Dynapac F1000W Wheeled 10ft Manual

Dynapac F1000W Wheeled 10ft Manual
OPERATION
&
MAINTENANCE
Paver
F1000W
Keep this manual for future reference
Order number for this manual: D716.41.00.38
1DEC2011
VALUE
QUALITY
THE ORIGINAL
Your Authorized Dynapac Dealer:
Table of contents
V
Preface ........................................................................................................... 1
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
General safety instructions .................................................................................................. 3
Acts, directives, accident prevention regulations ................................................................. 3
Warning instructions ............................................................................................................ 3
Prohibitive signs .................................................................................................................. 6
Protective gear .................................................................................................................... 7
Environmental protection ..................................................................................................... 8
Fire prevention ..................................................................................................................... 8
Further instructions .............................................................................................................. 9
A
Correct use and application ......................................................................... 1
B
Vehicle description ....................................................................................... 1
1
2
2.1
6.2
6.3
Application ........................................................................................................................... 1
Description of assemblies and functions ............................................................................. 2
Vehicle ................................................................................................................................. 3
Construction ................................................................................................................... 3
Danger Zones ...................................................................................................................... 6
Technical data, standard configuration ................................................................................ 7
Dimensions (all dimensions in inches) ................................................................................. 7
Allowed angle of rise and slope ........................................................................................... 8
Permissible approach angle ................................................................................................ 8
Turning circle ....................................................................................................................... 8
Weights, F1000W ................................................................................................................ 9
Performance data ................................................................................................................ 9
Traction drive/chassis ........................................................................................................ 10
Engine ............................................................................................................................... 10
Hydraulic systemOperator stations .................................................................................... 10
Electrical system ................................................................................................................ 10
Operator stations ............................................................................................................... 11
Material compartment (hopper) ......................................................................................... 11
Conveyor ........................................................................................................................... 11
Augerr ................................................................................................................................ 11
Permissible temperature ranges ........................................................................................ 11
Location of instruction labels and identification plates ....................................................... 12
EN standards ..................................................................................................................... 17
Continuous sound pressure level on the F1000W Wheeled Paver, Cummins
QSB-6.70 Tier III Engine. .................................................................................................. 17
Operating conditions during measurement ........................................................................ 17
Measuring point configuration ........................................................................................... 18
C1.1
Transport ....................................................................................................... 1
1
2
2.1
2.2
2.3
2.4
Safety regulations for transportation .................................................................................... 1
Transportation on low-bed trailers ....................................................................................... 3
Preparations ........................................................................................................................ 3
Driving onto the low-bed trailer ............................................................................................ 6
Secure the paver finisher to the low-bed trailer: .................................................................. 6
After transportation .............................................................................................................. 7
US_wheel_10ftIVZ.fm 1-6 - 02-0103
3
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
5
6
6.1
1
2
Transportation ..................................................................................................................... 8
Preparations ........................................................................................................................ 8
Driving mode ..................................................................................................................... 11
Loading by crane ............................................................................................................... 13
Towing ............................................................................................................................... 15
Safely parking the vehicle .................................................................................................. 16
D1.1
Operation ....................................................................................................... 1
1
2
2.1
3
4
Safety regulations ................................................................................................................ 1
Controls ............................................................................................................................... 2
Operating panel ................................................................................................................... 2
Auxiliary functions .............................................................................................................. 25
Left / right remote controls and handsets .......................................................................... 27
Left / right remote control .............................................................................................. 28
Left / right handset ........................................................................................................ 37
D2.0
Operation ....................................................................................................... 1
1
1.1
Operation of the graphical terminal ..................................................................................... 1
Navigation using Soft Keys .................................................................................................. 2
Brightness/Contrast
Adjustment ..................................................................................................................... 3
Main Menu - Start Menu ................................................................................................. 3
Main Menu - Basic Setup ............................................................................................... 4
Main Menu - Basic Setup
-Time / Date .................................................................................................................... 5
Main Menu - Basic Setup
-Language ...................................................................................................................... 5
Main Menu - Basic Setup
-Units .............................................................................................................................. 6
Main Menu - Diagnostics ................................................................................................ 7
Main Menu - Diagnostics
-System Info ................................................................................................................... 8
Main Menu - Diagnostics
-Fault Log ....................................................................................................................... 8
Main Menu - Diagnostics
-Fault Log
Active and Previous Faults ............................................................................................. 9
Main Menu - Diagnostics
-Fault Pop-Up Alarms ................................................................................................... 10
Main Menu - Diagnostics
-Device List ................................................................................................................... 11
Main Menu - Diagnostics
-Quick Data .................................................................................................................. 12
Start Display ................................................................................................................. 13
Display 01 ..................................................................................................................... 14
Display menu ................................................................................................................ 14
Display 02 ..................................................................................................................... 14
Display menu ................................................................................................................ 14
Active Faults Display .................................................................................................... 15
Fault Sources and Codes ............................................................................................. 15
Warnings Display .......................................................................................................... 17
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3
3.1
3.2
4
5
6
1.2
1.3
Engine Error messages ..................................................................................................... 18
FMI-codes .......................................................................................................................... 23
D3.0
Operation ....................................................................................................... 1
1
Operating elements on the paver ........................................................................................ 1
Operator’s platform ........................................................................................................ 1
Seat console ................................................................................................................... 1
Operating panel .............................................................................................................. 1
Driver's seat .................................................................................................................... 2
Batteries ........................................................................................................................ 2
Battery main switch ........................................................................................................ 3
Transport safeguards for the hopper ............................................................................. 4
Mechanical screed transport safeguard (to the left and the right beneath
the driver’s seat) ............................................................................................................. 4
Paving thickness indicator ............................................................................................. 5
Release Agent System ................................................................................................... 6
On/Off switch of working lights (1) .................................................................................. 7
On/Off switch hazard flasher (2): .................................................................................... 7
Warning Beacon ............................................................................................................. 7
Conveyor limit sensors ................................................................................................... 8
Ultrasonic auger limit sensors (left and right) ................................................................. 8
Sockets 24V ................................................................................................................... 8
D4.0
Operation ....................................................................................................... 1
1
Preparation of operation ...................................................................................................... 1
Required equipment and tools ........................................................................................ 1
Before starting work
(in the morning or when starting paving) ........................................................................ 2
Checklist for the machine operator ................................................................................. 2
Starting the paver ................................................................................................................ 5
Before starting the paver ................................................................................................ 5
“Normal” starting ............................................................................................................. 5
Jump starting .................................................................................................................. 7
After starting ................................................................................................................... 9
Transport Operation .......................................................................................................... 11
Lifting and securing the screed ..................................................................................... 11
Driving and stopping the paver ..................................................................................... 11
Switching off and securing the paver ............................................................................ 11
Preparations for paving ..................................................................................................... 12
Releasing agent ........................................................................................................... 12
Screed heater ............................................................................................................... 12
Direction marks ............................................................................................................. 12
Loading/distributing material ......................................................................................... 14
Starting for paving ............................................................................................................. 16
Check during paving .......................................................................................................... 17
Paver function .............................................................................................................. 17
Quality of the layer ....................................................................................................... 17
Interrupting/terminating operation ...................................................................................... 19
During breaks (i.e. the material supply truck is late) ..................................................... 19
During extended interruptions
(i.e. lunch break) ........................................................................................................... 19
1.1
1.2
US_wheel_10ftIVZ.fm 3-6 - 02-0103
1.3
1.4
1.5
1.6
3
4
E1.0
Set-up and modification ............................................................................... 1
1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3
4
4.1
4.2
4.3
4.4
4.5
4.6
Special notes on safety ....................................................................................................... 1
Auger ................................................................................................................................... 2
Height adjustment ................................................................................................................ 2
Auger crossbeam - hydraulic height adjustment .................................................................. 2
Auger extension ................................................................................................................... 3
Mounting extension parts .................................................................................................... 4
Mounting support tube extensions ....................................................................................... 5
Installing tunnel plates ......................................................................................................... 6
Installing additional braces .................................................................................................. 7
Screed ................................................................................................................................. 8
Electrical connections .......................................................................................................... 8
Remotes from screed to paver ............................................................................................ 8
Right hand conveyor sensor control .................................................................................... 8
Right hand auger sensor control ......................................................................................... 8
Left hand conveyor sensor control ...................................................................................... 9
Left hand auger sensor control ............................................................................................ 9
Auger Chart ....................................................................................................................... 10
F1.0
Maintenance .................................................................................................. 1
1
Notes regarding safety ........................................................................................................ 1
F2.1
Maintenance Overview ................................................................................. 1
1
Maintenance overview ......................................................................................................... 1
F3.0
Maintenance - Conveyor ........................................................ 1
1
1.1
1.2
Maintenance - Conveyor ..................................................................................................... 1
Maintenance intervals .......................................................................................................... 2
Points of maintenance ......................................................................................................... 3
Chain tension of the conveyor (1) ................................................................................... 3
Conveyor tensioning sprocket bearings (2) .................................................................... 5
Conveyor bearing (3) ...................................................................................................... 5
Conveyor drive - (5) drive chains .................................................................................... 6
Conveyor drive - (6) planetary drive (left/right) .............................................................. 7
Conveyor chain guards / conveyor plates (7) ................................................................. 8
F4.0
Maintenance - Auger ............................................................... 1
1
1.1
1.2
Maintenance - Auger sub-unit I ........................................................................................... 1
Maintenance intervals .......................................................................................................... 2
Points of maintenance ......................................................................................................... 3
Auger - outer bearing (1) ............................................................................................... 3
Auger middle bearing (2) ................................................................................................ 3
Auger - drive gear neck bearing (3) ................................................................................ 4
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2
2.1
2.2
When work is finished ................................................................................................... 21
Malfunctions ...................................................................................................................... 22
Problems during paving ..................................................................................................... 22
Malfunctions on the paver or screed ................................................................................. 24
US_wheel_10ftIVZ.fm 5-6 - 02-0103
Auger bevel gear (on the RH and LH sides) (4) ............................................................. 5
Auger blade (5) ............................................................................................................... 6
F5.0
Maintenance - Engine ............................................................. 1
1
1.1
1.2
Maintenance - engine sub-unit ............................................................................................ 1
Maintenance intervals .......................................................................................................... 2
Points of maintenance ......................................................................................................... 4
Engine fuel tank (1) ....................................................................................................... 4
Engine lube-oil system (2) ............................................................................................. 5
Engine fuel system (3) ................................................................................................... 7
Engine air cleaner (4) ..................................................................................................... 9
Engine Coolant system (5) ........................................................................................... 11
Engine drive belt (6) ..................................................................................................... 13
F6.0
Maintenance - Hydraulic System ........................................... 1
1
1.1
1.2
1.3
Maintenance - hydraulic system .......................................................................................... 1
Maintenance intervals .......................................................................................................... 2
Hydraulic System ................................................................................................................. 3
Points of maintenance ......................................................................................................... 4
Hydraulic oil tank (1) ....................................................................................................... 4
Suction/return flow hydraulic filter (2) ............................................................................. 6
Venting the filter: ............................................................................................................ 7
High pressure filter (3) .................................................................................................... 8
Pump distribution gear (4) .............................................................................................. 9
Hydraulic hoses (5) ....................................................................................................... 11
F7.1
Maintenance - Travel Drive, Steering .......................................................... 1
1
1.1
1.2
Maintenance - travel drive, steering .................................................................................... 1
Maintenance intervals .......................................................................................................... 2
Points of maintenance ......................................................................................................... 3
Wheel mounting nuts (1) ................................................................................................ 3
Rear wheels ................................................................................................................... 3
Front wheels (with front wheel drive) ............................................................................. 3
Planetary gear (2) ........................................................................................................... 4
Air pressure (driving wheels) (3) ..................................................................................... 6
Places of lubrication (4) .................................................................................................. 7
F8.1
Maintenance - Electronic System ................................................................ 1
1
1.1
1.2
Maintenance - Electronic system ......................................................................................... 1
Maintenance intervals .......................................................................................................... 2
Points of maintenance ......................................................................................................... 3
Batteries (1) .................................................................................................................... 3
Electric fuses / relays (3) ................................................................................................ 4
Fuses in terminal box (B) ............................................................................................... 5
Relays in terminal box (C) ............................................................................................. 7
F9.0
Maintenance - Lubricating Points ......................................... 1
1
Maintenance - Lubricating points ......................................................................................... 1
5
1.1
1.2
Maintenance intervals .......................................................................................................... 2
Points of maintenance ......................................................................................................... 3
Bearing points (1) ........................................................................................................... 3
F10.0 Checks, Decommissioning .................................................... 1
1
1.1
2
3
4
5
5.1
5.2
5.3
F11.0
Lubricants and Operating Substances ................................ 1
Lubricants and operating substances ................................................................................. 1
Capacities ............................................................................................................................ 2
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1
1.1
Tests, check-up, cleaning, stopping .................................................................................... 1
Maintenance intervals .......................................................................................................... 2
General observation ............................................................................................................ 3
Check performed by a specialist ......................................................................................... 3
Cleaning .............................................................................................................................. 4
Preservation for storage of paver ........................................................................................ 5
Downtime up to 6 months .................................................................................................... 5
Downtime between 6 months and 1 year. ........................................................................... 5
Re-commissioning: .............................................................................................................. 5
6
V Preface
Safe operation of the machine requires specific knowledge that is in these operating
instructions. The information is provided in a concise, clearly structured form. The individual chapters are arranged in alphabetical order and every chapter starts with
page 1. The individual pages are identified by the chapter letter and the page number.
Example: Page B 2 is the second page of chapter B.
These operating instructions cover various machine options. Make sure that during
operation and maintenance work the description appropriate to the machine option is
used.
Safety instructions and important notes are identified by the following:
Danger is used ot indicate the presence of a hazard which will
sonal injury, death, or substantial property damage if the warning is ignored.
cause severe per-
Warning is used to indicate the presence of a hazard which can cause sever personal
injury, death, or extensive property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personel injury or property damage if the warning is ignored.
Notifies people of installation, operation or maintenance information which is important but not hazard-related. Hazard warnings should never be included under the Notice indicator.
NOTE:
Note is used for supplementary information not directly effecting safety or damage to
the equipment. Note can also refer to special information on the efficient use of the
equipment.
V_01_US.fm
In the interest of continued development, the manufacturer reserves the right to make
changes to the machine (which will not, however, change the essential features of the
type of machine described) without updating the present operating instructions at the
same time.
V1
Dynapac USA, Inc.
V_01_US.fm
2100 N. First Street
Garland, Texas 75040
Telephone: (972) 496-7400
Fax: (972) 496-7310
www.dynapac.com
V2
1
General safety instructions
1.1
Acts, directives, accident prevention regulations
The locally applicable acts, directives and accident prevention regulations shall be
observed, even if the attention is not specifically directed to these.
The operator himself shall be responsible for the observation and performance of the
related regulations and actions!
The following alerts, prohibitions and instructions refer to the risks to which people,
machinery and environment are exposed.
Ignoring these instructions, bans and commands may lead to fatal injuries!
Furthermore, the Dynapac publication "Directives for the correct and specified application of pavers" shall also be observed.
1.2
Warning instructions
A paving machine has many components and implements that are controlled by a hydraulic system, either directly or indirectly. Before working on or inspecting any part
of a paving machine, it is important that the individual knows how the components
move and are controlled by the hydraulic system components including the respective control circuits.
Before working on or inspecting any component, it must be physically constrained
from any movement that chould cause injury to the worker. The worker must be alert
to not placing any part of his/her body where movement of a component could couse
injury, unless that component is physically contrained from moventment, if the hydraulic system fails, is disconnected, or is asignaled to cause movement.
It must also be recognized that there are occasions where component and or vehicle
movement may react to the release of potential energy. Where applicable it must be
confirmed that all measures are employed to ensure that any and all sources of potential energy are released and/ or physically restrained.
V_01_US.fm
It is also the responsibility of those involved to insure that all local, state and federal
safety regulations are followed, prior to, and during any work or inspection.
V3
Warning: areas of hazard or danger!
Not observing the warning instructions may lead to injuries or death!
Warning: rotating parts!
Rotating parts or transport parts can cause severe injury or death!
Perform each operation only with equipment switched off!
Attention: electric voltage!
All maintenance and repair work on the screed's electrical system
must always be carried out by an electrician!
Attention: suspended load!
Never stand under suspended loads!
Warning: risk of crushing!
Operation of certain parts or functions and moving the machine can
produce a risk of crushing.
Always make sure that no one is in the areas exposed to risk!
Caution: risk of hand injury!
V_01_US.fm
Caution: hot surfaces or hot liquids!
V4
Warning, risk of falling off!
Falling can cause severe injury or death!
Caution: hazardous batteries!
Combustible gas can cause severe burns, blindness or death!
Keep sparks and open flame away from batteries.
Caution: materials harmful to health and irritating substances!
Caution: flammable materials!
V_01_US.fm
Caution: gas bottles!
V5
1.3
Prohibitive signs
It is prohibited to open / step on / reach into / perform / adjust
during operation or when the paver engine is running!
Do not start the engine/drive!
Maintenance and repair can be carried out only with the Diesel engine turned off!
Do not spray with water!
Do not extinguish with water!
Unskilled maintenance is prohibited!
Maintenance can be performed by skilled professionals only!
Contact the Dynapac service for maintenance assistance!
Danger of fire: do not use open flame and no smoking!
V_01_US.fm
Do not turn on!
V6
1.4
Protective gear
The applicable local regulations may define the use of different protective gear!
Observe these specifications!
Protect your eyes with goggles!
Wear appropriate head protection!
Protect your hearing with appropriate ear mufflers!
Protect your feet with safety footwear!
Always wear tight, conforming working coveralls!
Wear visibility vest for good visibility!
V_01_US.fm
In case of polluted air, wear respiratory mask!
V7
1.5
Environmental protection
The locally applicable acts, directives and waste disposal regulations shall be observed, even if the attention is not specifically directed to these.
During cleaning, maintenance and repair operations, pollutants such as:
-
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
containers until professional disposal!
Material harmful for the environment!
1.6
Fire prevention
The applicable local regulations may specify that appropriate fire extinguishers be
mounted!
Observe these specifications!
V_01_US.fm
Fire fighting device
(optional equipment)
V8
1.7
Further instructions
Observe the manufacturer's and other instructions!
(i.e. the maintenance instructions from the engine manufacturer)
Indicates a bottled gas heated design!
V_01_US.fm
indicates an electrically heated design!
V9
V 10
V_01_US.fm
A Correct use and application
The “Guidelines for the Correct Use and Application of Paver” compiled by Dynapac
are included in the scope of delivery for the present machine. The guidelines are part
of the present operating instructions and must always be followed. Federal, state and
local regulations are fully applicable.
The road construction machine described in these operating instructions is a paver
that is suited for laying mixed materials, roll-down concrete or lean-mixed concrete,
track-laying ballast and unbound mineral aggregates for paving foundations.
This machine shall be used, operated and maintained for the purpose of the intended
work as included in the operation manual. Any other use is regarded as improper use
and can cause injury to persons or damage to the paver or other equipment or property.
Any use going beyond the range of applications described above is regarded as improper use and is expressly forbidden! Especially in those cases where the paver is
to be operated on inclines or where it is to be used for special purposes (i.e. construction of dumps, dams), it is absolutely necessary to contact the manufacturer.
Duties of the user: A “user” within the meaning of the present operating instructions
is defined as any natural or legal person who either uses the paver himself, or on
whose behalf it is used. In special cases (i.e. leasing or renting), the user is considered the person who, in accordance with existing contractual agreements between
the owner and the user of the paver , is charged with the observation of the operating
duties.
The user must ensure that the paver is only used in the stipulated manner and that
all danger to life and limb of the operator, or third parties, is avoided. In addition to
this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance guidelines are observed. The user must also ensure that all persons operating the equipment have read and understood the present operating instructions.
A_01_US.fm 1-2
Mounting attachments: The paver must only be operated in conjunction with
screeds that have been approved by the manufacturer. Mounting or installation of any
attachments that will interfere with or supplement the functions of the paver is permitted only after written approval by the manufacturer has been obtained. If necessary,
the approval of local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
A1
B Vehicle description
1
Application
B_F1000W_US.fm 1-18
The DYNAPAC F1000W is a rubber tire fitted paver finisher that is used for laying bituminous mixed material, roll-down or lean-mixed concrete, track-laying ballast and
unbound mineral aggregates for paving foundations.
B1
2
Description of assemblies and functions
14 15
17
2
1
16
13
12
10
3
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
B2
5
8 7
11
6
Standard
Designation
or Optional
Standard Material hopper
Standard Conveyor
Standard Truck push rollers
Option
Truck hitch
Standard Mounting tube for alignment indicator
Standard Front tandem axle
Standard Rear wheels
Standard Levelling cylinder (for paving thickness)
Standard Traction arm guide
Standard Traction roller
Standard Screed lifing arm
Standard Auger
Standard Screed
Standard Power pack enclosure
Standard Engine exhaust
Standard Operator’s platform
Standard Operator’s panels
B_F1000W_US.fm 2-18
4
9
2.1
Vehicle
Construction
The Dynapac F1000W is a rubber tire propelled paver built with a welded steel frame
on which the power pack, augers, conveyors, hopper and operator positons are
mounted.
The large drive wheels together with the front tandem shaft jointly compensate the
irregularities of the soil and as a result of the screed’s suspension, they guarantee a
particularly high paving precision.
The continuously adjustable hydrostatic traction drive allows the speed of the paver
to be matched to all work conditions.
The operation of the paver includes the automatic material handling system, the independent travel drives and the clearly structured operating components and controls.
The following options are available:
B_F1000W_US.fm 3-18
Grade Control
- Control System
- Averaging Ski
- Non-Contacting Averaging Ski
- Contacting Grade Control
Truck Hitch
Front Wheel Assist
Washdown System and Hose Reel
Auger Extensions
Frame Extensions
Steering Guide (Truck Hitch)
Secondary Drive Controller
Umbrella
Auxillary Power Panel (220/110V)
Bubble Lights
Road Lights (Tail Lights)
Warning Beacon
Magnetic Base Lights
Up Time Kit
Screed
Berm
Screed Corded Controls
Screed Extensions
Further equipment and upgrade options on request
B3
Engine: The paver is powered by a 6-cylinder, water cooled diesel engine with direct injection and a turbo charger. Electric starting and belt driven alternator battery charrging is standard. The engine power / rpm is controlled by the engine speed control on either of the
consoles. The engine is shut down either by removing the key “ON/OFF” switch or he emergency stop switch. For further details, see the technical data in the engine’s instruction manual.
Running gear: The paver is rear wheel, hydraulically driven and uses the hydraulics
on the second front wheels to assist with the steering. The steering wheel sends the
signal to the front tandem pivoting axle to turn. Once the front tandem pivoting axle
starts to turn, a signal is sent to the rear wheels requiring one wheel to use more flow
that the other to turn the machine. So as the front wheels receive the signal to turn
left, a signal is sent to the right rear wheel to use more power to turn that wheel faster
than the wheel on the left and the second front wheels assists hydraulically with the
turn . As the front wheels receive the signal to turn right, a signal is sent to the left rear
wheel to us more power to turn the wheel faster than the wheel on the right and the
second front wheels assist hydraulically with the turn.
As a result of this, the steering capability and the load capacity are improved, especially on soft ground. The paver is mounted with flexible solid tires on the front wheels
and large-size, tubeless, air filled tires on the rear wheels.
Hydraulic system: The diesel engine has the distribution gear box attached to it. This
drives the hydraulic pumps for all of the main and auxilary paver functions. The hydraulic system also drives the generator needed to heat materials to prevent the material from sticking
to the screed plate. All power on the paver comes from hydraulics.
Propel drive: The closed-loop propel drive system includes two speed track drive motors
that are connected to the drive pumps by means of high pressure hydraulic hoses. The hydraulic motors are mounted to the rear drive wheels which move the paver. Forward and reverse movement is controlled by directional control joysticks on the consoles while the
variable speed, independent drive wheels are controlled by a steering wheel on either of the
operator consoles.
Steering system/operator’s platform: The independent hydrostatic travel drives allow
the paver to be turned in a small radius. The eletronic synchronization, controlled from the
operating panel, ensures that the paver runs straight ahead. The operating panel can be secured in a position on the left-hand or the right-hand side of the paver by means of a latch
assembly.
Steering is accomplished by using the tandem steering axel in front of the machine. The
steering axel is controlled by the steering wheel at the opertor’s console. Rotate the steering
wheel clockwise to turn the machine right. Ratate the steering wheel counter-clockwise to
turn the machine left.
Material compartment (hopper): The hopper inlet is equipped with a conveyor system
that empties the hopper and transfers the material to the auger. The hopper can hold approximately 30,000 lbs. (13608 kg). To facilitate the emptying and to improve material transfer,
each of the lateral covers of the hopper are hydraulically moved.
B4
B_F1000W_US.fm 4-18
Push roller crossbar: The push rollers for material trucks are connected to a crossbar that
pivots at its center. This crossbar allows for differences in distances to the rear wheels on a
variety of material trucks. This permits the paver to deviate less from its course and makes
paving curves easier.
Conveyors (Material transfer): The paver is equipped with two conveyors driven separately with pressure from a single pump. The system consists of a single, pressure compensated, load sense style, variable displacement, open loop pump driving two fixed volume
hydraulic motors. This pump supplies hydraulic power for both conveyors of the machine and
provides power for the cylinders on the machine.
These conveyors transer the material from the hopper to the augers. By using sensors to
monitor the filling height during the paving proceedure, the transfer amount or speed regulation is completely automatic.
Augers: The augers are driven and controlled independently from the conveyors.
The auger hydraulics consist of two high pressure, variable displacement, closed loop
pumps driving two fixed volume motors. The left-hand and the right-hand half of the
auger can be controlled separately.
The conveying direction can be changed towards the center or the outside ensuring
that there is always a sufficient supply of material even if an excessive amount of material is required at one side. The auger speed is controlled by sensors that monitor
the material flow leaving the conveyor.
Height adjustment and extension of augers: Height adjustment and extension of
augers ensure an optimum variety of a wide range of paving thicknesses and widths.
Auger height is regulated at the operating panel and moved by means of hydraulic
cylinders.
Auger segments of different lengths can be attached to easily adapt to the different
paving widths.
Levelling/slope control system (option): The slope control system allows the paving thickness to be regulated at the left-hand or the right-hand side with a defined difference to the opposite side.
To determine the actual value, the two screed lifting arms are linked with a slope control rod.
The slope control system always operates in conjunction with the screed height adjustment of the opposite side.
By adjusting the height of the screed lifing arms, the paving thickness of the material
or the laying height of the screed can be controlled.
Activation occurs electro-hydraulically on both sides and can be controlled manually
by means of toggle switches or automatically by means of an electronic grade control
system.
Screed lifting arms: The screed lifting arms are used to lift the screed during transportation. Lifting occurs electro-hydraulically on both sides by actuating the hydraulic
cylinders on the screed lifting arms and is controlled by means of toggle switches on
the operating panel.
B_F1000W_US.fm 5-18
Truck hitch (option): The truck hitch holds the transport vehicle for paving material
in contact with the paver. They are located on the front of the hopper.
B5
3
Danger Zones
B_F1000W_US.fm 6-18
In the working areas around the machine (marked in red), there may be a risk of pulling in or crushing during normal operation caused by rotating and conveying elements, or by components in motion. The Danger Zones for the paver are illustrated
in the following drawing. Always be aware of Danger Zones.
B6
4
Technical data, standard configuration
4.1
Dimensions (all dimensions in inches)
60.64 in.
36.41 in.
(92.48 cm)
(154.03 cm)
129.10 in.
(327.9 cm)
101.70 in.
(258.3 cm)
78.80 in.
(200.15 cm.)
81.48 in.
(207.8 cm)
94.79 in.
(240.77 cm)
B_F1000W_US.fm 7-18
100.40 in.
(255.02 cm)
128.94 in.
(327.5 cm)
*Carlson EZ IV
B7
For screed technical data, refer to the screed operating instructions.
4.2
Allowed angle of rise and slope
max. 15°
max. 15°
max. 15°
Before operating your machine in an inclined position (gradient, slope, lateral inclination) which is above the specified limit value, please consult the customer service department for your machine!
Permissible approach angle
11.89
14.02 ° *
°
4.3
4.4
Turning circle
Turning radius - 1st, 2nd, 3rd gears
Turning radius - Pivot steer mode
B8
16 ft. (14.87 m)
5 ft (1.52 m)
B_F1000W_US.fm 8-18
* with truck hitch
4.5
Weights, F1000W
approx. 33000 lbs. (14969 kg)
Paver finisher without screed
Paver finisher with screed:
- Carlson EZ IV 1019
- Carlson EZ III 10
approx. 40000 lbs. (18144 kg)
approx. 39000 lbs. (17690 kg)
With filled hopper, include an
Additional maximum of:
approx. 30000 lbs. (13608 kg)
For the weights of the screed and the screed attachments, see the operating instructions for the screed.
Screed used
Basic width
(without cut-off shoes)
Minimum paving width
(with cut-off shoe)
Continuously hydraulically
adjustable up to
Maximum working widths
(with extension parts)
Performance data
Carlson EZ IV 1019
10
3.05
10
3.05
19
5.79
26
7.92
ft
m
Carlson EZ III 10
10
3.05
10
3.05
17
5.18
24
7.3
ft
m
Maximum transport speed
12
19.3
mph
km/hr
Maximum paving speed
285
86.9
fpm
m/min
Paving thickness
12
30.5
in
cm
Theoretical paving performance
2500
t/h
B_F1000W_US.fm 9-18
4.6
B9
Traction drive/chassis
Drive
Transmission
Speeds
Drive wheels
Steering wheels
Front wheel drive
Brakes
4.8
Performance
Fuel tank capacity
Pressure distribution
Hydraulic oil tank capacity
Hydraulic oil filling volume
B 10
Cummins QSB-6.7 Tier III (220 hp)
6-cylinder diesel engine (water-cooled)
230 hp @ 1800rpm
220 hp @ 2000rpm
2 tanks, 49 Gal (185 lt) each.
Hydraulic systemOperator stations
Hydraulic pressure supply source
4.10
(see above)
18 - 25TH, Rim Width 10” (air filled tires)
16”w - 22”h (solid rubber tires)
2 / 4 wheel hub hydro-motor, freely selected, variable drive performance,
Anti-spin control (o)
Running gear brake, hydraulic brake
Engine
Make/type
Version
4.9
Continuously variable hydrostatic drive, with
pump and engine
Planetary gear
Hydraulic pumps via distribution gear
(directly flanged to the engine)
Hydraulic circuits for:
- Propel system
- Auger drive system
- Works system (conveyor, hydraulic cylinders)
- Generator system
- Vibration system
- Front wheel system (including the FWA, or Front
Wheel Assist, and the steering
50 Gal (189 lt)
80 Gal (303 lt)
Electrical system
On-board voltage
Batteries
24 VDC
2 x 12 V, 32F 1050, RC 195
Alternator
Generator
24V, 70A
110/220, 36kw, 60Hz
B_F1000W_US.fm 10-18
4.7
4.11
Operator stations
Control consoles
4.12
Material compartment (hopper)
Volume
Minimum inlet height, center
4.13
4.14
approx. 207ft3 (5.86m3)
38.5 in (978mm)
Conveyor
Conveyor type
Dual independent slat conveyor
Conveyor control
Proportional speed control, both side driven independently
Augerr
Auger control
4.15
Dual swing out operation stations
Dual independent proportional augers
Permissible temperature ranges
Maximum Ambient Operating
Temperature
+120°F (+48.9°C)
B_F1000W_US.fm 11-18
For the filling volumes of the various lubricants and operating substances, see chapter F.
B 11
5
Location of instruction labels and identification plates
Manuals are located
behind operator seat
10
12
6
3
9
2
5
1
6
77
5
6
1
4
B_F1000W_US.fm 12-18
8
B 12
Item
Decal
Description
1
Warning! Crush area!
Keep a safe distance when machine is
running or moving. Do not work in this
area when the machine turns or machine parts move!
Crushing can cause severe injury or
death!
2
Warning! Do not work on this machine
unless you have read and fully understand the warnings and instructions in
the Operation/Maintenance and Safety Manual! Failure to follow the instructions or heed the warnings could
result in injury or death. Contact your
Dynapac dealer for replacement of
manuals. Proper care is your personal
responsibility!
3
Warning! Keep a safe distance from
rotating fans!
Do not work around or on the fan
when fan is in operation!
Rotating fan blades can cause severe
injury or death!
Filler neck for diesel fuel!
(Located on both sides of machine)
4
Tie-down points on machine!
(Located on both sides and front and
back of the machine)
5
B_F1000W_US.fm 13-18
Lifting point on machine!
(Located on both sides and front and
back of the machine)
6
B 13
Item
Decal
Description
Main battery switch location!
7
8
9
10
12
NOTE:
Follow instructions for using battery
main switch!
ON/OFF positions for battery main
switch.
ON - battery connected
OFF - battery disconnected
Warning! Hot parts or components
can cause burns! Keep a safe distance!
Hot surfaces can cause burns or personal injury. Do not come into contact
with hot parts or components. Wear
protective clothing or protective equipment!
Wear ear protection when using the
machine!
Hearing damage could result from
high noise level when ear protection is
not used!
Warning! Do not drive the machine
while standing!
Severe injury or death from an unseated position could occur!
Always use seat and seatbelt when
driving machine in transport gear!
Location of technical manuals on the
machine!
B_F1000W_US.fm 14-18
13
B 14
Identification label for the paver (6)
Item
Designation
1
Paver type
2
Operating Mass
3
Rated performance in kW
4
Year of Manufacture
5
Product identification number (PIN)
The Identification Label is located at the rear of the machine mounted onto the frame
near the lifting point. The paver type and the serial number can be found on this plate
as well as the operating mass, rated power and the year of manufacture.
B_F1000W_US.fm 15-18
The stamped vehicle identification number on the paver must match the product identification number.
B 15
6
EN standards
6.1
Continuous sound pressure
QSB-6.70 Tier III Engine.
level
on
the
F1000W
Wheeled
Paver,
Cummins
The operator always must use ear protection. The emission value at the ear of the
driver varies depending on the materials used for paving and may even rise above 85
dB(A). If no ear protection devices are used, hearing can be impaired.
The noise emission level of the paver finisher was measured under free-field conditions according to the EN 500-6 draft dated March 1997, and ISO 4872.
Sound pressure level at the operator’s position
(at the height of the head):
LH Console
LAF =
93.5 dB(A)
Sound capacity level:
RH Console
92.6 dB(A)
LWA = 122.34 dB(A)
Sound pressure level at the machine
Measuring point
Sound pressure level LAFeq (dB(A))
6.2
2
4
6
8
10
12
92.4
93.1
94.6
88.6
81.0
79.9
Operating conditions during measurement
B_F1000W_US.fm 16-18
The diesel engine was running at maximum speed. The screed was in working position, lowered to a rubber mat. Tamper and vibration unit were operated at min. 50%,
while the augers were operated at a minimum of 40% and the conveyors were operated at a minimum of 10% of their maximum speed.
B 16
6.3
Measuring point configuration
Hemispherical measuring surface with a radius of 16 m. The machine was at the centre. The measuring points had been assigned the following coordinates:
Measuring points 2, 4, 6, 8
X
Y
Z
X
Y
Z
±11.2
±11.2
1.5
- 4.32
+4.32
+10.4
-10.4
11.36
11.36
B_F1000W_US.fm 17-18
Co-ordinates
Measuring points 10, 12
B 17
B 18
B_F1000W_US.fm 18-18
C 1.1
1
Transport
Safety regulations for transportation
Accidents can happen when the paver and the screed are not properly prepared for
transportation or when transportation is carried out improperly!
Reduce both the paver and the screed to their basic widths. Remove all protruding
parts (such as the automatic levelling system, auger limit switches, aprons, etc.).
When transporting under a special permit, secure these parts!
Close the hopper lids and engage the hopper transport safeguards. Lift the screed
and engage the screed transport safeguards. Convert the protective roof (if equipped)
and engage the latch.
Check that the clamping device for the auger crossbeam is fastened and that the telescopic tube cannot slide out (see chapter E, section 2.5).
Pack all parts that are not permanently fixed to the paver finisher and the screed into
the appropriate boxes and into the hopper.
Close all coverings and check that they are securely seated.
When loading using ramps, there is a risk that the machine will slip, tilt or overturn.
Drive carefully! Keep people away from the danger area!
Additional stipulations for transportation on public roads:
C_1.1_01_US.fm 1-16
Depending on local regulations tracked pavers must not be driven as self-propelling
vehicles on public roads.
Note the different state and local regulations.
The operator must be in the possession of a valid permit for vehicles of this type.
1
The operating panel must be moved to the side of the oncoming traffic and secured
in this position.
The driving lights must be properly adjusted.
Only attachments and extension parts may be transported in the hopper, no material!
C_1.1_01_US.fm 2-16
If necessary, the operator must be assisted by a second person when driving on public roads – especially at road crossings and intersections.
2
2
Transportation on low-bed trailers
Reduce the paver and the screed to their basic widths; also remove any attached side
plates.
The maximum approach angle is indicated in the section entitled “Technical Data“!
Check the fill level of the operating fluids so that these do not escape when driving on
an incline.
Attachment and loading equipment must meet the federal, state and local safety regulations!
The weight of the paver finisher must be taken into consideration when selecting the
attachment and loading equipment!
2.1
Preparations
C_1.1_01_US.fm 3-16
- Prepare the paver for transportation (see chapter D).
- Remove all overlaying or loose parts from paver finisher and screed (see also Operating instructions for the screed). Store these parts in a safe place.
- Move the paver to the uppermost position if necessary.
3
Transport on Low Bed Trailers
1
7
10
8
4
2
9
5
C_1.1_01_US.fm 4-16
11
4
Item
Operation
1
-
Select the master console.
2
-
Close the hopper lids.
3
-
Engage both hopper transport safeguards.
4
-
Lift the screed.
-
Retract the screed to the basic width of the
paver.
6
-
Engage both screed transport safeguards.
7
-
Lift the auger.
8
-
Turn the range shift selector to zero.
-
Turn the travel speed preselecting regulator
to zero.
10
-
Move the drive lever forward.
11
-
Extend levelling cylinders completely.
12
-
Set the drive lever to the center position.
5
C_1.1_01_US.fm 5-16
9
5
2.2
Driving onto the low-bed trailer
Make sure that there are no persons in the danger area during loading.
A
1
2.3
2
Use the work gear and low engine speeds to drive onto the low-bed trailer.
Lower the screed onto wooden blocks on the low-bed trailer.
Turn the switch off.
Attach and secure the protective hood to protect the operating panel.
Secure the paver finisher to the low-bed trailer:
C_1.1_01_US.fm 6-16
- Use only proper and permitted load fastening devices.
- Use the four tie-down points provided (1, 2). These points have a capacity of 10,000
lbs. (3545 kg) each.
- Wait until the exhaust extension pipe has cooled down; then swing and secure it.
6
2.4
After transportation
Remove the chains, hooks and all other transport tie-down tools.
Swing the exhaust extension pipe up and secure it.
Lift the screed to the transport position.
Start the engine and drive from the trailer at a low speed.
Park the paver in a secure spot, lower the screed and switch off the engine.
Remove the key and cover the operating panel with the protective hood, then secure it.
C_1.1_01_US.fm 7-16
-
7
3
Transportation
Reduce the paver and the screed to their basic widths; also remove any attached side
plates.
3.1
Preparations
C_1.1_01_US.fm 8-16
- Prepare the paver for transportation (see chapter D).
- Remove all overlaying or loose parts from paver and screed (see also Operating
instructions for the screed). Store these parts in a safe place.
8
Transport Preparation
1
7
10
8
4
2
9
5
C_1.1_01_US.fm 9-16
11
9
Item
Operation
1
-
Select the master console.
2
-
Close the hopper lids.
3
-
Engage both hopper transport safeguards.
4
-
Lift the screed.
-
Retract the screed to the basic width of the
paver finisher.
6
-
Engage both screed transport safeguards.
7
-
Lift the auger.
8
-
Turn the range shift selector to zero.
-
Turn the travel speed preselecting regulator
to zero.
10
-
Move the drive lever forward.
11
-
Extend levelling cylinders completely.
12
-
Set the drive lever to the center position.
5
C_1.1_01_US.fm 10-16
9
10
3.2
Driving mode
3
1
C_1.1_01_US.fm 11-16
2
11
Item
1
Operation
-
Turn the selector to position 3.
-
Turn the preselecting regulator to its maximum point.
-
Use the drive lever to regulate the speed.
2
3
C_1.1_01_US.fm 12-16
Press the emergency stop button when a dangerous situation arises!
12
4
Loading by crane
Use only lifting gear that can bear the load.
(See chapter B for weights and dimensions).
Attachment and loading equipment must meet the conditions of the applicable accident prevention regulations!
The vehicle's center of gravity is dependent on the mounted screed.
2
1
C_1.1_01_US.fm 13-16
Four lifting eyes (1, 2) are provided for loading the vehicle with a crane.
Depending on the type of screed used, the paver's center of gravity, with the screed
mounted, is located in the area of the drive unit's rear reversing roller.
- Secure vehicle wherever it is parked.
- Engage the transport safeguards.
13
- Remove any attachments and extension parts from the paver and the screed until
the basic width has been attained.
- Remove all protruding or loose parts(see chapters E and D).
- Attach lifting gear to the four attachment points (1, 2).
The max. permissible attachment point load is
Attachment point (1): 20,000 lbs. (9071.9 kg) each for a total of 40,000 lbs. (18144 kg)
Attachment point (2): 20,000 lbs. (9071.9 kg) each for a total of 40,000 lbs. (18144 kg)
C_1.1_01_US.fm 14-16
Make sure that the paver is secured in a horizontal position during transport!
14
5
Towing
Follow all regulations and apply all safety measures applicable for towing heavy construction machines.
The towing vehicle must be capable of securing the paver, even on slopes.
Use only approved tow bars!
If necessary, remove any attachments and accessories from the paver finisher and
the screed until the basic width has been attained.
A hand pump is located in the engine compartment (left side) that must be activated
to be able to tow the machine.
Pressure for releasing the brakes is built up with the hand pump.
Do not release the track drive system brakes until the machine is sufficiently secured
against accidental rolling or is already properly connected to the towing vehicle.
- Attach the towing device to the tiedown points located in the bumper under the hopper.
- Push down and turn the Pump Pressure Lock and Release Handle (2) to
the DOWN position.
- Pump the Handle (3) of the hand
pump up and down until sufficient
pressure has been built up for the
track drive system brakes to release.
3
2
Now carefully and slowly tow the paver out of the construction area. The maximum
towing speed is 2 mph (3.2 kph).
C_1.1_01_US.fm 15-16
Always tow the machine the shortest distance to the means of transport or the next
parking opportunity.
After towing, return the Pump Pressure Lock and Release Handle (2) to the UP position. This will release pressure in the Hand Pump and will allow the braking system
to engage.
The track drive system brakes are now reactivated and the machine is secured
against rolling.
15
6
Safely parking the vehicle
When the paver is parked at a location accessible to the public, it must be secured in
such a way that unauthorized persons or playing children cannot damage the vehicle.
- Remove the ignition key and the main
switch (1) and take it with you – do not
hide them somewhere on the machine.
1
2
C_1.1_01_US.fm 16-16
- Protect the operating panel with the
dust cover (2) and lock it.
- Store loose parts and accessories in a
safe place.
16
D 1.1
1
Operation
Safety regulations
Starting the engine, the traction drive, the conveyor, the auger, the screed or the lifting
devices can cause injuries or even the death of persons.
Make sure before starting any of these devices that no-one is working on, in or beneath the paver finisher or within its danger area!
- Do not start the engine or actuate any controls if this is expressly forbidden!
Unless otherwise specified, the controls may only be actuated when the engine is
running!
Never crawl into the auger tunnel or step into the hopper or onto the conveyor. Danger to 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 damage is detected, eliminate it immediately! Operation must not be continued when the machine is defective!
- Do not let any persons ride on the paver finisher or the screed!
- Remove obstacles from the road and the work area!
- Always try to choose a driver position which is opposite to the flow of traffic! Lock
the operating panel and the driver's seat.
- Maintain sufficient safety clearance from overhanging objects, other machines and
points of danger!
- Be careful when traveling on rough terrain to keep the paver finisher from slipping,
tipping or turning over.
D_1.1_01_US.fm 1-42
Always maintain control of the machine; never try to use it beyond its capabilities!
D 1.1 1
2
Controls
2.1
Operating panel
4
3
C
B
Left Hand
Operator’s Panel
D
A
2
1
4
3
C
B
Right Hand
Operator’s Panel
D
2
1
D 1.1 2
D_1.1_01_US.fm 2-42
A
Item
Designation
Brief description
-
1
2
NOTE:
-Use the turn signals when turning!
-For precise adjustment, see
trimming".
Steering wheel
Operating panel
latch
Steering is regulated by the speed of the two drive units.
"Straight-ahead
travel
Secures the adjustable operating panel into position.
- Pull the locking knob and swivel the operating panel to the
desired position.
Allow the latch to engage in one of the possible positions
again.
When not secured, the operating panel can move. Danger of accidents!
EIC
Engine Information Center
4
Console lights
-
Display for engine information, diagnostic information and
configuration.
Illuminates the instrument panels when the parking light is
switched on.
D_1.1_01_US.fm 3-42
3
D 1.1 3
PANEL A
10
14
11
Left Hand
Operator’s Panel
12
15
14
11
Right Hand
Operator’s Panel
15
D 1.1 4
D_1.1_01_US.fm 4-42
12
Item
10
Designation
Brief description
Ignition lock
Key positions:
- 1: Ignition OFF
- 2: Ignition ON
- 3: Starter function
NOTE:
The key can only be removed in position 1.
Press in case of emergencies and to indicate when the machine starts to move!
11
Horn
NOTE:
The horn can also be used to communicate acoustically
with the truck driver for material loading!
Setting the maximum speed that can be performed when the
drive lever is at its stop.
12
13
Travel drive preselector
Straight-ahead
travel trimming
NOTE:
The speed level is preset with the "Travel drive/engine
pre-selector switch".
This potentiometer has the following functions:
- Steering the paver through a large curved radius:
- Turn the potentiometer in the corresponding direction until the required steering angle is achieved.
- Straight-ahead travel trimming in speed level 3 :
- Set the steering wheel to position "0"; then adjust
the potentiometer until the paver is traveling straight
ahead.
NOTE:
Automatic straight-ahead travel trimming takes place in
preset speed levels 1 and 2.
14
Truck hitch
Opening and closing the truck hitch device at the front of the
paver.
Toggle switch function:
- Toggle the switch left: Open truck hitch.
- Toggle the switch right: Close truck hitch.
D_1.1_01_US.fm 5-42
Do move or tow the paver until all persons and equipment are out of the Danger Zone!
D 1.1 5
15
Open/close hopper
To open/close both halves of the hopper.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Close hoppers.
- Toggle the switch back (toward the operator): Open
hoppers.
D_1.1_01_US.fm 6-42
Do not open or close the hopper until all equipment and
persons are out of the Danger Zone!
D 1.1 6
PANEL B
28
27
30
29
22
26
23
Left Hand
Operator’s Panel
20
25
20a
21
22
26
30
Right Hand
Operator’s Panel
20
21
D_1.1_01_US.fm 7-42
20a
D 1.1 7
Item
20
Designation
Drive lever
(traction)
Brief description
For switching on the paver finisher functions and for continuously regulating the road speed – forward or reverse.
Zero position: starting is possible; engine at idling speed; no
traction; protection against inadvertent start.
To move the lever, lift the ring (20a).
Depending on the position of the drive lever, the following functions can be activated:
- 1st position:
Engine runs at preselected speed
(see "Travel drive/engine preselector
switch").
- 2nd position: Conveyor and auger on.
- 3rd position: Travel drive (propel) is on; increase speed by
turning the speed control until it stops (maximum speed).
The maximum speed is set with the travel drive/engine
preselector switch and with the travel drive preselector.
The floating position function is only active when the
drive lever is moved from its central position!
If the drive lever is moved to the central position, the
paver finisher automatically switches to screed stop
(lock).
To preselect the desired speed level.
- Switch setting 0: Preselected vehicle speed "0"
- Switch setting 1: Vehicle speed – for paving with low
operating speed.
- Switch setting 2: Vehicle speed – for paving with higher operating speed.
- Switch setting 3: Transport speed – for transportation.
D_1.1_01_US.fm 8-42
21
Preselector switch
travel drive/engine
fast/slow
D 1.1 8
PANEL B
28
30
29
27
22
26
23
20
25
Left Hand
Operator’s Panel
20a
21
22
26
30
Right Hand
Operator’s Panel
20
21
D_1.1_01_US.fm 9-42
20a
D 1.1 9
Item
22
23
24
Designation
Brief description
Pushbutton
parking brake
Use the pushbutton to activate the parking brake.
The parking brake must be activated anytime the vehicle is stationary.
- Parking brake activated – push button illuminated
- Parking brake de-actived – push button not illuminated
Front wheel drive
On/Off
In the upper position the supplementary front-wheel drive is
engaged.
- Switch On: Paver Gear Selection in Idle
Drive Assist is on.
- Switch On: Paver Gear Selection in 1st
Drive Assist is on
- Switch On: Paver Gear Selection in 2nd
Drive Assist is on
- Switch On: Paver Gear Selection in 3rd
Drive Assist is on
- Switch Off: Paver Gear Selection in any
Drive Assist is off
position, the
position, the
position, the
position, the
position, the
not used
Switches the working lights on and off.
Toggle switch function:
- Toggle the switch to setting 0: Working lights OFF.
- Toggle the switch to setting 1: Working lights ON.
25
Working
lights ON / OFF
Avoid using hi-beam lights with on coming traffic. Hibeam lights can cause temporary blindness to on coming drivers!
Direction of travel
indicator ("flasher")
D_1.1_01_US.fm 10-42
26
The turn signal indicates the direction the paver is turning.
Detent switch function:
- Left switch position: Left-hand flasher.
- Right switch position: Right-hand flasher.
D 1.1 10
PANEL B
28
27
30
29
22
26
23
Left Hand
Operator’s Panel
20
25
20a
21
22
26
30
Right Hand
Operator’s Panel
20
21
D_1.1_01_US.fm 11-42
20a
D 1.1 11
Item
27
Designation
Vibration
ON / OFF
Brief description
Switches screed vibration on and off.
Toggle function:
- Toggle the switch to setting 0: Vibration OFF.
- Toggle the switch to setting 1: Vibration ON.
NOTE:
Speed control
screed")
28
(o)
Tamper
ON / OFF
(see
"Operating
instructions
for
the
for
the
Switches the screed tamper function on and off.
Toggle switch function:
- Toggle the switch to setting 0: Tamper OFF.
- Toggle the switch to setting 1: Tamper ON.
NOTE:
Speed control
screed")
(see
"Operating
instructions
To select the primary activated operating panel.
Toggle switch function:
To avoid operator errors, only one operating panel –left
or right- can be activated at any one time.
29
30
Selector switch
left / right operating
panel (19)
+ active panel LED
(20)
- Toggle the switch left: Left operating panel active.
- Toggle the switch right: Right operating panel active.
The active panel LED indicates whether the relevant
operating panel is activated or deactivated by switch
(19).
D_1.1_01_US.fm 12-42
- LED "ON": Operating panel active.
- LED "OFF": Operating panel inactive.
D 1.1 12
PANEL C
46
45
40
42
47
41
44
48
D_1.1_01_US.fm 13-42
43
D 1.1 13
Item
Designation
Brief description
In the case of an emergency (danger to persons, possible collision, etc.), press the Emergency Stop button!
- Pressing the Emergency Stop button switches the engine,
the drives and the steering system off.
40
Emergency stop
button
Paving, lifting the screed or other functions are no longer possible! Do not reset the Emergency Stop Button
until the danger is no longer present!
-
41
42
43
Left conveyor
OFF /
max. output
Overrides the conveyor function in automatic mode.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Conveyor OFF.
- Toggle the switch back (toward the operator): Conveyor is at 100% feed capacity.
Right conveyor
OFF /
max. output
Overrides the conveyor function in automatic mode.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Conveyor OFF.
- Toggle the switch back (toward the operator): Conveyor is at 100% feed capacity.
Left auger
OFF /
max. output
Overrides the auger function in automatic mode.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Auger OFF.
- Toggle the switch back (toward the operator): Auger
is at 100% feed capacity.
Right auger
OFF /
max. output
Overrides the auger function in automatic mode.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Auger OFF.
- Toggle the switch back (toward the operator): Auger
is at 100% feed capacity.
D_1.1_01_US.fm 14-42
44
To restart the engine, the button must be pulled out again.
D 1.1 14
PANEL C
46
45
40
42
47
41
44
48
D_1.1_01_US.fm 15-42
43
D 1.1 15
Item
45
Designation
Conveyor + auger
ON + activation
LED / OFF
Brief description
Toggles the conveyor and auger (automatic or manual mode)
on and off.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Auger + conveyor are ready for operation (LED ON).
- Toggle the switch back (toward the operator): Auger
+ conveyor OFF.
If the vehicle must be restarted, this function is automatically switched OFF.
Toggles between AUTOMATIC and MANUAL operating
modes for the conveyor + auger.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Operating mode "AUTO" (LED ON).
46
Operating mode
conveyor + auger
AUTO
+ activation LED
/ MANUAL + activation LED
The auger + conveyor are switched on by moving the
drive (propel) lever from the center position and are
controlled by the relevant material limit switches.
- Toggle the switch back (toward the operator): Operating mode "MANUAL" (LED ON).
The auger + conveyor are permanently switched on
(without material control thru the relevant limit switches).
D_1.1_01_US.fm 16-42
If the vehicle must be restarted, this function is automatically switched OFF.
D 1.1 16
PANEL C
46
45
40
42
47
41
44
48
D_1.1_01_US.fm 17-42
43
D 1.1 17
Item
Designation
Brief description
Hydraulically adjusts the height of the left auger.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raise auger.
- Toggle the switch back (toward the operator): Lower
auger.
47
Raise / lower
left auger
Toggle both switches (raise / lower left + right auger) at
the same time to keep the auger crossbeam level!
Do not raise or lower the auger until all equipement and
persons are clear of the machine
Hydraulically adjusts the height of the right auger.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raise auger.
- Toggle the switch back (toward the operator): Lower
auger.
48
Raise / lower
right auger
Toggle both switches (raise / lower left + right auger) at
the same time to keep the auger crossbeam level!
D_1.1_01_US.fm 18-42
Do not raise or lower the auger until all equipement and
persons are clear of the machine
D 1.1 18
PANEL D
53
52
54
51
55
50
53
52
51
D_1.1_01_US.fm 19-42
50
D 1.1 19
Item
50
Designation
Extend / retract
left screed extension
Brief description
Hydraulically retracts and extends the left extendable part of
the screed.
Toggle switch function:
- Toggle the switch left: Extend screed extension.
- Toggle the switch right: Retract screed extension.
Do not extend or retract the screed until all equipement
and persons are away from the machine
51
Extend / retract
right screed extension
Hydraulically retracted and extended the right
extendable part of the screed.
Toggle switch function:
- Toggle the switch left: Retract screed extension.
- Toggle the switch right: Extend screed extension.
Do not extend or retract the screed until all equipement
and persons are away from the machine
Hydraulically raises and lowers the screed.
Push button function:
- Toggle the switch up: Raise screed.
- Toggle the switch down: Lower screed.
52
Raise / lower
screed
D_1.1_01_US.fm 20-42
Do not raise or lower the screed until all equipement
and persons are away from the machine
D 1.1 20
PANEL D
53
52
54
51
55
50
53
52
51
D_1.1_01_US.fm 21-42
50
D 1.1 21
Item
Designation
Brief description
Switches between floating screed functions and screed stop.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Screed stop.
- "Screed stop" is used to lock the screed hydraulics
to prevent the screed from sinking into the paved
material when the paver is stationary (intermediate
stop).
"Screed stop" is not sufficient as a safeguard during
transport or maintenance work! Insert the mechanical
screed transport safeguard!
53
Screed floating position
+ activation LED
/ screed stop
+ activation LED
- Toggle the switch back (toward the operator): Lower
the screed and switch to "floating position".
- During paving, the screed must always be in its
floating position.
This also applies to intermediate stops and truck
changes.
As soon as the floating position function has been activated and the screed is lowered, the screed lifting cylinder pressure is reduced.
The raise / lower screed function can be carried out
while the screed is switched to the floating position. Following adjustment, the screed is automatically switched
back to the floating position.
D_1.1_01_US.fm 22-42
The floating position function is only active when the
drive lever is moved from its central position!
If the drive lever is moved to the central position, the
paver automatically switches to screed stop (or locked
position).
The activation LED for screed stop is then activated.
D 1.1 22
PANEL D
53
52
54
51
55
50
53
52
51
D_1.1_01_US.fm 23-42
50
D 1.1 23
Item
54
Designation
Left leveling
cylinder
Brief description
Manually extends and retracts the leveling cylinder when the
vehicle is being operated without the automatic leveling system.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Retract or raise leveling cylinder.
- Toggle the switch back (toward the operator): Extend
or lower leveling cylinder.
Do not raise or lower the leveling cylinder until all equipment and persons are clear of the machine!
55
Right leveling
cylinder
To manually extend and retract the leveling cylinder when the
vehicle is being operated without the automatic leveling system.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Retract or raise leveling cylinder.
- Toggle the switch back (toward the operator): Extend
or lower leveling cylinder.
D_1.1_01_US.fm 24-42
Do not raise or lower the leveling cylinder until all equipment and persons are clear of the machine!
D 1.1 24
3
Auxiliary functions
61
62
D_1.1_01_US.fm 25-42
60
D 1.1 25
Item Designation
Brief description
Controls the working lights.
- Toggle the switch up: Turns on the lights.
- Toggle the switch down: Turns off the lights.
60
Headlights
ON / OFF
To prevent the battery from being drained, switch the
headlights “ON” only when the diesel engine is running!
Activates the Release Agent fluid spraying system.
- Toggle the switch up: Turns on the sprayer.
- Toggle the switch down: Turns off the sprayer.
61
Release Agent fluid spray system
ON/OFF
To prevent the battery from being drained, switch the
sprayer “ON” only when the diesel engine is running!
Hazard warning
flasher
NOTE:
The Hazard Warning Flasher button is also for activating
the rotary beacon when attached.
D_1.1_01_US.fm 26-42
62
Push button to turn the Hazard Warning Flasher “ON”. Hazard
Warning Flasher must be turned “ON” on roads and in the construction site area.
D 1.1 26
4
Left / right remote controls and handsets
D
B
A
C
Item Designation
Brief description
Controls certain functions on the left-hand side of the vehicle
and various overall functions.
RIGHT remote
control
-
B
Controls certain functions on the right-hand side of the vehicle and various overall functions.
C
LEFT handset
Removable handset for controlling certain functions on the
left-hand side of the vehicle.
D
RIGHT handset
Removable handset for controlling certain functions on the
right-hand side of the vehicle.
D_1.1_01_US.fm 27-42
LEFT remote control
-
A
D 1.1 27
Left / right remote control
86
70
85
73
84
83
71
75
77
82
78
80
70
87
85
74
84
76
83
77
82
79
81
D_1.1_01_US.fm 28-42
72
D 1.1 28
Item Designation
Brief description
In case of an emergency (danger to persons, possible collision,
etc.), press the Emergency Stop button!
- Pressing the Emergency Stop button switches the engine,
the drives and the steering system off.
70
Emergency stop
button
Paving, lifting the screed or other functions are no longer
possible! Do not reset the Emergency Stop Button until
the danger is no longer present!
-
71
72
73
74
To restart the engine, the button must be pulled out again.
Left auger
OFF /
max. output
Overrides the conveyor function in automatic mode.
Toggle switch function:
- Toggle the switch right: Auger OFF.
- Toggle the switch left: Auger 100% feed capacity.
-
Right auger
OFF /
max. output
Overrides the auger function in automatic mode.
Toggle switch function:
- Toggle the switch left: Auger OFF.
- Toggle the switch right: Auger 100% feed capacity.
-
Left conveyor
OFF /
max. output
Overrides the conveyor function in automatic mode.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Conveyor OFF.
- Toggle the switch back (toward the operator): Conveyor 100% feed capacity.
-
Right conveyor
OFF /
max. output
Overrides the conveyor function in automatic mode.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Conveyor OFF.
- Toggle the switch back (toward the operator): Conveyor 100% feed capacity.
The conveying direction of the left half of the auger can be reversed in order to slightly reverse a material supply which may
be too high.
D_1.1_01_US.fm 29-42
75
Left auger reversing switch
The switch can be activated as often as needed to allow
the conveyor to run further in the reverse direction.
D 1.1 29
The conveying direction of the right half of the auger can be reversed in order to slightly reverse a material supply which may
be too high.
76
Right auger reversing switch
D_1.1_01_US.fm 30-42
The switch can be activated as often as needed to allow
the conveyor to run further in the reverse direction.
D 1.1 30
86
70
85
73
84
83
71
75
77
82
78
80
70
87
85
74
84
76
83
77
82
79
81
D_1.1_01_US.fm 31-42
72
D 1.1 31
Item Designation
Brief description
Sound the horn to warn of danger!
77
78
Horn
Left leveling
cylinder
NOTE:
The horn can also be used to communicate with the vehicle driver!
Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system.
Toggle switch function:
- Toggle the switch forward (away from the screed): Retract leveling cylinder.
- Toggle the switch back (toward the screed): Extend
leveling cylinder.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
79
Right leveling
cylinder
Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system.
Toggle switch function:
- Toggle the switch forward (away from the screed): Retract leveling cylinder.
- Toggle the switch back (toward the screed): Extend
leveling cylinder.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
80
Extend / retract
left screed
Hydraulically retracts and extends the left extendable part of the
screed.
Toggle switch function:
- Toggle the switch left: Extend screed extension.
- Toggle the switch right: Retract screed extension.
D_1.1_01_US.fm 32-42
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
D 1.1 32
81
Extend / retract
right screed
To hydraulically retract and extend the right
extendable part of the screed.
Toggle switch function:
- Toggle the switch left: Retract screed extension.
- Toggle the switch right: Extend screed extension.
D_1.1_01_US.fm 33-42
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
D 1.1 33
86
70
85
73
84
83
71
75
77
82
78
80
70
87
85
74
84
76
83
77
82
79
81
D_1.1_01_US.fm 34-42
72
D 1.1 34
Item Designation
82
Raise / lower
extendable screed
part
Brief description
Hydraulically raises and lowers the extendable screed part.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raise extendable part.
- Toggle the switch back (toward the operator): Lower
extendable part.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
83
Raise / lower extension scope
Hydraulically raises and lowers the extension slope.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raise extension slope.
- Toggle the switch back (toward the operator): Lower
extension slope.
Before operating the toggle switch, ensure that equipment and persons are clear of the machine!
Berm lock / unlock
84
Locks and unlocks the Berm.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Unlocks the Berm.
- Toggle the switch back (toward the operator): Locks
the berm.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
Berm raise / lower
D_1.1_01_US.fm 35-42
85
Hydraulically raises or lowers the Berm.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raises Berm.
- Toggle the switch back (toward the operator): Lowers
Berm.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
D 1.1 35
86
Crowning Adjustment
The screed is equipped with adjustable crowning; adjusting this
enables the required crowning to be set.
Toggle switch function:
- Toggle the switch forward (away from the operator): Increases Crowning.
- Toggle the switch back (toward the operator): Decreases Crowning.
D_1.1_01_US.fm 36-42
87
Screed heater system ON / OFF
+ activation LED
Jointly switches all of the screed heater system's heating sections on and off.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Screed heater system ON and indicator (LED) light
ON.
- Toggle the switch back (toward the operator): Screed
heater system OFF.
D 1.1 36
Left / right handset
100
106
102
104
101
107
103
D_1.1_01_US.fm 37-42
105
D 1.1 37
Item Designation
100
Left leveling
cylinder
Brief description
Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raises the left screed side arm.
- Toggle the switch back (toward the operator): Lowers
the screed side arm.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
101
Right leveling
cylinder
Manually extends and retracts the leveling cylinder when the vehicle is being operated without the automatic leveling system.
Toggle switch function:
- Toggle the switch forward (away from the operator):
Raises the right screed side arm.
- Toggle the switch back (toward the operator): Lowers
the screed side arm.
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
102
Left auger
OFF /
max. output
Overrides the auger function in automatic mode.
Toggle switch function:
- Toggle the switch right: Auger OFF.
- Toggle the switch left: Auger 100% feed capacity.
103
Right auger
OFF /
max. output
TOverrides the auger function in automatic mode.
Toggle switch function:
- Toggle the switch left: Auger OFF.
- Toggle the switch right: Auger 100% feed capacity.
Extend / retract
left screed
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
D 1.1 38
D_1.1_01_US.fm 38-42
104
Hydraulically retracts and extends the left extendable part of the
screed.
Toggle switch function:
- Toggle switch left: Extend screed.
- Toggle switch right: Retract screed.
105
Extend / retract
right screed
Hydraulically retracts and extends the right extendable part of
the screed.
Push button function:
- Toggle switch left: Retract screed.
- Toggle switch right: Extend screed.
D_1.1_01_US.fm 39-42
Before operating the toggle switch, ensure that eqipment
and persons are clear of the machine!
D 1.1 39
100
106
102
104
101
107
103
D_1.1_01_US.fm 40-42
105
D 1.1 40
Item Designation
Brief description
Handset connection cable
-
Connects to the left remote control.
107
Handset connection cable
-
Connects to the right remote control.
D_1.1_01_US.fm 41-42
106
D 1.1 41
D 1.1 42
D_1.1_01_US.fm 42-42
D 2.0
1
Operation
Operation of the graphical terminal
1
2
Item
1
Brief description
Display
- Display for engine information, diagnostic information and
configuration.
Softkeys
- Terminal is controlled by navigation through a set of four
soft keys.The keys are context dependent. Soft key
selection options are displayed above each key and are
dependent on the current navigation location within the
engine monitor software program.
D_2.0_01_US.fm 1-24
2
Designation
D 2.0 1
Navigation using Soft Keys
Item
1
2
3
4
5
2
3
6
5
2
3
7
Designation
Brief description
1
Brightness/Contrast
-
Press to access brightness and contrast settings.
2
Navigate Up
-
Press up to move up through menu items.
3
Navigate Down
-
Press up to move down through menu items.
4
Main Menu
-
Press to go to Main Menu screen.
5
Exit/back one screen
-
Press to go back one screen.
6
Select
-
Press to make selection.
7
Next
-
Press to navigate to next digit or screen element.
As a general rule, the far right soft key is the selector button and the far left soft key
is the step back one screen key. To engage full screen use, the on-screen selections
are not displayed when not in use. Press any soft key to display current selection options. The selection options will be displayed for three seconds.
D 2.0 2
D_2.0_01_US.fm 2-24
1.1
Brightness/Contrast
Adjustment
- Adjust brightness and
trast levels by pressing
far left soft key. This
display the brightness
contrast soft key bar.
conthe
will
and
The bar will disappear after 3 seconds of inactivity.
Main Menu - Start Menu
D_2.0_01_US.fm 3-24
The Main Menu screen is the
starting point for configuring
the terminal.
Basic Setup
-
Use to set time/date, language and units.
Diagnostics
-
Use to set system info, info fault log and J1939 lists.
Screen Setup
-
(PIN protected)
System Setup
-
(PIN protected)
D 2.0 3
Main Menu - Basic Setup
Use the Basic setup screen
to set time, language and
display units for the terminal.
-
Use Time/Date set date and display style for time and
date information.
-
Use Language to set the system language.
-
Use Units to set speed, distance, pressure, volume,
temperature and fuel rates and economy settings.
Time/Date
Language
D_2.0_01_US.fm 4-24
Units
D 2.0 4
Main Menu - Basic Setup
-Time / Date
Use Time/Date screen to set
Time, Date, calendar style
and time style. Use up, down
select and next soft keys to
navigate.
Main Menu - Basic Setup
-Language
D_2.0_01_US.fm 5-24
Use Language screen to select program language. Languages available, English,
French, German, Italian,
Swedish and Spanish.
The default language setting
is English.
D 2.0 5
Main Menu - Basic Setup
-Units
Use the up, down, select and
next soft keys to define unit
measurements.
-
km/h, mph
Distance
-
km, mi
Pressure
-
kPa, bar, Ibs/ sq in
Volume
-
l, gal, imp gal
Temperature
-
°C, °F
Fuel Economy
-
1/100km, mpg, mpig
Fuel Rate
-
l/h, g/h, ig/h
D_2.0_01_US.fm 6-24
Speed
D 2.0 6
Main Menu - Diagnostics
D_2.0_01_US.fm 7-24
Use the Diagnostics screen
to display current system information, view and monitor
fault logs and display all
J1939 devices connected to
the graphical terminal.
D 2.0 7
Main Menu - Diagnostics
-System Info
The system info screen displays the hardware system
serial number, current software version, current system
version and node number.
Only information is displayed
in the System Info window.
No changes can be made.
Main Menu - Diagnostics
-Fault Log
D_2.0_01_US.fm 8-24
Fault information is saved
and stored to the fault log.
Select either Active or Previous Faults to monitor fault
activity. Select specific faults
to list more information.
D 2.0 8
Main Menu - Diagnostics
-Fault Log
Active and Previous Faults
Selecting Active Faults in the
Fault Menu will display all active faults on the CAN network.
D_2.0_01_US.fm 9-24
Selecting Previous Faults in
the Fault Menu will display all
previously active faults on
the CAN network.
D 2.0 9
Main Menu - Diagnostics
-Fault Pop-Up Alarms
When a fault is detected on
the CAN network, a flashing
red warning alarm will be activated and a fault information pop-up window will be
displayed listing current fault
information.
Warning lights will flash when
a popup alarm occurs and
will stay flashing until acknowledged.
Warning lights will remain lit
until the fault is no longer on
the CAN network.
Fault pop-up softkey actions:
-
Select to clear pop up and return directly to previous
screens
-
Scroll between screens and within screens.
-
Scroll between screens and within screens.
-
Confirm any selections or acknowledge any fault/
warning and to go back to normal screen.
Fault Pop-Up Alarms
D_2.0_01_US.fm 10-24
- Faults no longer active will also be displayed in the Previous Faults log.
- Faults that have been acknowledged and are no longer active will be shown in the
Currently Active Faults log in italics.
- Pop-up fault alarms can be disabled by setting the Fault Pop-Up to off in the CAN
section of the System.
D 2.0 10
Main Menu - Diagnostics
-Device List
D_2.0_01_US.fm 11-24
The Device list page will list
all J1939 devices and addresses that are currently being monitored on the
network.
D 2.0 11
Main Menu - Diagnostics
-Quick Data
The Quick Data function allows selected signals to be
monitored in a scrollable single view display.
To select signals for display,
press the far right soft key.
Quick Data softkey
D_2.0_01_US.fm 12-24
Scroll through signal list using the up and down arrow
soft keys and select/de-select signals for Quick View
monitoring by pressing the
far right (check mark) soft
key. Signals selected for display will show an asterisks to
the left of the signal name.
D 2.0 12
Start Display
Appears at system start.
2
3
4
D_2.0_01_US.fm 13-24
1
D 2.0 13
Display 01
Display menu
- Vehicle Speed (1)
in fpm.
- Engine RPM (2)
in rpm - with bar chart.
- Diesel tank filling (3)
in % - with bar chart.
- Engine
Coolant
Temperature(4) in °F.
1
2
3
4
1
2
3
4
Display 02
Display menu
D_2.0_01_US.fm 14-24
- Actual Engine Torque(1)
in %.
- Engine RPM (2)
in rpm - with bar chart.
- Actual Engine Torque(1)
in% - with bar chart.
- Engine
Coolant
Temperature(4) in °F - with bar
chart.
D 2.0 14
Active Faults Display
Appears when a fault occurs.
- To see a list with active
faults, first use button 2 or 3
from the current screen and
go to Active Fault Screen,
then press button 4 to get
into
the
Active
Fault
Screen.
- After entering the Active
Fault Screen, Scroll thru
the faults by using buttons
2 or 3.
- To leave the Active Fault
Screen, press button 1
1
2
3
Fault Sources and Codes
Source
1
Sensor Power
2
Battery
3
Left Joystick
4
Right Joystick
5
Left Steer Wheel/
Position Sensor
6
Right Steer Wheel/
Position Sensor
7
Left Trim Steer POT
8
Right Trim Steer POT
9
Left Max Speed POT
10
Right Max Speed POT
11
Left Pump
12
Right Pump
13
Generator Pump
14
Left PPU
15
Right PPU
16
Generator PPU
D_2.0_01_US.fm 15-24
Nr.
D 2.0 15
Cause of Issue
10
Open circuit
11
Input at 0V
12
Short circuit
13
Input at 5V
20
Too low
21
Too high
30
No response
40
Invalid calibration
41
Invalid configuration
D_2.0_01_US.fm 16-24
Nr.
D 2.0 16
Warnings Display
Appears due to faulty machine operation.
- Line (1): Actual displayed
Warning of (x) active Warnings. Code number is displayed
- Scroll between the active
warnings by using buttons 2 or 3.
- Leave Warning display by
using button 1
1
Warning Codes
Situation
Code
Display Message
1
Counter Rotate: stroke
joystick forward
Propel Selector in Position 4, while
joystick is in neutral for long (e.g. more
than 10 seconds)
2
Counter Rotate: stroke
joystick forward
Change Propel selector switch while
machine in moving
3
Change propel selector
when machine is stopped
Change Propel selector switch while
joystick is not neutral
4
Change propel selector
when
joystick is in neutral
Joystick not in neutral when machine is
powered up
5
Return Joystick to neutral
Brake is applied, try to stroke joystick
6
Release the brake before
driving
Change console selector switch while machine in moving
7
Change active console
when machine is stopped
Change console selector switch while joystick is not in neutral
8
Change active console
when joystick is in neutral
Propel Selector in Position 4, Joystick is
moved forward with no steering command
for more than 5 seconds
9
Slope detection beyond the allowable limit
11
Beyond allowable slope.
Bring the gear down.
If the Generator frequency goes beyond
the allowable limits
12
Generator is not within allowable limit
D_2.0_01_US.fm 17-24
Propel Selector in Position 4, while joystick is stroked backward
D 2.0 17
Engine Error messages
D_2.0_01_US.fm 18-24
1.2
D 2.0 18
D 2.0 19
D_2.0_01_US.fm 19-24
D 2.0 20
D_2.0_01_US.fm 20-24
D 2.0 21
D_2.0_01_US.fm 21-24
D 2.0 22
D_2.0_01_US.fm 22-24
FMI-codes
D_2.0_01_US.fm 23-24
1.3
D 2.0 23
D 2.0 24
D_2.0_01_US.fm 24-24
D 3.0
1
Operation
Operating elements on the paver
Operator’s platform
1
2
4
3
Seat console
The seat console can pivot beyond the outer edge of the vehicle, providing the driver
with a better view of the paving area in this position.
- Step on the lock release (1).
- Swing the seat console to the desired position.
- Engage the lock into one of the fixed positions (2).
After locking the seat console, check it to ensure it will not move into another position!
Operating panel
The operating panel can be pivoted so that the seat console is beyond the outer edge
of the vehicle.
D_3.0_01_US.fm 1-8
- Pull the locking knob (3).
- Swing the operating panel to the desired position.
- Engage the lock in one of the fixed positions (4).
After locking the panel, check it to ensure it will not move to another position!
D 3.0 1
Driver's seat
To avoid injury, the individual seat settings should be checked and adjusted before
starting the vehicle.
After the adjustments are set, check the
seat to ensure it does not move out of
adjustment.
- Seat forward and back adjustment
(1): The seat can be moved forward or
3
it can be moved back. to adjust the
seat, raise the lever on the lower left
side of the seat to release the lock.
2
Once the seat is in the desired position, release the lever and the seat will
lock into place
1
- Seat back rest adjustment (2): The
back rest can be adjusted to lean forward or lean back. To adjust the back rest, turn the knob on the lower front part of
the seat. Turn the knob clockwise to lean the back rest forward; turn the knob counter-clockwise to lean the back rest back.
- Armrest positions (3): The armrest can be lowered to support the arm or it can be
raised to be stowed out of the way.
Batteries
The batteries are located under the right
hand side (from operator platform) maintenance door.
There are two 12 V batteries to produce
the 24 V needed for the electrical system.
For servicing, see chapter F.
Follow the instructions when jump starting the paver. (see section D 4).
D 3.0 2
D_3.0_01_US.fm 2-8
Batteries
Battery main switch
The main switch interrupting the circuit
between the battery and the main fuse is
located under the center maintenance
door.
1
See chapter F for fuse locations and fuse order.
- To switch the ignition off, turn the key
(1) to the left and pull it out.
1
D_3.0_01_US.fm 3-8
Do not lose the key. Without it the paver can no longer be moved!
D 3.0 3
Transport safeguards for the hopper
Before parking or transporting the paver,
the hopper halves must be pivoted upwards and the transport safeguards for
the hopper must be inserted.
- Insert the safeguards on both sides of
the machine (1) into the pinning hole.
- Without transport safeguards inserted,
the hopper halves will slowly open; danger during transportation!
1
Do not enter the hopper while the engine is running! Danger of being caught by the
conveyor!
Mechanical
screed
transport
safeguard (to the left and the right beneath the driver’s seat)
1
Used to protect the lifted screed from inadvertent lowering. The screed transport
safeguard must be inserted before transportation and when work is finished.
- Lift the screed.
- Activate the levers (1).
- Check that the safeguards (to the left
and to the right) engage under the
crossbeams.
Insert screed lock only at crown adjustment “zero“! Lock the screed only for transportation. Use the lock for transportation only! Do not enter or work under screed if it is
only secured with the screed locked for transportation!
D 3.0 4
D_3.0_01_US.fm 4-8
Transportation with an unsecured screed bears the danger of accidents!
Paving thickness indicator
1
The Paving Thickness Indicator scales
are located on the left and right sides of
the vehicle.
- The Paving Thickness Indicator
shows the setting on the Scale (2).
(1)
- In normal paving situations, the same
paving thickness should be set on
both sides of the vehicle!
2
:
Before transporting the vehicle, ensure the Paving Thickness Indicator and the Scale
swing in against the machine. Do not transport the machine unless the indicator and
the scale are in against the machine.
D_3.0_01_US.fm 5-8
Avoid different settings on the scales as this will produce un-even pavement.
D 3.0 5
Release Agent System
Used to spray the parts coming into contact with asphalt with a separator emulsion.
4
NOTE:
Check local regulations concerning
of cleaners and use of solvents!
use
1
- Pull hose (1) out of the guide until
there is an audible click. The hose will
lock in this position.
NOTE:
The hose will retract automatically into
the guide by pulling out until it clicks
again, then it will reel in again.
3
- On/off switch (2) for the emulsion
pump.
- Press hand-valve (3) to spray, release
to stop spraying.
- The spraying system is fed by the tank
(4). (Only fill the tank when the machine is not moving.)
2
Don’t spray into open flame or onto hot surface! Danger of explosion!
D 3.0 6
D_3.0_01_US.fm 6-8
Switch on the spraying system only when the diesel engine is running; otherwise, the
battery will be drained. Switch off after use.
On/Off switch of working lights (1)
Toggle switch (1) to switch on all installed working lights.
On/Off switch hazard flasher (2):
Activate switch (2) to switch on installed
flasher.
1
2
Warning Beacon
1
NOTE:
2
The function of the warning beacon must
be checked daily before starting work.
- Place the warning beacon onto the
plug-in contact and secure with a wing
bolt (1).
- Slide the warning beacon with tube (2)
to the desired height and secure with
the both clamping screws (3).
- Turn the switch on to activate the
warning beacon.
3
NOTE:
D_3.0_01_US.fm 7-8
The rotary warning beacon is easy to remove and should be stored securely when the
work is done.
D 3.0 7
Conveyor limit sensors
The ultrasonic conveyor limit sensors
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.
NOTE:
This requires that the auger height has
been adjusted correctly (see chapter E).
Sensor
Ultrasonic
and right)
auger
limit
sensors
The limit sensors control the
flow at the respective auger half.
(left
Sensor
material
The ultrasonic sensor is mounted to the
side plate. Loose clamping lever for adjustment and modify angle / height of the
sensor.
The cables must be connected to the remote control units located at the sides of
the screed.
NOTE:
Adjust the limit sensor positions while the material is distributed.
Sockets 24V
Connect the working lights (24 V) or other devices here.
- Power is present when the main switch
is switched on.
NOTE:
Sockets
D 3.0 8
D_3.0_01_US.fm 8-8
As an option, one socket can be used to
provide power for accessories.
D 4.0
1
Operation
Preparation of operation
Required equipment and tools
To avoid delays on site, check before starting work whether or not the following equipment and tools are present:
Wheel loader for transporting heavy extendable parts
Diesel fuel
Engine oil and hydraulic oil, lubricants
Separating agents (emulsion) and manual injector
Shovel and broom
Scraper (shovel or scoop) for cleaning the auger and the hopper intake area
Necessary parts for extending the auger
Necessary parts for extending the screed
Percentage spirit level and levelling rail, 4 yards (4 m) long
Levelling wire
Protective clothing, signal vest, gloves, hearing protection
D_4.0_01_US.fm 1-26
-
D 4.0 1
Before starting work
(in the morning or when starting paving)
-
Follow the safety instructions.
Check personal protective equipment.
Take an inspection walk around the paver and check for leaks and damages.
Install parts removed for transportation or for the night.
Perform the check according to the ”Checklist for the machine operator” given below.
Checklist for the machine operator
Check!
How?
Push in the button.
The diesel engine and all running drives
must stop immediately.
Button must be pulled out to start
machine again
Steering
The paver must follow every movement
of the steering wheel. Check straight
running.
Horn
- on the operating panel
- on both remote control units
Briefly press the horn button.
The horn must sound.
Lights
Switch on (with the paver started), walk
around the paver and inspect it, then
switch off again.
D_4.0_01_US.fm 2-26
Emergency stop button
- on the operating panel
- on both remote control units
D 4.0 2
Check!
How?
Screed covers and walkways
For larger working widths, the walkway
plates must be extended.
Hinged walkway plates must be swung
down.
Check that the side shields, the side
plates and the covers are securely
seated.
Screed transport safeguard
When the screed is lifted, the operator
must be able to engage both screed
transport safeguards.
Hopper transport safeguard
When the hopper is closed, the operator
must be able to engage both hopper
transport safeguards.
Miscellaneous:
- Engine hood
- Lateral flaps
Check that the hoods and flaps are
closed and secured.
Accessories:
- First-aid kit
The accessories must be in the provided holders.
D_4.0_01_US.fm 3-26
Auger covers
For larger working widths, the walkway
plates must be extended and the auger
tunnels must be covered.
D 4.0 3
40
20
21
10
12
40
20
21
D_4.0_01_US.fm 4-26
12
D 4.0 4
1.1
Starting the paver
Before starting the paver
Before starting the diesel engine and beginning operation, the following steps must
be performed:
- Daily maintenance of the paver (see chapter F)
Check the operating hours counter to determine whether or not additional maintenance work (such as monthly or yearly maintenance) must be performed.
- Check the safety devices and protective devices.
“Normal” starting
- Set the drive lever (20) to the center position and the speed preselector (12) and
the selector (21) for traction drive / engine to minimum.
- Insert the ignition key (10) in position “0”. The lights should be switched off during
starting to reduce the current drain on the battery.
Starting is not possible if the drive lever is not in the central position or if the emergency stop button (40) is depressed,
D_4.0_01_US.fm 5-26
- Turn the ignition key (10) into position 3 to start the engine. Once engine has started, release the key and it will spring-return to the “On” position. Do not let the starter
run continuously for more than 20 seconds; wait 1 minute before turning the starter
again.
D 4.0 5
40
20
21
10
12
40
20
21
D_4.0_01_US.fm 6-26
12
D 4.0 6
Jump starting
The engine can be started with the help of an external power source if the batteries
are low and the starter no longer turns.
Suitable power sources are:
- Other vehicles with a 24 V system
- Additional 24 V battery
- Start device that is suitable for jump starting (24 V/90 A).
Standard 12V chargers or quick chargers cannot be used for jump starting.
To jump start the engine:
- Set the drive lever (20) to the center position. Set the speed preselector (12) and
the selector (21) for traction drive / engine to minimum.
- Insert ignition switch (10) to position “0“ to turn on the ignition.
- Connect the power source with the appropriate cables.
Check for proper polarity! Always connect the negative cable last and remove it first!
D_4.0_01_US.fm 7-26
- Turn the ignition key (10) completely to the right to start the engine. Once the engine starts, release the key and it will spring-return to the “ON” position. Do not let
the starter run for more than 20 seconds; wait 1 minute after every attempt before
turning the starter again!
D 4.0 7
40
20
21
10
12
40
20
21
D_4.0_01_US.fm 8-26
12
D 4.0 8
After starting
To increase the engine speed:
- Set selector (21) for traction drive / engine to position 2.
Let the paver warm up for about 5 minutes if the engine is cold.
D_4.0_01_US.fm 9-26
Read and follow Chapter D2 of this manual for possible warnings on the graphical terminal!
D 4.0 9
40
20
47
21
48
10
52
12
54
55
40
20
47
21
48
12
D_4.0_01_US.fm 10-26
52
D 4.0 10
1.2
Transport Operation
Lifting and securing the screed
- Raise the screed using switch (52).
- Center the levelling cylinders using the switches (54)/(55).
The remote control must be connected and this function must be set to “Manual“.
- Raise the auger crossbeam using switches (47)/(48).
Engage both screed transport safeguards to secure the screed in the raised position.
Driving and stopping the paver
- Set the selector (21) for traction drive / engine to position 3.
- Set the preselector (12) for traction drive to approx. 50%.
- To start driving, carefully tilt the drive lever (20) forward or backward according to
the drive direction desired.
In case of an emergency, press the emergency stop button (40)!
- To stop the vehicle, move the drive lever (20) into its center position.
Switching off and securing the paver
- Lower the screed using switch (52).
- Turn off the engine by turning the ignition key (10) to the “0“ position. Pull the key
out of the switch.
D_4.0_01_US.fm 11-26
The battery may become drained if the paver stands still for long periods of time even
though the ignition is not switched on.
D 4.0 11
1.3
Preparations for paving
Releasing agent
Spray the parts coming into contact with
asphalt (hopper, screed, auger, push
roller) with a separator emulsion.
Do not use diesel fuel as it dissolves the bitumen.
Screed heater
Switch the screed heater “On” for about 15–30 minutes (depending on the ambient
temperature) before paving begins. Warming up prevents the material from sticking
to the screed plates.
Direction marks
To ensure straight paving, a direction
mark must be present or established
(road edge, chalk lines or similar).
D_4.0_01_US.fm 12-26
- Slide the operating panel to the desired side and secure it.
- Pull the alignment indicator out of the
bumper (see arrow) and adjust it accordingly.
D 4.0 12
45
20
46
21
15
45
46
20
21
D_4.0_01_US.fm 13-26
15
D 4.0 13
Loading/distributing material
- Open the hopper with switch (15).
Have the truck back short of the paver and pull the paver against the truck tires.
Guide the truck driver when dumping the material mix.
- Set the switch (45) of the auger and conveyor to the “ON” position.
- Set the switch (46) of the auger and conveyor to “AUTO“ position.
- Set the appropriate auger switch on the remote control and conveyor switch (if applicable) to “auto“ position.
- Set the selector (21) for traction drive / engine to position 2 and push the drive lever
(20) forward (away from operator).
Conveyor and auger will begin to work.
The limit sensors for the conveyors and augers must switch off the function when the
material has reached the height limit in the area beneath the auger crossbeam (conveyor sensors) or at the auger ends (auger sensors).
Check that the material is being conveyed properly.
D_4.0_01_US.fm 14-26
- If the material is not being conveyed properly, switch conveyor and auger to “MANUAL“ by using switch (46) until a sufficient amount of material lies in front of the
screed.
- Switch conveyor and auger to “AUTO“ using switch (46).
D 4.0 14
45
46
27
28
20
21
53
24
12
45
46
20
21
53
D_4.0_01_US.fm 15-26
12
D 4.0 15
1.4
Starting for paving
Set the switches, levers and controls listed below to the specified positions when the
screed has reached its operating temperature and a sufficient amount of material lies
in front of the screed:
Item
Switch
Position
21
Selector
position 2
12
Preselector
approx. 50%
53
Screed position
to floating position.
27
Vibration
ON
24
Tamper (option)
ON
45
Auger+conveyor
ON
46
Auger+conveyor
AUTO
- Push the drive lever (20) to it’s most forward position and start driving. Screed floating position is activated now.
- Observe the distribution of the material and adjust the limit sensors if necessary.
- Set the compacting elements (vibration and/or tamper) according to the required
compaction ratio.
- Let the paving supervisor check the layer thickness after 15-20 feet (5–6 meters)
and correct if necessary.
Carry out the 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.
D_4.0_01_US.fm 16-26
The basic screed setting must be corrected when the actual layer thickness deviates
significantly from the values needed for the job requirement (see the operating instructions for the screed).
D 4.0 16
1.5
Check during paving
The following points must be constantly observed during paving:
Paver function
-
Screed heater
Tamper and vibration
Engine oil and hydraulic oil temperature
The screed parts must be retracted and extended in time when obstacles are in the
way
- Uniform material transport and distribution or supply to the screed; may require corrections to settings of the material switches for conveyor and auger.
NOTE:
See the section D4 ”Malfunctions” when paver functions fail.
Quality of the layer
-
Mat thickness
Slope
Evenness in the driving direction and at right angles to it (check with a level)
Surface structure/texture behind the screed.
NOTE:
D_4.0_01_US.fm 17-26
See section D 4 ”Malfunctions, Problems during Paving” if the paving quality is poor.
D 4.0 17
27
28
45
20
25
21
24
10
12
45
20
21
D_4.0_01_US.fm 18-26
12
D 4.0 18
1.6
Interrupting/terminating operation
During breaks (i.e. the material supply truck is late)
- Determine the approximate duration.
- When the material’s temperature drops below the minimum
run the paver empty and create an edge like the end of a layer.
- Set the drive lever (20) to the center position.
paving
temperature,
Screed will be switched into “STOP“ function automatically.
During extended interruptions
(i.e. lunch break)
- Turn drive lever (20) to center position. Move the preselector (12) and selector (21)
to minimum position.
Screed will be switched into “STOP“ function automatically.
- Switch off conveyor+auger (45), vibration (27), tamper (if equipped)(24), lights (25)
and exhaust system (28).
- Switch ignition (10) off.
- Switch screed heater (system) off.
D_4.0_01_US.fm 19-26
The screed must be heated up to the correct paving temperature before paving can
be resumed.
D 4.0 19
27
28
45
48
20
47
25
21
54
52
24
55
10
50
12
51
45
20
48
47
21
52
54
12
50
D_4.0_01_US.fm 20-26
51
D 4.0 20
When work is finished
- Run the paver empty, then bring it to a stop.
- Turn drive lever (20) to the center position. Move the preselector (12) and selector
(21) to minimum position.
- Switch off conveyor+auger (45), vibration (27), tamper (if equipped)(24), lights (25)
and exhaust system (28).
- Lift the screed by using switch (52).
- Retract the screed parts to the basic screed width with switches (50) and (51).
- Use switch (47) and (48) to lift the auger .
- Where applicable, completely extend the levelling cylinders by using switches (54)
and (55).
- Insert the mechanical screed transport
safeguard (74) on both screed lifting
cylinders.
- While operating the tampers at a low
speed, let any material residue drop
out.
74
Switch the ignition (10) off.
- Switch screed heater (system) off.
- Remove the levelling units and stow
them away in their boxes and close
the boxes.
- Remove all parts that extend beyond the paver width. Secure them if the paver is
to be transported over public roads on a low-bed trailer.
D_4.0_01_US.fm 21-26
Do not turn the main switch off until 15
seconds after the ignition has been
turned off! The engine electronics requires this length of time to back up data.
- Read and check the operating hour
meter to determine whether maintenance work must be performed (see
chapter F).
- Cover and lock the operating panel.
- Remove material residue from the
screed and the paver and spray all
parts with release agent fluid.
D 4.0 21
Malfunctions
2.1
Problems during paving
Problem
Cause:
-
Wavy surface
(”short waves”)
-
Wavy surface
(”long waves”)
Cracks in the layer
(over the entire
width)
D 4.0 22
change in the material temperature, segregation
wrong material composition
incorrect operation of the roller
incorrectly prepared foundation
long idle standing times between loads
grade control reference line is not suitable
grade control jumps to the reference line
grade control toggles between up and down
(inertia setting is too high)
bottom plates of the screed are loose
bottom plates of the screed are warped or not uniformly
worn
screed does not work in the floating position
too much play in the mechanical screed link/suspension
paver speed is too high
augers are overloaded
changing material pressure against the screed
-
change in the material temperature
segregation
roller has stopped on the hot material
roller has turned or roller speed has been changed too
quickly
incorrect roller operation
incorrect foundation preparation
truck brake is applied too tight
long idle standing times between loads
grade control reference line is not suitable
incorrect installation of the grade control
limit sensors are not correctly set
screed is empty
screed has not been switched to the floating position
too much play in the mechanical screed link
auger is set too deep
auger is overloaded
changing material pressure against the screed
-
material temperature is too low
change in the material temperature
moisture on the foundation
segregation
wrong material composition
wrong layer height for the maximum grain size
cold screed
bottom plates of the screed are worn or warped
paver speed is too high
D_4.0_01_US.fm 22-26
2
Problem
Cause:
Cracks in the layer
(center strip)
-
temperature of the material
cold screed
bottom plates are worn or warped
wrong crowning
Cracks in the layer
(outer strip)
-
temperature of the material
screed extendable parts are incorrectly installed
limit switch is not correctly set
cold screed
bottom plates are worn or warped
paver speed is too high
Layer composition is
not uniform
-
temperature of the material
change in the material temperature
moisture on the foundation
segregation
wrong material composition
incorrectly prepared foundation
wrong layer height for the maximum stone size
long idle standing times between loads
vibration is too slow
screed extendable parts are incorrectly installed
cold screed
bottom plates are worn or warped
screed does not work in the floating position
paver speed is too high
auger is overloaded
changing material pressure against the screed
Marks in the surface
- truck hits against the paver too much while aligning to the
paver
- too much play in the mechanical screed link/suspension
- truck parking brake is applied
- vibration is too high while standing in one spot
Screed does not
react to corrective
measures as
expected
-
D_4.0_01_US.fm 23-26
temperature of the material
change in the material temperature
wrong layer height for maximum grain size
incorrect installation of the grade control
vibration is too slow
screed does not work in the floating position
too much play in the mechanical screed link
paver speed is too high
D 4.0 23
2.2
Malfunctions on the paver or screed
Malfunction
Cause:
At the diesel engine
Diverse
Diesel engine does
not start
Batteries drained
Tamper or vibration
does not operate
Other
Tamper is obstructed by
cold bitumen
Hydraulic oil level in the
tank is too low
Pressure limiting valve is
defective
Remedy
See operating instructions for
the engine
See ”External starting”
(start assistance)
see ”Towing”
Properly heat the screed
Fill with oil
Replace the valve; if necessary,
repair and adjust the valve
Seal or replace the connections
Oil filter is dirty or plugged
(clogged)
Hydraulic oil level in the
tank is too low.
Power supply is interrupted
Conveyor or augers
run too slowly
Sensor is defective
One of the pressure limiting valves is defective
Pump shaft broken
Limit sensor does not regulate correctly
Pump is defective
Oil filter is dirty or plugged
Engine speed is too low
Hopper cannot be
swung open
D 4.0 24
Hydraulic oil level is too low
Leak in the suction line
Flow rate regulator
defective
Tighten or replace the hose
clamps
Replace the filter
Fill with oil
Check fuses and cables; replace
if necessary
Replace the sensor
Repair or replace the valves
Replace the pump
Check the sensor; replace the
sensor if necessary
Replace the pump. Check the
system for contaminants
Replace the filter
Increase the speed
Fill with oil
Tighten the connections
Replace
Leaking seals in the
hydraulic cylinder
Replace
Control valve is defective
Replace
Power supply interrupted
Check fuse and cables; replace
if necessary
D_4.0_01_US.fm 24-26
Leak in the suction line of
the pump
Malfunction
Hoppers lowers
inadvertently
Screed cannot be
lifted
Lifting Arms cannot
be lifted or lowered
Remedy
Control valve is defective
Replace
Leaking seals in the
hydraulic cylinder
Replace
Oil pressure too low
Increase the oil pressure
Leaking seal
Replace
Screed relieving or
charging is switched on
Switch must be in the center
position
Power supply is interrupted
Check fuse and cables; replace
if necessary
Check to see if the switch
on the remote control is set
to ”auto”
Set the switch to ”manual”
Power supply is interrupted
Check fuse and cables; replace
if necessary
Switch on the operating
panel defective
Replace
Excess pressure valve
defective
Replace
Flow rate regulator defective
Replace
Seals defective
Replace
Control valves defective
Replace
Pilot-controlled non-return
valves defective
Replace
Seals defective
Replace
D_4.0_01_US.fm 25-26
Lifting Arms lower
inadvertently
Cause:
D 4.0 25
Malfunction
Traction does not
work
Cause:
Remedy
Traction drive fuse
defective
Replace
(Fuse holder is on the operating
panel)
Power supply is interrupted
Check potentiometer, cables,
connectors; replace if necessary
Traction drive monitoring
defective
Replace
Electro-hydraulic servo unit
of the pump is defective
Replace the servo unit
Check and adjust if necessary
Insufficient supply pressure
Drive shaft at hydraulic
pumps or engine is broken
Replace pump or engine
Fuel level too low
Check the fuel level; refill fuel if
necessary
Fuse for ”engine speed
control” defective
Replace
(fuse strip on the operating
panel)
Defective power supply
cables (cables broken or
short-circuits)
Check potentiometer, cables,
connectors; replace if necessary
D_4.0_01_US.fm 26-26
Irregular engine
speed, engine stop
function does not
work
Check the suction filter; replace
the supply pump and the filter if
necessary
D 4.0 26
E 01
1
Set-up and modification
Special notes on safety
Inadvertently starting the engine, the traction drive, the conveyor, the auger, the
screed or the lifting units can be dangerous. Unless specified otherwise, work may
only be performed when the engine is not running!
- To protect the paver against inadvertent starting:
Set the drive lever to the center position and set the preselector to zero; if applicable, pull out the ignition key and the 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 required.
When connecting or disconnecting hydraulic hoses and when working on the hydraulic system, hot hydraulic fluid can escape at a high pressure.
Switch the engine off and de-pressurize the hydraulic system! Protect your eyes!
E_1.0_01_US.fm. 1-10
- Mount all protective and safety devices before re-commissioning the paver.
- The walking platform must always reach over the entire width of the screed. The
hinged walkway (optional for all variable screeds) may only be swung up under the
following circumstances:
- When paving next to a wall or a similar obstacle.
- During transportation on a low-bed trailer.
E 01 1
2
Auger
2.1
Height adjustment
1
Depending on the mix of materials,
when working with layer thicknesses of
up to 10 in. (25.4 cm), the height of the
distribution auger (1) – measured from
its bottom edge – should be around 5 cm
(2 inches) above the material layer thickness (depending on its mix of materials).
Example:
Layer height 3 in. (7.6 cm)
Adjustment: 5 in. (12.7 cm)
from the ground
An incorrect height adjustment can result in the following problems:
- Auger too high:
Too much material in front of the screed; material overflow. When operating with
larger widths, segregation and traction problems may occur.
- Auger too low:
Not enough material that can be pre-compacted by the auger. Irregularities resulting from this cannot be completely compensated for by the screed (wavy surface).
In addition, an increased wear on the auger segments occurs.
2.2
Auger crossbeam - hydraulic height adjustment
- Measure the set height of the auger crossbeam (left and right).
NOTE:
Equally
press
both
switches/buttons
(47)/(48) so that the auger beam stays
level.
47
48
E_1.0_01_US.fm. 2-10
- Check whether the height on the left
and on the right are identical.
E 01 2
2.3
Auger extension
Depending on the type of screed, the most diversified working widths can be reached.
Auger and screed extension must match. See the operating instructions for the appropriate screed, chapter ”Set-up and modification”, especially:
– Screed extension chart,
– Auger extension chart.
To attain the desired working width, the respective screed extensions, side plates, augers, tunnel plates or cut-off shoes must be mounted.
For widths of more than 11.5 ft. (3.5 m.), the auger should be fitted with extension
parts on both sides to improve material distribution and to reduce the wear.
E_1.0_01_US.fm. 3-10
The diesel engine must be switched off whenever work is performed on the auger as
there is a danger of being pulled into rotating parts. This could cause severe injury or
death!
E 01 3
2.4
Mounting extension parts
5
- Loosen the clamping screws (6) on
the support tube. Then turn in the
center expanding screw (5) to expand
the clamping joint.
6
- Pull the telescopic tube out of the support tube (7).
- Mount the required extension parts.
7
NOTE:
Observe the guide groove of the spline!
Make sure that the shaft end is clean!
- Install auger so pick end of auger is
“IN TIME” with the discharge of the
main auger. This is called “IN TIME” or
“NORMAL” set up and is used to prevent segregation (or separation) of
material. The auger pickup can be
mounted 180 degrees away from the
discharge. This called “OUT OF TIME”
and is used with large or rounded stone to prevent segregation. If alsready mounted and segregation occurs in the mat at extension to main connection, move the
auger pickup 180 degrees from the current position.
- Slide in the telescopic tube. When doing so, make sure that 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). Finally
tighten the expansion screw by hand.
When clamped insufficiently, the telescopic tube can slide out of the support tube and
can cause severe injury or death as well as damage to the machine!
E 01 4
E_1.0_01_US.fm. 4-10
Before the clamping screws (6) can be tightened again, the expansion screw (5) must
be sufficiently turned back!
Otherwise, the telescopic tube cannot be safely clamped and the splined shaft ends
break.
2.5
Mounting support tube extensions
If the working width exceeds 25 ft.
(7.62 m.), an auger crossbeam extension must be mounted.
The support tube extension of the auger
crossbeam consists of two halves (8)
and is attached to the existing support
tube by using a total of 5 screws. After
the two halves have been screwed to the
support tube, they also must be linked to
each other by means of screwed connections.
8
Clamping of the telescopic tube occurs
by tightening the screwed connections
(9) linking the support tube extension.
9
If the working width exceeds 14 ft. (6.26 m.) the hydraulic hoses (10) for the auger
motors must be replaced with longer ones.
These long hoses are included in the scope of delivery for this working width.
E_1.0_01_US.fm. 5-10
When connecting or disconnecting hydraulic hoses, hydraulic fluid can spray out at a
high pressure and can cut or enter the skin.
Switch the paver off and de-pressurize the hydraulic circuit! Protect your eyes!
When installing the hoses, make sure that the area around the connections is clean.
Any contaminants that enter the hydraulic system can cause damage to the hydraulic
system.
E 01 5
2.6
Installing tunnel plates
To ensure an optimum material flow –
especially in the case of large paving
widths – so-called tunnel plates (11)
must be installed.
They are located directly in front of the
auger distributor and – in conjunction
with the auger – are an ideal system for
conveying the material.
When operating with widths of
than 14.4 ft (4.4 m), two or more
bined tunnel plates (13) must be used.
In this case, additional stabilizing
ports (12) must be attached to the
scopic tube.
more
com11
suptele-
12
13
The tunnel plates must be directly
screwed to the receptacles provided for
this purpose (14); they are located on
the auger frame sides and can be adjusted in height.
Refer to the auger extension chart to determine which parts of the conveyor system are required for the desired paving
width.
E_1.0_01_US.fm. 6-10
14
E 01 6
2.7
Installing additional braces
When operating with width of more than 25 ft. (7.62 m.) the augers must be provided
with an additional support.
To do so, attach two braces on both the left-hand and the right-hand side, between
the tunnel plate support and the bracket provided on the paver.
E_1.0_01_US.fm. 7-10
The braces are included in the scope of delivery for this working width.
E 01 7
3
Screed
The operating instructions for the screed explains what is required for mounting, setting up and extending the screed.
4
Electrical connections
Ensure the following connections have been made once the screed has been mounted and set up:
4.1
Remotes from screed to paver
The screed plugs into the back of the
paver socket (15). The paver and the
screed communicate through this connection.
15
4.2
Right hand conveyor sensor control
The Conveyor Sensor plugs into the remote control unit on the right hand side
at socket (16a). The remote then sends
the signal from the sensor to the paver
thru the cable shown.
16a
17a
Right hand auger sensor control
The Auger Sensor plugs into the remote
control unit on the right hand side at
socket (17a). The remote then sends the
signal from the sensor to the paver thru
the cable shown.
Conveyor
Sensor
Auger
Sensor
E 01 8
E_1.0_01_US.fm. 8-10
4.3
4.4
Left hand conveyor sensor control
The Conveyor Sensor plugs into the remote control unit on the left hand side at
socket (16a). The remote then sends the
signal from the sensor to the paver thru
the cable shown.
16a
17a
4.5
Left hand auger sensor control
The Auger Sensor plugs into the remote
control unit on the left hand side at socket (17a). The remote then sends the signal from the sensor to the paver thru the
cable shown.
Conveyor
Sensor
E_1.0_01_US.fm. 9-10
Auger
Sensor
E 01 9
Auger Chart
E_1.0_01_US.fm. 10-10
4.6
E 01 10
F 1.0
1
Maintenance
Notes regarding safety
Maintenance work: Maintenance work may only be carried out when the engine is
not running.
Secure the paver and the attachments against inadvertent starting before beginning
any maintenance work:
- Set the drive lever to the center position and the speed preselector to zero.
- Remove the ignition key and the battery main switch.
Lifting and jacking up: Secure lifted machine parts (i.e. screed or hopper) against
lowering by means of mechanical supports.
Spare parts: Use only approved parts and install them according to the specifications! If in doubt, contact the manufacturer!
Re-commissioning:
er.
Mount
all
protective
devices
before
re-commissioning
the
pav-
Cleaning: Cleaning must not be carried out while the engine is running.
Do not use any flammable substances (such as gasoline or diesel fuel).
Avoid directly cleaning electrical parts and insulation material with a steam jet; cover
them up beforehand.
F_1.0_01_US.fm 1-2
Working in closed environments: Always run the engine in a well ventilated area.
In addition to these Maintenance Instructions, the Maintenance Instructions of the engine manufacturer must always be observed. All other maintenance work and intervals noted in these instructions are also binding.
F 1.0 1
F 1.0 2
F_1.0_01_US.fm 2-2
F 2.1
1
Maintenance Overview
Maintenance overview
9.0
10.0
8.1
3.0
6.0
5.0
4
F_2.1_01_US.fm 1-2
7.1
1
If necessary
20000
5000
2000 / every 2 years
500
250
100
50
Chapter
10
Assembly
1000 / annually
Maintenance required after the
following service hours
Conveyor
F3.0
q q q
q q
q
Auger
F4.0
q q q
q q
q
Engine
F5.0
q
q q q q
q
Hydraulics
F6.0
q q
q q q
q
Travel drive, steering
F7.1
q
q
q
q
Electronics
F8.1
q q
q
q q q
Lubrication points
F9.0
Checking/decommissioning
F10.0
Maintenance required
q
q
q
q
q
q
F_2.1_01_US.fm 2-2
q
q
2
F 3.0
1
Maintenance - Conveyor
Maintenance - Conveyor
6
5
7
2
4
1
3
F_3.0_01_US.fm 1-8
1
F 3.0 1
1.1
Maintenance intervals
10
50
100
250
500
1000 / year
2000 / 2 years
as required
No.
Interval
Remark
- Checking the tension of the
conveyor chain
q
q
- Adjusting the tension of the
conveyor chain
- Conveyor chain Check chain
q
1
Points of maintenance
q
q
- Conveyor chain Replace chain
- Clean Conveyor chain supports
2
q
- Conveyor tensioning sprocket Lubricate grease zert
3
q
- Conveyor bearing Lubricate grease zert
4
q
- Conveyor drive bearings Lubricate grease zert
- Conveyor drive / drive chains
Check chain tension
q
5
q
- Conveyor drive / drive chains
Set chain tension
- Conveyor drive - planetary gear
oil level check
q
q
6
g
- Conveyor drive - planetary gear
fill with oil
- Conveyor drive - planetary gear
Oil change (g indicates initial
break-in period)
q
- Check conveyor chain guards,
conveyor plates
q
7
F 3.0 2
- Replace conveyor chain guards,
conveyor plates
Maintenance
q
Maintenance during break-in period
g
F_3.0_01_US.fm 2-8
q
1.2
Points of maintenance
Chain tension of the conveyor (1)
Checking the track tension:
For daily inspection look straight through
under the bumper. The chain must not
hang below the bottom edge of the bumper.
Should readjustment be necessary, measure the slack unloaded from the bottom
edge of the floor plate to the bottom edge of the chain (see the figure). Also conveyor
chain supports should be inspected daily and can be seen by looking straight through
under the bumper. Clean the support every 1000 hours of operation and before adjusting the tension.
The chains should not be too tight or too
slack. If the chain is too tight, material
between the chain and the sprocket
wheel
can lead to stoppage or breakage.
If the chain is too slack, it may get stuck
in the protruding objects and be damaged.
11 in.
11 in.
With the paver resting on a level surface the sag of both portions should be a minimum of 11 inches!
Checking the chain tension:
Chain tension can be adjusted with 4
tension-screws (A) The tension-screws
are located at the front of the crossbeam.
- Loosen the bolts (B) and remove the
locking clamp (C).
- Set the necessary chain tension by
turning the tension-screws (A).
- Remount the locking clamp (C) with
the bolt (B).
C
A
F_3.0_01_US.fm 3-8
B
F 3.0 3
Check / replace chain:
When the conveyor chains (A) have stretched so far that they can no longer be adjusted, they must be replaced.
A
Chain links must not be removed to
shorten the chain!
Shortening the chains would lead to the
destruction of the drive sprockets!
Adjust the tensioning instead!
If components have to be replaced as a result of wear, the following components
should always be replaced in sets:
-
Conveyor chain
Conveyor chain guards
Conveyor plates
Conveyor chain tensioning sprockets
Conveyor gear drive sprockets
representative
for
support
during
mainte-
F_3.0_01_US.fm 4-8
Contact your Dynapac customer service
nance, repair and the replacement of worn parts!
F 3.0 4
Conveyor
ings (2)
tensioning
sprocket
bear-
The tensioning sprocket bearings for the
conveyors are lubricated at the grease
zerts (A) located behind the crossbeam.
The center bearings are lubricated at the outer lubricating grease zerts.
Pump 5 strokes of grease with a grease
gun.!
5x
A
Conveyor bearing (3)
The conveyor bearings are lubricated
with grease zerts (B) located behind the
crossbeam, r.h. side.
Pump 5 strokes of grease with a grease
gun.!
5x
Conveyor drive bearing (4)
B
The conveyor drive bearings are lubricated with grease zerts (C) located behind the crossbeam, r.h. and l.h. side.
Pump 5 strokes of grease with a grease
gun.
F_3.0_01_US.fm 5-8
C
F 3.0 5
Conveyor drive - (5) drive chains
Checking for chain tension:
- In normal conditions, the chain has to
have approximately .4 to .6 inch (10 15 mm) of play.
To set the chain tension:
- Loosen the locking bolts (A) and the
lock-nut (B).
- Set the necessary chain tension with
the tension-screw (C).
- Tighten the locking bolts (A) and locknut (B) again.
A
B
F_3.0_01_US.fm 6-8
C
F 3.0 6
Conveyor drive
(left/right)
-
(6)
planetary
drive
- To check the oil level, unscrew the
inspection plug (A).
NOTE:
For proper oil level, the oil must be at the
lower edge of the inspection port or a little oil flows from the hole.
To add oil:
- Check oil at oil level site glass (A).
- Fill with oil of the correct specification
through port (B) until the oil level
reaches the middle of the oil level site
glass (A). Use only recommended oil.
B
A
Oil change:
NOTE:
Change the oil when the engine is at operating temperature.
- Remove the the filling plug (B) and the
drain plug (C).
- Drain the oil.
- Return plug (C).
- Fill oil through the filling port until the
oil level reaches the middle of the oil
level site glass (A).
- Replace the plug at the filling port (B).
C
F_3.0_01_US.fm 7-8
Make sure that no pollution or foreign matter gets into the drive.
F 3.0 7
Conveyor
plates (7)
chain
guards
/
conveyor
NOTE:
When the lower edges of the conveyor
chain guards (A) are worn or reveal holes, they must be replaced.
The conveyor chain is not protected
when the conveyor chain guards are
worn!
A
- Remove conveyor chain guard bolts.
- Remove the conveyor chain guards
from the material tunnel.
- Install new conveyor chain guards
with new bolts.
NOTE:
The conveyor plates (B) must be replaced when the wear limit of .2 inch (5
mm) in the rear area beneath the chain
has been reached.
B
If components have to be replaced as a result of wear, the following components
should always be replaced in sets:
-
Conveyor chain
Conveyor chain guards
Conveyor plates
Conveyor chain tensioning sprockets
Conveyor gear drive sprockets
representative
for
support
during
mainte-
F_3.0_01_US.fm 8-8
Contact your Dynapac customer service
nance, repair and the replacement of worn parts!
F 3.0 8
F 4.0
1
Maintenance - Auger
Maintenance - Auger sub-unit I
1
5
2
4
F_4.0_01_US.fm 1-6
3
F 4.0 1
1.1
Maintenance intervals
1
10
50
100
250
500
1000 / year
2000 / 2 years
as required
No.
Interval
Points of maintenance
Remark
- Auger - outer bearing
Lubrication
q
- Auger central bearing
Lubrication
q
2
- Auger drive neck bearing
Lubrication
q
3
- Auger bevel gear
oil level check
q
q
4
- Auger bevel gear
topping up the oil
- Auger bevel gear
oil change
q
-
Auger wear plates (auger segments)Check wear
-
Auger wear plates (auger segments)Replace auger blade
q
5
q
q
Maintenance during run-in period
g
F_4.0_01_US.fm 2-6
Maintenance
F 4.0 2
1.2
Points of maintenance
Auger - outer bearing (1)
The grease zerts (A) are located on each
side on the top of outer bearing. These
zerts must be lubricated each time work
is finished.
The outer bearings of the auger must be
lubricated when hot, so that the eventual
bitumen residue is expelled.
A
Pump 5 strokes of grease with a grease
gun!
Auger middle bearing (2)
The central bearing (A) is lubricated on
the LH-side of the auger.
To do so, slide the bevel gear out.
The central bearing must be lubricated
when hot, so that the eventual bitumen
residue is expelled.
A
F_4.0_01_US.fm 3-6
Pump 5 strokes of grease with a grease
gun!
5x
F 4.0 3
Auger - drive gear neck bearing (3)
Remove the hexagonal plug (A) in the
neck of the drive. Replace the plug under it with an extended grease zert 10x1.
Use a grease gun to pump about 10
strokes of grease.
Next, unscrew the grease zert and
screw back in both plugs. The neck of
the drive is sealed downwards and is lubricated with grease only.
F_4.0_01_US.fm 4-6
A
F 4.0 4
Auger bevel gear (on the RH and LH
sides) (4)
- To check the oil level unscrew the inspection / filling plug (A).
NOTE:
The oil level is full when the oil is at the
lower edge of the inspection port or a little oil flows from the hole.
To add oil:
- Remove the inspection / filling plug
(A).
- Add the proper oil through port (A) until the oil level reaches the lower edge
of the inspection hole (A). Use only approved oil.
- Replace the inspection / filling plug
(A).
To change the oil:
NOTE:
Change the oil when the engine is at operating temperature.
B A
- Remove the inspection / filling plug (A)
and the drain plug (B).
- Drain the oil.
- Return the oil drain plug (B) and tighten.
- Fill oil, using an approved fluid, through the filling port (A) until the oil level reaches
the lower edge of the inspection hole (A).
- Replace the inspection / filling plug (A).
F_4.0_01_US.fm 5-6
Keep the work area clean. Clean any spills!
F 4.0 5
Auger blade (5)
If the surface of the auger blade (A) becomes sharp-edged, the diameter of the auger
is reduced and the blades (B) have to be replaced.
C
A
B
E
D
- Remove the bolts (C), washers (D), nuts (E) and auger blade (B).
Sharp-edged parts can cause personal injury!
Auger blades must be installed with out any play and the contact surfaces must be
dirt-free!
F_4.0_01_US.fm 6-6
- Install the new auger blade (B); replace the bolts (C), washers (D) and nuts (E) if
necessary.
F 4.0 6
F 5.0
1
Maintenance - Engine
Maintenance - engine sub-unit
2
2
6
3
2
F_5.0_01_US.fm 1-14
1 - Fuel Tank (Not Shown)
4 - Air Cleaner (Not Shown)
5 - Radiator (Not Shown)
F 5.0 1
In addition to these Maintenance Instructions, the Maintenance Instructions of the engine manufacturer must always also be observed. All other maintenance work and intervals noted in these instructions are also binding.
1.1
Maintenance intervals
10
50
100
250
500
1000 / year
2000 / 2 years
as required
No.
Interval
Points of maintenance
Remark
- Fuel tank
Check the filling level
q
q
1
- Fuel tank
Refill with fuel
- Fuel tank
Clean the tank
q
- Engine oil system
Check oil level
q
q
- Engine oil system
Fill with oil
2
q
- Engine lube-oil system
Change the oil
q
- Engine lube-oil system
Oil filter change
- Engine fuel system
Fuel filter (drain the water separator)
q
- Engine fuel system
Replace the fuel pre-filter
q
- Engine fuel system
Replace the fuel filter
3
q
F 5.0 2
- Engine fuel system
Bleeding the fuel system
Maintenance
q
Maintenance during run-in period
g
F_5.0_01_US.fm 2-14
q
10
50
100
250
500
1000 / year
2000 / 2 years
as required
No.
Interval
Points of maintenance
q
- Engine air filter
Check the air filter
q
- Engine air filter
Empty the dust collecting bin
4
q
q
Remark
- Engine air filter
Clean / Replace the filter cartridge
- Engine cooling system
Inspection the radiator fins
q
q
- Engine cooling system
Clean the radiator fins
- Engine cooling system
Check the level of the coolant.
q
5
q
- Engine cooling system
Fill with coolant
- Engine cooling system
Changing the coolant
q
- Engine cooling system
Check coolant level
(additive concentration)
q
- Engine drive belt
Checking of drive belt
q
6
q
q
- Engine drive belt
Tightening the drive belt
- Engine drive belt
Replace drive belt
q
Maintenance during run-in period
g
F_5.0_01_US.fm 3-14
Maintenance
F 5.0 3
1.2
Points of maintenance
Engine fuel tank (1)
NOTE:
There is one fuel tank on each side of
the machine!
- Check the fuel level on the operating
panel (check display).
Fill the fuel tank before each work shift to prevent the fuel system of running dry. If
the tank is ran dry, the system will have to be bled causing work delay.
To add fuel:
- Unscrew cap (A) (under the tank covers, r.h. and l.h. paver side).
- Fill with fuel through the filler neck until
the tank is full.
- Replace the cap (A).
- Repeat the process for the other tank.
A
Cleaning the fuel tanks:
- Unscrew the plug (B) at the bottom of
the tank and drain about 1 qt. (1 L) of
fuel into an environmentally safe collection pan.
- After draining, add a new seal ring to
the plug and screw the plug back in
place.
B
F_5.0_01_US.fm 4-14
Repeat the process for the second fuel
tank.
F 5.0 4
Engine lube-oil system (2)
Check oil level
Check that the oil level is between the
maximum and minimum lines on the dipstick (A).
NOTE:
Check the oil level with the paver parked
on a flat surface!
Some state and federal agencies in the United States of America have determined
that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid
inhaling vapors, ingestion and common prolonged contact with used engine oil. Do
not allow used oil to drain into the ground. Always used proper proceedures to dispose of the oil.
To avoid personal injury, avoid direct contact of hot oil with your skin.
If there is too much oil in the engine, the
gaskets and seals may become damaged, while too little oil can lead to the oil
overheating and damage to the engine.
A
B
To add oil:
F_5.0_01_US.fm 5-14
- Remove the cap (B).
- Add oil until the correct level is
achieved.
- Return and tighten the cap (B).
- Check the oil level once again using
the dipstick.
F 5.0 5
Oil change:
Do not drain the
cals settle on the
draining cold oil.
case with the oil
be drained properly.
oil when the engine is cold. As the oil cools, suspended waste partibottom of the oil pan. The waste particles are not removed with the
Drain the crankcase with the engine stopped. Draining the crankwarm will allow the waste particles that are suspended in the oil to
Avoid contact with hot oil or components. Do not allow used oil to drain into the
ground.
There is a drain hose stored behind the
left hand side flap.
- Place the end of the hose into a pan to
catch the oil.
- Remove the oil drain port plug (C) and
let the oil drain.
- Return the plug.
- Remove the oil cap (B) and add only
approved oil until the oil level reaches
the full mark on the dipstick (A).
D
Changing the oil filter:
When changing the oil, mount the new
filter after the used oil has been drained.
- Remove the filter (D) and clean where
the new filter will go.
- Apply a thin coat of oil to the seal of
the new filter and fill the filter with oil,
then mount the filter and tighten by
hand.
C
F_5.0_01_US.fm 6-14
Fill the oil filter(s) with clean lubricating oil before installation onto the engine. Lack of
engine lubrication while the filter(s) are pumped full of oil is harmful to the engine.
F 5.0 6
Engine fuel system (3)
The fuel filter system consists of two filters:
- Pre-filter (A) with water separator (located in the engine compartment).
- Main filters (B)
Pre-filter - drain the water
Empty the condensation prior to every
engine start or when the engine electronics indicate a fault.
- Drain the water at the drain valve (C),
collect it, then close the drain valve again.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To
help prevent possible injury, turn the start switch off when chaning fuel filter or water
separtor elements. Clean up any spilled fuel immediately.
Change the pre-filter:
F_5.0_01_US.fm 7-14
- Drain the separated water at the tap
(C), collect it, then close the tap again.
- Remove the water detection indicator
connection (D).
- Loosen the filter cartridge (E) using an
oil filter wrench or oil filter strap and remove it.
- Clean the sealing surface where the
new filter will mount.
- Apply a thin coat of oil to the gasket of
the collection sump, mount it under
the filter cartridge and tighten by hand.
- Apply a thin coat of oil to the gasket of
the filter cartridges, mount them under
the holder and tighten by hand.
- Replace the water detector indicator
connection (D).
- Unscrew hand wheel of the pump (F).
Pump the hand wheel until the filter
has filled with fuel.
A
B
F
A
E
C
The system is filled with fuel when resist- D
ance at the hand wheel is noticeable
during pumping!
- Screw in pump’s hand wheel (F).
F 5.0 7
Main filter replacement:
- Loosen the filter (A) and clean the surface
where the new filter will mount.
- Apply a thin coat of oil to the gasket of the
new filter.
- Tighten the filter by hand.
NOTE:
After mounting the filter, check it for proper
tightness.
A
F_5.0_01_US.fm 8-14
Do not fill the fuel filters with fuel before installing them. Then fuel would not be filtered
and could be contaminated. Comtaminated fuel will cause accelerated wear to the
fuel system parts.
F 5.0 8
Engine air cleaner (4)
The function of the engine air cleaner is
to filter the air taken into the engine
through the engine’s air intake. The engine air cleaner is the dry type with two
elements: a primary element that is
cleanable and replacable, and a safety
element that should only be replaced
and not cleaned. The assembly also include a dust vacuator valve and an air
cleaner indicator.
Emptying the dust vacuator valve
- Discharge the dust by pressing together the upper part of the valve (B).
Clean the vacuator valve periodically.
Cleaning / replacing the air filter cartridge
NOTE:
E
A
Air intake filter pollution depends on the
dust content in the air and the mesh size
of the filter selected.
D
B
The maintenance of the filter becomes
necessary if:
- The visual restriction indicator (C) is
red when the engine is stopped. This
indicates that a restriction has occured. This usually means the filters
are dirty. A RED indicator requires
opening th eair cleaner and cleaning
or replacing the elements.
- When the engine electronic unit indicates service required.
F
C
F_5.0_01_US.fm 9-14
Never leave the air cleaner open longer than necessary!
F 5.0 9
To remove the filter cartridges:
- Open the air filter lid.
- Remove the filter cartridge (D) and the safety cartridge (E)
NOTE:
Clean the filter cartridge (D) and replace at least once per year.
- Blow out with dry pressure air (max. 30 psi / 2.07 bar) from inside blowing out. In
case of an urgency, tap the cartridge to remove dust.
- Check the filter’s paper of the filter cartridge (by exposing to light) and inspect the
seals. Replace them as required.
Replace the safety cartridge (E) after 3 filter maintenance intervals, but no longer than
once per year (never clean it!).
After completing the maintenance:
F_5.0_01_US.fm 10-14
- Press the reset button (F) for the maintenance indicator (if equipped). The maintenance indicator is ready for operation.
F 5.0 10
Engine Coolant system (5)
Fully formulated antifreeze must be
mixed with quality water at a 50/50 ratio.
A 50/50 mixture of water and ethylene
glycol or propylene glycol antifreeze to
fill the cooling system. The 50/50 mix
gives protection to the cooling system at
a range of --34_F(--36_C) freezing point
and a 228_F (110_C) boiling point,
which is adequate for locations in North
America. The actual lowest freezing
point of ethylene glycol antifreeze is 68
percent. Using higher concentrations of
antifreeze will raise the freezing point of the solution and increase the possibility of a
silica gel problem.
Do not remove the radiator cap from a hot engine. Wait until the temperature is below
120° F (50° C) before removing the pressure cap. Failure to do so can result in personal injury from heated coolant spray or steam. Remove the filler cap slowly to relieve coolant system pressure.
Checking / filling coolant level
A
The coolant level is checked when the
engine is cold. Check the coolant level
daily (10 hours or as needed). Use a Refractometer to ensure the antifreeze and
anti-corrosive liquid is sufficient (-25° F /
-31.6° C).
- Add
sufficient amount of coolant
through the fill cap (A) on the coolant
tank. Check the coolant level at the
site-glass (B) inside the fuel fill door.
Do not mix coolants. Only use Dynapac approved coolants.
B
F_5.0_01_US.fm 11-14
Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the
engine to cool to 120° F (50° C) before adding coolant.
Changing the coolant
To change the coolant:
- Remove the radiator cap.
F 5.0 11
- Open the drain valve at the bottom of the radiator and drain the cooler into an environmentally approved drain pan with a capacity of about 5 gallons (19 liters).
- Inspect the hoses to and from the radiator and replace them if they look worn or
cracked.
- Once drained, dispose of the coolant fluid in an appropriate manner.
Coolant is toxic. Keep away from children and pets. Dispose of in accordance with
federal, state and local environmental regulations
- Close the drain valve.
- Fill the radiator with a 50/50 mix of water and ethylene glycol or propylene glycol
antifreeze.
- Install the radiator cap.
- Start the engine and allow it to run a few minutes.
- While the engine is running, check the radiator and hoses for leaks.
- When the engine coolant temperature reaches about 180°F (80°C), turn the engine
off and check the coolant level again.
Checking and cleaning of the radiator fins
F_5.0_01_US.fm 12-14
- If necessary, remove leaves, asphaltic oils and residue, dust or sand from the radiator.
F 5.0 12
Engine drive belt (6)
Check drive belt/replacement
Under normal operating conditions, the
engine drive belt(s) should be inspected
daily. Belt damage can be caused by incorrect size or length, pulley misalignment,
incorrect
installation,
severe
operating environment and oil or grease
on the belt(s).
Adjust the belt tension in order to minimize belt slippage. Belt slippage will decrease the life of a belt. If the belt is too
loose, the belt will vibrate. This vibration
is enough to cause unnecessary wear
on the belt(s) and on the pulleys. If the
belt(s) are too tight, unnecessary stresses are placed upon the pulley bearings and upon the belts. These stresses will shorten the life of the belt(s) and the pulley bearings.
To maximize the engine performance, visually inspect the belts for tension, wear,
breaks, cracks or other damage. Replace the belts that are cracked or frayed. Adjust
belts that have a glazed or shiny surface which indicates belt slippage. Correctly installed and tensioned belst will show even pulley and belt wear.
F_5.0_01_US.fm 13-14
Refer to the Engine Manual for proper proceedure for removing and installing the
belts.
F 5.0 13
F 5.0 14
F_5.0_01_US.fm 14-14
F 6.0
1
Maintenance - Hydraulic System
Maintenance - hydraulic system
3
4
1
2
F_6.0_01_US.fm 1-12
5 Hydraulic Hoses - Not Shown
F 6.0 1
1.1
Maintenance intervals
10
50
100
250
500
1000
2000 / 1 years
as required
No.
Interval
Points of maintenance
Remark
- Hydraulic oil tank
Check the oil level
q
q
1
- Hydraulic oil tank
Fill with oil
- Hydraulic oil tank
Oil change and cleaning
q
- Hydraulic oil tank
Check the maintenance indicator
q
q q
2
g
q
- Hydraulic oil tank
Intake / return
q - Change the hydraulic filter
- High pressure filter
Check the maintenance indicator
q
3
g
q
q
- High pressure filter
Replace the filter cartridge
- Pump distribution gear
Check the oil level
q
q
4
- Pump distribution gear
Fill with oil
- Pump distribution gear
Oil change
q
- Hydraulic hoses
Inspect hoses
q
5
q q
- Hydraulic hoses
Replace the hoses
q
Maintenance during break-in period
g
F_6.0_01_US.fm 2-12
Maintenance
F 6.0 2
1.2
Hydraulic System
A paving machine has many components and implements that are controlled by a hydraulic system, either directly or indirectly. Before working on or inspecting any part
of a paving machine, it is important that the individual knows how the components
move and are controlled by the hydraulic system components including the respective control circuits.
Before working on or inspecting any component, it must be physically constrained
from any movement that chould cause injury to the worker. The worker must be alert
to not placing any part of his/her body where movement of a component could couse
injury, unless that component is physically contrained from moventment, if the hydraulic system fails, is disconnected, or is asignaled to cause movement.
It must also be recognized that there are occasions where component and or vehicle
movement may react to the release of potential energy. Where applicable it must be
confirmed that all measures are employed to ensure that any and all sources of potential energy are released and/ or physically restrained.
F_6.0_01_US.fm 3-12
All tramming, hopper and conveyor functions and augers are hydraulically powered.
The hydraulic system consists of a 50 gallon (189.21 liter) hydraulic reservoir with a
10 micron filtration system. The propel pumps, conveyor and auger pump, generator
pump and screed functions are driven by the pump drive gear box which is mounted
directly to the engine. The hydraulic system includes various motors, cylinders,
valves, filters and hose piping. A hydraulic oil cooler assures optimum oil temperatures to maximize sytem efficiency and component life.
F 6.0 3
1.3
Points of maintenance
Hydraulic oil tank (1)
- Oil level check at sight level gauge (A)
on the side of the tank.
NOTE:
View the sight level gauge by the opening fuel tank flap on the L.H. side of the
machine.
With the cylinders fully retracted, the oil
level should be at the upper mark.
A
To add oil:
- Remove cap (B).
- Add oil through the fill port until the level shows full at the sight level gauge
(A).
- Return cap (B).
B
NOTE:
Use only the recommended hydraulic oils - see section “Recommended hydraulic
oils“.
F 6.0 4
F_6.0_01_US.fm 4-12
Regularly clean dust and contaminants
from the vent port on the oil tank. Clean
the surfaces of the oil cooler.
To change the oil:
- To drain the hydraulic oil unscrew
drain plug (C) at the bottom of
tank.
- Collect the oil in an appropriate
tainer using a funnel.
- After draining, add a new seal ring
then screw the plug back into place.
the
the
C
conand
Hot oil or components can burn. Oil must be at normal operation temperature when
draining. Avoid contact with hot oil or components.
Gearbox must be filled with fresh, clean oil.
F_6.0_01_US.fm 5-12
Always change the hydraulic oil filter(s) when changing the hydraulic oil.
F 6.0 5
Suction/return flow hydraulic filter (2)
Change the filter at the intervals specified or when the maintenance indicator
(A) is at the red mark or when changing
hydraulic oil. The hydraulic oil must be at
least 175° F (80° C).
When changing
change the filter.
the
hydraulic
oil
B
also
- Remove the lid fastening screws (B)
and remove the lid.
- Disassemble the withdrawn unit into
the following parts:
- lid (C)
- separating plate (D)
- filter (E)
- dirt collection cage (F)
- Clean the filter case, the lid, the separating plate and the dirt collection
cage.
- Check and replace the O-rings (G)
when required.
- Wet the seal surfaces and the O-ring
with clean fuel.
A
H
G
F
E
D
C
F_6.0_01_US.fm 6-12
I
F 6.0 6
Venting the filter:
- Fill the open filter case with hydraulic oil to just below the upper rim.
- Should the oil level drop, fill with oil.
The oil level slowly lowering by about 1/4 in./min. (1 cm/min) is normal!
- When the oil level remains steady, mount the assembled unit with the new filter cartridge, carefully 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 container.
- Start the engine and run it at idle speed.
- Shut-off the bleeding screw (H) as soon as the oil discharged through the hose is
clean and free of air bubbles.
The process from mounting the filter lid until starting the engine should take place
within 3 minutes or the oil level will drop too much in the filter case.
F_6.0_01_US.fm 7-12
Check the seal after changing the filter.
F 6.0 7
High pressure filter (3)
Replace the filter cartridge when the
maintenance indicator on top of the filter
cartridge head turns “red”.
- Unscrew filter housing (B).
- Remove the filter cartridge
- Clean the filter housing.
- Insert the new filter cartidge.
- Replace the seal (o’ring) on the filter
housing.
- Screw the filter housing on by hand,
then tighten it using the appropriate
tool.
- Test the filter for tightness and leaks.
B
Always replace the seal (o’ring) whenever the filter cartridge is replaced.
F_6.0_01_US.fm 8-12
After the filter cartridge has been replaced, the indicator on top of the filter cartridge
head will return to “green”.
F 6.0 8
Pump distribution gear (4)
- Check the Oil level at the sight glass
(A) (at the side of the distribution box).
NOTE:
The oil level must be up to the center of
the sight glass.
To add oil:
- Unscrew the plug (B).
- Add oil until the sight glass (A) shows
the correct fluid level.
- Return and tighten the plug (B).
B
A
Keep the work area clean!
Hot oil or components can burn. Oil must be at normal operation temperature when
draining. Avoid contact with hot oil or components.
F_6.0_01_US.fm 9-12
Gearbox must be filled with fresh, clean oil.
F 6.0 9
Oil change:
Change the oil when the engine is at operating temperature.
B
- Remove the cap for the oil drain port
(C) and screw on the hose provided as
an accessory.
- Place the end of the hose in an appropriate container and catch the oil.
- Open the shut-off valve and let the oil
drain completely.
- Shut off the valve, remove the hose
and return the cover cap.
- Add only approved oil to the distribution box (B) until the oil level is at the
center of the sight glass (A).
A
C
F_6.0_01_US.fm 10-12
Hot oil or components can burn. Oil must be at normal operation temperature when
draining. Avoid contact with hot oil or components.
F 6.0 10
Hydraulic hoses (5)
Frayed
stantly
spray
place
ately.
or damaged hoses can break incausing hot hydraulic fluid to
causing severe burns. Always reworn or damage hoses immedi-
Hot oil or components can burn. Oil must be at normal operation temperature when
draining. Avoid contact with hot oil or components.
- Check the condition of the hydraulic
hoses carefully.
- Immediately
replace
any
damaged
hoses.
Old hoses may become porous and burst! Hot oil spraying from a burst hose can
cause severe burns!
Each hose has the maximum pressure allowed for that hose printed on it.
F_6.0_01_US.fm 11-12
Do not use hoses that have been in storage for a long time. Check for the proper pressure rating printed on the hose.
F 6.0 11
F 6.0 12
F_6.0_01_US.fm 12-12
F 7.1
1
Maintenance - Travel Drive, Steering
Maintenance - travel drive, steering
2
3
1
F_7.1_01_US.fm 1-8
4
1
1.1
Maintenance intervals
10
50
100
250
500
1000 / year
2000 / 2 years
as required
No.
Interval
Points of maintenance
g
- Rear wheels - wheel mounting
nuts
g
- Front wheels - wheel mounting
nuts
Remark
1
- Check the oil level of
the planetary gear
q
q
2
- Check the oil level of
the planetary gear (drive)
- Planetary gear (drive) Change the oil
q
- Air pressure (drive wheels) check
q
3
q
- Air pressure (drive wheels) adjust
q
- Lubrication points lubrication of axle stubs
q
- Lubrication points lubrication of steering
q
- Lubrication points lubrication of swing axle
q
- Lubrication points lubrication of swing axle
4
q
Maintenance during run-in period
g
F_7.1_01_US.fm 2-8
Maintenance
2
1.2
Points of maintenance
Wheel mounting nuts (1)
Rear wheels
The 16 wheel mounting nuts have to be
tighten in the
described order with a
torque of
375 ft. lbs. ( 508 Nm) dry
thread.
1
16
3
5
14
12
7
9
10
8
11
6
13
4
15
2
Front wheels (with front wheel drive)
5
The 10 wheel mounting nuts have to be
tighten in the described order with a
torque of
400 ft. lbs. ( 542 Nm) dry
thread.
7
3
9
1
2
10
4
6
F_7.1_01_US.fm 3-8
8
3
Planetary gear (2)
Care must be taken to ensure fluids are
contained during performance of inspection, maintenance, testing, adjusting and
repair of the paver. Be prepared to collect
the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids. Always dispose of fluids according to local
regulations and mandates.
To check the oil level in the Planetary Gearbox
- Position the planetary gearbox so
that the oil drain (B) is vertical at its
lowest point (about the 6 o’clock position). The oil filler plug (C) should
then be on the Left or Right outside
fo the planetary middle.
- Clean the area around the check and
fill plugs and the drain plug.
C
A
B
- Place an oil collection container underneath the planetary gearbox.
The proper oil level is at the lower edge of the inspection port (A) or a little oil flows
from the hole.
- Remove the oil level check plug (A). The oil level should be at the oil level check
port.
- If the level is low, add oil.
Gearbox must be filled with fresh, clean oil.
- Fill with oil until the level has reached the oil level check port (A). Insert check and
fill plugs and then tighten
4
F_7.1_01_US.fm 4-8
If the oil looks contaminated, it must be drained and replaced with clean, fresh oil.
To change oil:
Change the oil when the engine is at operating temperature.
Hot oil or components can burn. Oil must be at normal operation temperature when
draining. Avoid contact with hot oil or components.
Make sure that no pollution or foreign matter gets into the drive.
F_7.1_01_US.fm 5-8
- Stop the machine so that the “TOP” is at the topmost position and the drain plug is
at the bottom.
- Place an oil collection container underneath the planetary gearbox.
- Unscrew the drain plug and the filling plug and drain the oil.
- Check and replace the seals of both screw plugs.
- Return drain plug.
- Remove the inspection plug.
- Fill oil through the filling hole until the oil level reaches the lower edge of the inspection hole. Use only approved fluids.
- Replace and tighten the inspection plug and filling plug.
5
Air pressure (driving wheels) (3)
Check/adjust the air pressure:
The required tire pressure is 45
(pounds per square inch) for each tire.
valve and
F_7.1_01_US.fm 6-8
Check the air pressure at the
adjust as required.
psi
6
Places of lubrication (4)
Steering
5x
The grease zert is located on the right
side wall and the steering linkage is supplied with grease through a lubrication
line.
Grease Points
Pump the grease gun 5 times into the
zert at the end of the lubrication line for
the steering linkage.
Wheel bearing
Non-curb side
Curb side
The grease zerts are found on the wheel
hub of each wheel.
There is no grease zert in the driven
wheel.
Grease Point
Pump the grease gun 5 times at each of
the wheel hubs.
F_7.1_01_US.fm 7-8
Wheel Hub
7
8
F_7.1_01_US.fm 8-8
F 8.1
1
Maintenance - Electronic System
Maintenance - Electronic system
3
F_8.1_01_US.fm 1-10
1
1
1.1
Maintenance intervals
10
50
100
250
500
1000 / annually
5000
20000
If necessary
Item
Interval
Maintenance point
Note
Check the charge level of the
batteries, replace if necessary
q
1
q
3
Apply grease to battery terminals
q Electric fuses
q
Maintenance during the running-in period
g
F_8.1_01_US.fm 2-10
Maintenance
2
1.2
Points of maintenance
Batteries (1)
Maintenance of batteries
NOTE:
The batteries equipped with the paver
are “Maintenance Free” batteries. When
batteries can no longer hold a charge,
they must be replaced.
The battery terminal clips must be free of
corrosion (oxide) and protected with
grease.
Terminals
When removing the batteries, always remove the negative terminal first, ensuring that
the battery terminals do not short circuit. After batteries are replaced, connect the
negative terminal last
F_8.1_01_US.fm 3-10
Always where protective glasses when working with batteries.
Never disconnect any charging unit circuit or battery circuit cable from the battery
when charging unit is operating. A spark can cause explosions.
3
Electric fuses / relays (3)
Main fuses (A)
F3
F7
F1
F2
F4
Fuse No.
F1
Alternator Fuse
Key Switch Line Fuse
Air Heater Fuse
ECM Power Supply Fuse
Rating (A)
100
100
50
125
30
F_8.1_01_US.fm 4-10
F2
F3
F4
F7
Description
Main Battery Fuse
4
Fuses in terminal box (B)
27
F_8.1_01_US.fm 5-10
!
Fuse No.
F5
F6
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F22
F23
F24
F25
F26
F27
F28
F29
F30
Description
Propel Controler
Emergency stop
ECM Key Switch Signal
Key Switch Power
Multi functional Display
Horn Power Supply
Hour Meter & Track Low pressure Alarm
Propel Input Devices
Console Select switch & parking brake
Auger / Conveyor status LED´s on Console
Auger / Conveyor Controller & Sensor
Auger & Hopper Raise/Lower
Levelling Controls
Screed Extend/Retract, Float / Lock
Vibration Solenoid
Work Lights
Dash Board Lamp
DC 24 V outlet front
DC 24 V outlet front
DC 24 V outlet rear
DC 24 V outlet rear
Warning / Turning Lights
Warning / Turning Lights
Roading lights
Rating (A)
10
5
5
10
5
3
10
10
5
5
15
10
10
10
3
10
3
10
10
10
10
10
10
10
5
Description
Wash Down & Truck Hitch
Screed Power Supply
Screed Power Supply
FWA Switch & Steering Position Sensors
Rating (A)
3
15
15
3
F_8.1_01_US.fm 6-10
Fuse No.
F31
F32
F33
F34
6
Relays in terminal box (C)
!
F_8.1_01_US.fm 7-10
Relay No.
Description
R1
Starter
R2
Anti Start Circuit
R3
Emergency Stop Circuit
R4
Intake Air Heater
R5
Auger / Conveyor ON / OFF
R6
Auger / Conveyor Auto / Manual
R7
Auger / Conveyor Auto Mode
R8
Left Conveyor OFF
R9
Right Conveyor OFF
R10
Starter Lock Out
R11
Screed Float / Lock
R12
Console Select Indication
R13
Left Auger OFF
R14
Right Auger OFF
R15
Key Switch Power
R16
Flasher - Warning / Turning Signal
R17
Flasher - Warning / Turning Signal
7
8
F_8.1_01_US.fm 8-10
10
F_8.1_01_US.fm 10-10
F 9.0
1
Maintenance - Lubricating Points
Maintenance - Lubricating points
F_9.0_01_US.fm 1-4
NOTE:
The information on the lubrication points for the various assemblies is assigned to the
specific maintenance descriptions (I.E. grease points for the auger are in the auger
section and grease points for the undercarriage are in the section on undercarriages)!
F 9.0 1
1.1
Maintenance intervals
1
10
50
100
250
500
1000 / annually
2000 / every 2 years
If necessary
Item
Interval
q
Maintenance point
-
Note
Bearing points
q
Maintenance during the break-in period
g
F_9.0_01_US.fm 2-4
Maintenance
F 9.0 2
1.2
Points of maintenance
Bearing points (1)
2x
One grease zert (A) is located at each
hydraulic cylinder bearing point (top and
bottom).
F_9.0_01_US.fm 3-4
A
F 9.0 3
F10.0
Tests, check-up, cleaning, stopping
F_10.0_01_US.fm. 1-6
1
Checks, Decommissioning
F10.0 1
1.1
Maintenance intervals
1
10
50
100
250
500
1000 / year
2000 / 2 years
as required
No.
Interval
q
2
Points of maintenance
Remark
- General observation
q
q - Checked by a specialist
3
q - Cleaning
4
q - Preservation for storage of paver
q
Maintenance during run-in period
g
F_10.0_01_US.fm. 2-6
Maintenance
F10.0 2
2
General observation
The daily check includes a walk around the machine while checking the following
items:
- Are any of the parts or controls damaged?
- Are there leaks at the engine, the hydraulics, the gear box, etc.?
- Are all the locking points secure (conveyor, auger, screed)?
Repair the damages and clean any spills immediately to avoid risks of accidents and
environmental pollution!
3
Check performed by a specialist
The paver, the screed and the electrical equipment MUST be checked regularly by a
specialist:
F_10.0_01_US.fm. 3-6
- as required (according to the circumstances of application and operating conditions),
- however, at lease once a year, so that the machine retains its reliable operating
condition.
F10.0 3
4
Cleaning
- Clean all parts that come into contact with the material to be laid.
- Spray these parts with the release agent spray equipment.
Before cleaning with high pressure jet, lubricate all the bearings with grease as specified.
- Clean the machine with water after laying mineral mixes, lean concrete etc. Remove all residue of the materials laid.
Do not spray water on
electric or electronic parts.
- Remove
laid.
the
residue
of
the
the
bearings,
material
After cleaning with the high pressure jet, lubricate all of the bearings with grease as
specified.
F_10.0_01_US.fm. 4-6
Slippery walkways and steps can result
in severe or deadly slipping and falling!
Ensure the cleanliness of the walkways
and steps and that they are free of
grease and oil.
F10.0 4
5
Preservation for storage of paver
5.1
Downtime up to 6 months
- Stop the machine in a place protected from intensive sunshine, wind, moisture and
frost.
- Lubricate all the lubrication points with grease as specified.
- Change the oil in the Diesel engine
- Seal the muffler of the exhaust pipe.
- Remove the batteries, charge and store them at room temperature in well ventilated premises.
Recharge the stored batteries every 2nd month.
- Protect all metal surfaces, (i.e. hydraulic cylinder piston rods) against corrosion using an appropriate agent.
- If the machine cannot be parked in a garage, barn or a shed, it must be covered
with an appropriate canvas. In each case all the air inlets and outlets must be tightly
sealed using plastic film and adhesive tape.
5.2
Downtime between 6 months and 1 year.
- Perform all operations described for “Downtime up to 6 months“.
- After draining the engine oil, fill the engine with preservative oil permitted by the
manufacturer of the engine. Contact the Dynapac, USA (a part of Atlas Copco) customer center for further detail.
5.3
Re-commissioning:
F_10.0_01_US.fm. 5-6
- Reverse the steps in the section “Downtime“.
F10.0 5
F 11.0
1
Lubricants and Operating Substances
Lubricants and operating substances
Use only the lubricants listed below or their equivalents.
Only use clean containers for filling oil or fuel.
Follow to the correct filling volumes (see the section “Capacities“).
Incorrect oil or lubricant levels increase the wear and cause the paver to fail.
Never mix synthetic oils with mineral oils!
BP
Exxon
Total Fina
(Total)
Mobil
Shell
Shell
Grease
Engine oil
Hydraulic oils
Synthetic gearbox
oil
Delvac MX
Rimula 15W - 40
DTE 10 Excel - 46
Tellus T46
Delvac Synthetic Gear Oil
80W - 140
Spirax
80 W - 140
Dist. water
Diesel fuel
Cooling liquid: 50% ethylene glycol or propylene glycol based antifreeze and 50% water mix (to -25°F)
F_11.0_01_US.fm 1-2
Cooling liquid
F 11.0 1
Capacities
Substance
Volume
Fuel tanks
Diesel fuel
49 gal (185.43 L) each
Hydraulic oil tank
Hydraulic oil (Multigrade Oil
ISO 46-68)
50 gal (189.21 L)
Pump distribution gear
80W-140 full synthetic oil
1.4 gal (5.3 L)
Planetary gear - track
80W-140 full synthetic oil
0.8 gal (3.0 L) each
Conveyor - gear box
80W-140 full synthetic oil
1.58 qt. (1.5 L) each
Auger - gear box
80W-140 full synthetic oil
2.64 qt. (2.5 L) each
Diesel engine oil (with filter)
Engine oil 15W-40
(API CI-4)
18.5 qts (17.5 L)
Diesel - cooling system
Engine coolant 50:50 Mix
6.5 gal (24.6 L)
Batteries
Distilled water
F_11.0_01_US.fm 2-2
1.1
F 11.0 2
TRAINING/
EDUCATION
We offer our Customers various
training programs on DYNAPAC
equipment in our specialised
training center in our factory. We
hold training sessions also for
special arrangements in addition
to courses and programs held on
SERVICE
In case of operational failures and questions related to parts, please, contact one
of our authorised service representations. Our skilled specialists will arrange
for fast and professional repair.
OPERATING ADVICE
Anytime when our dealers cannot help
you, please, feel free to contact us directly. Our team of "Technical Advisors"
is at your disposal.
Don’t hesitate to contact
your local dealer for:
service
spare parts
documentation
accessories
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