soiled Clean the filter if necessary replace the filter Conveyor or augers run too slowly H...

Page 183: ...ase the speed Hydraulic oil level is too low Top up oil Leak in the suction line Tighten the connections Flow rate regulator defective Replace Leaking seals of the hydraulic cylinder Replace Control v...

Page 184: ...eplace 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 interrupted Check fuse and cables replace if necessary...

Page 185: ...e 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 broken Re...

Page 186: ...D 40 12 34...

Page 187: ...ever into centre position and turn preselector controller to zero remove ignition key and battery main switch Protect lifted vehicle parts e g screed or hopper against lowering by means of mechanical...

Page 188: ...d void and can cause severe to fatal injuries Only use original spare parts and approved accessories After maintenance and repair work ensure that any dis mantled protective and safety devices are all...

Page 189: ...f the screed material overflow When operating with larger working widths demixing and traction problems may occur Auger too low Not enough material that can be precompacted by the auger Irregularities...

Page 190: ...dditional auger segment 1 is fitted to the auger shaft Assembly Remove outermost screw connection 2 from the basic auger Remove plug 3 Fit the auger extension 1 to the corresponding side Fit screw con...

Page 191: ...erial shaft 4 in the provided bracket on the basic unit and secure with the rod 5 Remove original shaft 4 Fit extension shaft 6 Secure original shaft 4 to extension shaft 6 m Switch off engine and sec...

Page 192: ...paving width first has to be equipped with the compensation part 2 corre sponding to the height of the layer These compensation parts 2 are in serted into the cut off shoe mounting The compensation pa...

Page 193: ...rear wall of the paver finisher A The cut off shoe s spring tension pre vents the ingress of material between the cut off shoe and the screed vehicle Then move the side shield in m Ensure that nobody...

Page 194: ...E 10 12 8 Raise the screed and carry out a visu al inspection A Make sure that the cut off shoe lies on the bottom plate Ensure that nobody is located in the dan ger area...

Page 195: ...alves to raise the hopper flap o Remove hopper rubber 2 Dismantle retaining pin 3 using a suitable bolt extractor Bring the push roller crossbar into the front rear position A Shift the push roller cr...

Page 196: ...e left side A The automatic levelling system can be suspended in the opened vandalism protection facility on the remote control Connect the coiled cable of the automat ic levelling system with the soc...

Page 197: ...s 5 of the automatic levelling system Slope controller to left automatic level ling system socket 5 Slope controller to right automatic lev elling system socket 6 Connect the height controller 4 to th...

Page 198: ...inisher from the remote control Swivel the remote control into the required position and secure with retaining brack ets 1 and 2 A To operate with remote control o the driver s platform handrail can b...

Page 199: ...trol without fastening the safety cut out belt to the driver A The travel drive is blocked after a safety shutdown To release it again the drive lever 6 has to be put in neutral position first Set the...

Page 200: ...lock nut 6 to this end Connect the left or right sensor s con nection cable to the intended remote control bracket sockets A The connection cables are connected to the relevant sockets on the remote c...

Page 201: ...Ensure that maintenance and repair work is always only carried out by trained specialist staff All maintenance repair and cleaning work should only be carried out with the engine turned off Remove ig...

Page 202: ...ces Surfaces including those behind covering parts together with combustion fuels from the engine or screed heater can be very hot and cause injuries Wear your personal safety gear Do not touch hot pa...

Page 203: ...F 2 12 1 F 2 12 Maintenance review 1 Maintenance review 8 12 4 12 5 12 3 12 7 12 6 12 11 12 100 02...

Page 204: ...red after the following service hours 10 50 100 250 500 1000 annually 2000 every 2 years 5000 20000 If necessary Conveyor F3 12 q q Auger F4 12 q q q Engine F5 12 q q q q q q Hydraulical system F6 12...

Page 205: ...F 3 12 1 F 3 12 Maintenance conveyor 1 Maintenance conveyor...

Page 206: ...may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting...

Page 207: ...te 10 50 100 250 500 1000 annually 2000 every 2 years If necessary 1 q Conveyor chain Check tightness q Conveyor chain Adjust tension q Conveyor chain Replace chain 2 q Replace conveyor conveyor drive...

Page 208: ...can cause the chain to be stopped or to break when material falls into the space between the chain and the sprocket An excessively slack chain may catch on protruding objects and be destroyed Adjustm...

Page 209: ...engthened to such an extent that it can no longer be retight ened m Chain links must not be removed to shorten the chain Incorrectly dividing the chains would lead to the destruction of the drive whee...

Page 210: ...the system is no longer sealed or there are holes in the parts m The conveyor chain is not offered pro tection by worn cover m Check the following wear parts in the conveyor drive section and replace...

Page 211: ...F 4 12 1 F 4 12 Maintenance auger assembly 1 Maintenance auger assembly...

Page 212: ...emove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts togeth...

Page 213: ...q Auger drive chains Adjust tension q Auger drive chains Chains and chain sprockets Replace 2 q Auger box Check grease fill q Auger box Top up grease q Auger box Change grease 3 q Seals and sealing ri...

Page 214: ...both augers to the right and left In this case movement clearance C at the augers outer circumference should be 3 4 mm f Risk of injury due to sharp edged parts To re tension the chains Release the mo...

Page 215: ...ger shaft or drive are worn The chains A have lengthened to such an extent that they can no longer be retightened m Chains and chain sprockets must al ways be replaced in sets A Your Dynapac customer...

Page 216: ...tity and quality a film of grease ad heres to the full length of both chains B Top up with grease if necessary Reinstall cover A Change grease A The grease should be changed regularly when proceeding...

Page 217: ...fter reaching operating temperature check the gearbox for leaks m In case of visible leaks e g between the flange surfaces A of the drive auger shaft B or at the side cover C re placement of the seals...

Page 218: ...mes sharp edged the diameter of the auger is reduced and the auger shafts B have to be replaced f Risk of injury due to sharp edged parts A Your Dynapac customer service will be happy to provide suppo...

Page 219: ...nce engine assembly m In addition to these maintenance instructions the maintenance instructions issued by the engine manufacturer must be adhered to under all circumstances All mainte nance work and...

Page 220: ...emove the ignition key before any maintenance work Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces including those behind covering parts togeth...

Page 221: ...n the tank and system 2 q Engine lube oil system Check oil level q Engine lube oil system Top up oil q Engine lube oil system Change oil q Engine lube oil system Change oil filter 3 q Engine fuel syst...

Page 222: ...ilter Air filter cartridge Replace 5 q Engine cooling system Check radiator fins q q Engine cooling system Clean radiator fins q Engine cooling system Check level of the coolant q Engine cooling syste...

Page 223: ...50 100 250 500 annually 1000 annually 2000 every 2 years If necessary 6 q Engine drive belt Check drive belt q Engine drive belt Tighten drive belt q q Engine drive belt Replace drive belt Maintenanc...

Page 224: ...t run dry and time consuming venting bleeding can therefore be avoided For filling in the fuel Open lateral flap Remove cap A Fill in fuel through the filling port until the required fill lever is ach...

Page 225: ...heck the oil level when the finisher is in a horizontal position A The sensor rod is located at the front end of the engine m Too much oil in engine damages gas kets too little oil results in overheat...

Page 226: ...e correct mark on the sensor rod A Changing the oil filter A The new filter is inserted during an oil change once the used oil has been drained out A The oil filter is located at the front end of the...

Page 227: ...n the collecting vessel at regular in tervals or in response to an error mes sage from the engine control unit Put a suitable drip pan underneath Disconnect the electrical connection cable connection...

Page 228: ...lectric fuel feed pump Do not attempt to start the vehicle while the fuel system is being bled to ensure that no error message is generated Ignition ON A The electronic fuel feed pump switches on for...

Page 229: ...of the filter selected A Filter maintenance becomes necessary if Maintenance interval or Engine electronics service indicator Open the air filter lid Pull out the filter cartridge D and the safety ca...

Page 230: ...tank Change coolant f When hot the system is under pressure When it is opened there is danger of scalding m Use only approved coolants A Observe the instructions in the chapter entitled Operating subs...

Page 231: ...sary remove leaves dust or sand from the radiator A Observe engine s operating instructions Check coolant concentration Check the concentration using a suitable tester hydrometer Adjust the concentrat...

Page 232: ...transverse cracks in the belt are acceptable m In the event of longitudinal cracks which intersect with transverse cracks and damaged material surfaces belt re placement is necessary A Observe engine...

Page 233: ...F 6 12 1 F 6 12 Maintenance hydraulic system 1 Maintenance hydraulic system...

Page 234: ...ecure the vehicle to prevent it being switched on again Consult a doctor immediately if injured Comply with all further information in these instructions and in the safety manual Hot surfaces Surfaces...

Page 235: ...ng level q Hydraulic oil tank Top up oil q Hydraulic oil tank Change oil and clean q Hydraulic oil tank Ventilation filter sensor rod Replace 2 q Hydraulic oil tank Check maintenance indicator q q Hyd...

Page 236: ...up oil g q Pump distribution gear Change oil q Pump distribution gear Check bleeder q Pump distribution gear Clean bleeder 5 g q Hydraulic hoses Visual inspection g q Hydraulic system Leak test q Hyd...

Page 237: ...or rod B again m Use only the recommended hydraulic oils see section Recommended hy draulic oils A When filling for the first time all hydraulic cylinders should be extended retracted at least 2x for...

Page 238: ...F 6 12 6 Ventilation filter A The ventilation filter is integrated in the sensor rod The sensor rod must be replaced according to the maintenance interval...

Page 239: ...filter head and take out of the engine compartment together with the filter housing A To avoid impurities do not let the filter cartridge fall back into the housing again Remove the filter cartridge E...

Page 240: ...collect the draining oil Remove the screw in neck with strain er element D Shake any remaining oil out of the housing E into a vessel for used oil then clean the filter housing with cleaning solvent...

Page 241: ...g glass A Screw in the filler screw B again m Make sure to clean the screw and the vi cinity of the drain bore Oil change Place the end of the oil drain port hose C in the collection container Remove...

Page 242: ...F 6 12 10 Bleeder The functioning of the bleeder A must be ensured If soiling has occurred the bleeder should be cleaned A...

Page 243: ...ing pinched or buckled points leaks damage or deformation to the hose fittings affecting the sealing function replace ments are not necessary for minor damage to the surface hose coming away from the...

Page 244: ...ening of the hoses prevents them from chafing on components or on each other components with sharp edges must be covered when installing hydraulic hoses bending radii are not smaller than the permitte...

Page 245: ...oth er and always ensure that they are at the correct pressure In individual cases the period of use can be stipulated according to experience and may differ from the following general indications Whe...

Page 246: ...the filter then close the non return valve again Replace filter element B and sealing ring C Turn filter element clockwise with the help of carrier straps and at the same time raise it slightly Wait...

Page 247: ...F 7 12 1 F 7 12 Maintenance drive unit 1 Maintenance drive unit...

Page 248: ...may only be raised at the marked lifting points Heed the operating weight of the vehicle Do not enter the danger zone Only use approved ramps and adequately dimensioned ramps or pits Use only lifting...

Page 249: ...0 1000 annually 2000 every 2 years If necessary 1 q Chain tension Check q Chain tension Adjust q Chains Relieve 2 q Bottom plates Check wear q Bottom plates Replace 3 q Rollers Check for leaks q Rolle...

Page 250: ...years If necessary 4 q Planetary gear Check oil level q Planetary gear Top up oil g q Planetary gear Change oil q Planetary gear Check oil quality q Planetary gear Screw connections Check q Planetary...

Page 251: ...ves significant safety measures and should only be carried out by a specialist workshop A Your Dynapac customer service will be happy to provide support during maintenance repair and the replacement o...

Page 252: ...ncreasing wear levels m If the chains are tensioned too tightly this increases wear on the idler wheel and drive unit mounting and also increases wear on track bolts and bushes Checking adjusting chai...

Page 253: ...nnection A then re move the grease gun Check the chain tension once again as described above A If the tension is too high see section Relieving the chain A Repeat this procedure on both drive units Re...

Page 254: ...ioners The tension adjusters A are located left and right on the front beam of the main frame Check the sag of the chain by powerfully pressing and lifting the drive chain in the area B The sag C must...

Page 255: ...ning the adjusting bolt Therefor dissemble cap E untighten counter nut F turn adjusting bolt G untill the two bolts C have a clearance of 5 mm between the flanges A Check the clearance by moving the b...

Page 256: ...e the bottom plate with the front edge A over the chain links bolt eye B Lubricate the threads and the contact surfaces beneath the bolt heads with a thin film of oil or grease Insert the bolts C into...

Page 257: ...measures when rais ing and securing loads Remove the defective roller Install the new roller using new as sembly parts Tighten the bolts without applying sig nificant torque Tighten the bolts diagona...

Page 258: ...bore at A until the oil level has reached the lower edge of the filler bore Screw the filler screw A back in Oil change A The oil should be changed when at oper ating temperature m Ensure that no dir...

Page 259: ...components The correct tightening torque for the connecting screws for the gearbox chain sprocket A is 73Nm The correct tightening torque for the connecting screws for the gearbox chain sprocket chee...

Page 260: ...F 7 12 14...

Page 261: ...F 8 12 1 F 8 12 Maintenance electrical system 1 Maintenance electrical system...

Page 262: ...not remove any protective safeguards Never spray water on electric or electronic components Maintenance work to the electric system should only be carried out by trained specialist staff When equippe...

Page 263: ...r Electrical system insulation monitoring Check function o q Alternator Visual check for pollution or damage Check the cooling air openings for pollution or clogging clean if necessary o q Check the d...

Page 264: ...fficient check and possible recharge the batteries A Regularly check the charge of the battery and recharge if necessary m A maintenance free battery must be recharged slowly with a special battery ch...

Page 265: ...every cell if this needs to be topped up only use distilled water m When recharging batteries every cell must be opened i e plugs and or covers must be removed m Only use commercially available automa...

Page 266: ...e function of the insulation monitor not whether an insula tion error has occurred on the heating sections or consumers Start the paver finisher s drive engine Switch heating system switch 1 to ON Pre...

Page 267: ...creed or with connected external equipment f The screed and equipment must be checked or repaired by a specialist electri cian Only then may work again be undertaken with the screed and equipment f Da...

Page 268: ...ried out If the control light goes out the switches of the heater and external equipment can be switched back to ON one after another until a message again appears and the system is shut down The equi...

Page 269: ...g the alternator m The alternator must be regularly checked for excessive dirt and must be cleaned if necessary The air intake 1 must be kept free of dirt m Cleaning with a high pressure cleaner is no...

Page 270: ...strument A The following tension measuring instru ments are available Mechanical tension measuring instru ment A Article number 4753200045 Electronic tension measuring instru ment B Article number 481...

Page 271: ...n ing fixture Using the adjusting screw C set the required level of belt tension Tighten lock nuts B and mounting screws A back down Replacing belt Reduce the belt tension on the adjust ing device so...

Page 272: ...F 8 12 12 2 Electrical fuses 2 1 Main fuses 1 Main fuses A F A 1 1 Main fuse 50 1 2 Main fuse 30 1 4 Preheating ignition system 100 A...

Page 273: ...F5 Vibration 7 5 F6 Retract and extend screed 7 5 F7 Travel drive 7 5 F10 Auger 7 5 F11 Monitoring equipment 10 F12 Conveyor 7 5 F13 Free 5 F14 Levelling 7 5 F15 Screed heater 10 F16 12V socket 10 F17...

Page 274: ...F 8 12 14 F A F25 Fuel pump 10 F26 Ignition 7 5 F27 Main computer 10 F28 Working lights 15 F29 Working lights 15 F30 Engine diagnosis 2 F31 Main computer 3...

Page 275: ...4 Switched positive C K5 Levelling C K6 Left screed C K7 Right screed C K8 Horn C K9 Emergency stop C K10 Start inhibit C K11 Vibration C K12 Tamper C K13 Conveyor C K14 Left auger C K15 Right auger C...

Page 276: ...F 8 12 16...

Page 277: ...lities of well known brands m Only use containers which are clean on inside and outside for filling oil or fuel A Note capacities see section Capacities m Incorrect oil or lubricant levels promote rap...

Page 278: ...F 11 12 2 2 7 1 3 5 6 6 4...

Page 279: ...l 8 0 litres 2 Engine cooling system Cooling liquid 9 0 litres 3 Fuel tank Diesel fuel 50 0 litres 4 Hydraulic oil reservoir Hydraulic oil 90 0 litres 5 Pump distribution gear Gearbox oil 1 8 litres 6...

Page 280: ...on at http www deutz com 2 3 Drive engine TIER IV o fuel specification m Low sulphur diesel fuel is prescribed for correct operation of the exhaust gas treat ment system The maximum sulphur level must...

Page 281: ...8 Drive unit planetary gear A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Paroil E Emission Green Dynapac AGIP Chevron Caltex Delo Petronas Coolant 100 Antifreeze Special Extended Life C...

Page 282: ...ox A recommended 2 10 Grease A recommended Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Auger Grease Gadus S5 V142W 00 Dynapac Aral BP Esso Exxon Fuchs Mobil Shell Chevron Paver Grease Gadus S5 T460 1...

Page 283: ...oil pressure fluids to biodegradable pressure fluids please contact our factory advisory service Manufacturer ISO viscosity class VG 46 Dynapac Hydraulic 120 Shell Natural HF E46 Panolin HLP SYNTH 46...

Page 284: ...F 11 12 8...

Page 285: ...F 100 1 F 100 Tests stopping 1 Tests checks cleaning stopping...

Page 286: ...100 250 500 1000 annually 2000 every 2 years If necessary 1 q General visual inspection 2 regularly Check that the bolts and nuts fit firmly 3 q q Inspection by an expert 4 q Cleaning 5 q Preserving...

Page 287: ...actions to correct any detected malfunction to avoid damages dan gers or environmental hazards 3 Check that the bolts and nuts fit firmly Bolts and nuts must be checked regularly to ensure that they f...

Page 288: ...lube points acc to specification Clean the vehicle with water after laying mineral aggregates lean mixed concrete etc m Do not spray bearing points electrical or electronic components with water Remo...

Page 289: ...rts can cause severe or fatal injuries Do not enter the danger zone Do not reach into rotating or conveying parts Only wear close fitting clothing Comply with the warning and information signs on the...

Page 290: ...ved batteries every 2 months Protect all bare metal components e g piston rods on hydraulic cylinders with a suitable corrosion inhibitor If it is not possible to park the vehicle is an enclosed build...

Page 291: ...sposal must be carried out after replacing wear and spare parts and after the machine has been withdrawn from service scrapped The materials must be sorted correctly according to metal plastic electro...

Page 292: ...1 6 4 1 6 7 7 1 9 M6 8 2 1 12 3 14 3 7 8 1 9 11 2 7 13 3 3 M8 20 5 28 7 1 34 8 19 4 7 26 6 6 31 7 9 M10 41 10 57 14 70 17 37 9 52 13 62 16 M12 73 18 97 24 120 30 63 16 89 22 107 27 M14 115 29 154 39 1...

Page 293: ...M8x1 21 7 5 4 30 6 7 6 36 7 9 2 19 5 4 9 27 4 6 8 32 8 8 2 M10x1 25 42 1 10 5 59 2 15 71 17 8 37 7 9 4 53 13 63 6 15 9 M12x1 25 75 7 18 9 106 2 26 127 31 9 67 2 16 8 94 5 24 113 28 3 M14x1 5 119 29 7...

Page 294: ...F 100 10...

Page 295: ...encounter any operational problems or have enquiries about spare parts Our trained specialist staff will ensure that you receive prompt attention and repairs in the event of any ac cident or malfuncti...

Page 296: ...www dynapac com...