Dynapac Svedala Demag DF 115 P/D, Svedala Demag DF 125 P/D Operation & Maintenance Manual

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OPERATION

MAINTENANCE

Paver finisher

Svedala Demag

DF 115 P/D DF 125 P/D

Typ 34

Keep this manual for future reference

Order number for this manual: D900981408

02-0107

.........................

VALUE

QUALITY

THE ORIGINA L

Your Authorized Dynapac Dealer:

34_DF115PD_DF125PD_OMM_CON_02_G BIVZ.fm 1-

Table of conten ts

V Preface ..................................................................................... 1

1 General safety instructions ........................................................................2

1.1 Acts, directives, accident prevention regulations .......................................2

1.2 Warning instructions ..................................................................................2

1.3 Prohibitive signs ............................................. ......... .......... ......... ......... .......4

1.4 Protective gear ...................................... ......... ......... .......... ......... ......... .......5

1.5 Environmental protection ...........................................................................6

1.6 Fire prevention ...........................................................................................6

1.7 Further instructions ....................................................................................7

A Correct use and application ...................................................1

B Vehicle description .................................................................1

1 Application .................................................................................................1

2 Description of assemblies and functions ....................................................2

2.1 Vehicle .......................................................................................................3

Construction ...........................................................................................3

3 Danger zones .............................................................................................6

4 Safety devices ............................................................................................7

4.1 Emergency stop button .............................................................................7

4.2 Service brake („foot brake“) .......................................................................7

4.3 Steering ......................................................................................................7

4.4 Horn ...........................................................................................................7

4.5 Ignition key / lights .....................................................................................7

4.6 Main switch (17) ........................................................................................8

4.7 Hopper transport safeguards (18) .............................................................8

4.8 Screed transport safeguards (19) ..............................................................8

4.9 Latch for protective roof (20) ......................................................................8

5 Technical data, standard configuration .................................................... 10

5.1 Dimensions (all dimensions in mm) .........................................................10

5.2 Allowed angle of rise and slope ...............................................................11

5.3 Allowed angle of driving up ......................................................................11

5.4 Turning circle ...........................................................................................11

5.5 Weights DF115P/D (all weights in t) .......................................... ......... .....12

5.6 Weights DF125P/D (all weights in t) .......................................... ......... .....12

5.7 Performance data DF115P/D ...................................................................13

5.8 Performance data DF125P/D ...................................................................14

5.9 Traction drive/chassis ..............................................................................15

5.10 Engine DF115P/D ....................................................................................15

5.11 Engine DF125P/D ....................................................................................15

5.12 Hydraulic system ..................................................... .................................15

5.13 Material compartment (hopper) ................................................................16

5.14 Material conveying ...................................................................................16

5.15 Material distribution ..................................................................................16

5.16 Screed lifting device .................................................................................17

5.17 Electrical system ......................................................................................17

6 Location of instruction labels and identification plates .............................18

6.1 Identification label for the paver finisher (6) ..........................................20

7 EN standards ...........................................................................................21

7.1 Continuous sound level DF115P/D, Deutz TCD2013L04 ........................21

7.2 Operating conditions during measurement ..............................................21

7.3 Measuring point configuration ................................. .......... ......... ......... .....21

7.4 Continuous sound level DF125P/D, Deutz TCD2013L06 ........................22

7.5 Operating conditions during measurement ..............................................22

7.6 Measuring point configuration ................................. .......... ......... ......... .....22

7.7 Vibration acting on the entire body ..........................................................23

7.8 Vibrations acting on hands and arms .......................................................23

7.9 Electromagnetic compatibility (EMC) ......................................... ......... .....23

C1.0 Transpor tation ........ .......... ......... ..... .......... ......... .......... .......... ..1

1 Safety regulations for transportation ..........................................................1

2 Transportation on low-bed trailers .............................................................2

2.1 Preparations ...............................................................................................2

2.2 Drive onto the low-bed trailer .....................................................................4

2.3 Secure the paver finisher in its position to the low-bed trailer: ...................5

2.4 After transportation ....................................................................................5

3 Transportation ............................................................................................ 6

3.1 Preparations ...............................................................................................6

3.2 Traction drive: ............................................................................................8

4 Loading by crane .......................................................................................9

5 Towing .....................................................................................................10

6 Safely parking the vehicle ........................................................................12

D1.3 Operation ................................................................................. 1

1 Safety regulations ......................................................................................1

2 Operating elements ....................................................................................2

2.1 Operating panel .........................................................................................2

3 Remote control .........................................................................................21

Front side .............................................................................................22

Reverse side ........................................................................................23

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D3.0 Operation ................................................................................. 1

1 Operating elements on the paver finisher ..................................................1

Batteries (71) .......................... .......... ............................ ......... ......... .......1

Battery main switch (72) ........................................................................1

Transport safeguards for the hopper (73) ..............................................2

Mechanical screed transport safeguard

(to the left and the right beneath the driver’s seat) (74) .........................3

Seat lock (behind the driver’s seat) (75) ................................................3

Service brake („foot brake“) (76) ............................................................4

Separator fluid spraying system (80) (o) ................................................5

on / off switch for additional headlight in the roof (85): ..........................6

On / off switch for fuel tank filler pump (85a) .........................................6

On / off switch special lighting (85b) ......................................................6

On / Off switch Exhaust of asphalt vapours (85c) ..................................6

On/Off switch of work headlights (85d): .................................................7

On/Off switch of flasher (85e): ...............................................................7

230 V On / Off switch Connection sockets (85f) ....................................7

Locking of the collapsible roof (LH and RH on the roofs console) (86):.7

Hydraulic folding roof (87) (o) ...............................................................8

Electric setting of the transportation volume of the conveyor (o) (88) ....9

Conveyor limit switches (89) ..................................................................9

Ultrasonic auger limit switches (90) (left and right) ..............................10

Sockets for working lights (left and right) (92) .....................................10

Pressure control valve for screed charging/relieving (93) ....................11

Pressure control valve for screed stop with pretensioning (93a) .........11

Pressure gauge for screed charging/relieving and screed stop

with pretensioning (93b) ......................................................................11

Front wheel drive pressure regulating valve (94) (o) ...........................12

Pressure gauge of the front wheel drive (94a) (o) ...............................12

Central lubrication unit (o) (100) ..........................................................13

Particle filter - control light (102) (o) ....................................................14

Front and side window (o) (103) ..........................................................15

Adjustment of screed eccentric (o) (104) .............................................16

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D4.5 Operation ................................................................................. 1

1 Preparation of operation ............................................................................1

Required devices and aids ....................................................................1

Before starting work (in the morning or when starting paving) ..............1

Checklist for the machine operator ........................................................2

1.1 Starting the paver finisher ..........................................................................4

Before starting the paver finisher ...........................................................4

„Normal” starting ....................................................................................4

External starting (starting aid) ................................................................5

After starting ..........................................................................................6

Indicator lamps ......................................................................................6

Battery charge indicator (1) ...................................................................6

Oil pressure indicator lamp for the traction drive (2) ..............................6

1.2 Preparations for paving ..............................................................................8

Separating agent ...................................................................................8

Screed heater ........................................................................................8

Direction marks ................................. ............................ ......... ......... .......8

Loading/distributing material ..................................................................9

1.3 Starting for paving ................................. ......... ......... .......... .......................11

1.4 Checks during paving ..............................................................................13

Paver function ......................................................................................13

Quality of the layer ...............................................................................13

1.5 Paving with functions "screed control, stopping of paver finisher"

and "screed loading / unloading" .............................................................14

General ................................................................................................ 14

Screed charging/relieving ....................................................................15

Screed control with the paver finisher standing still

(Floating position with and without prestressing) .................................15

Screed control with the paver finisher at standstill -

with floating position prestressing ........................................................16

Adjusting the pressure .........................................................................16

Adjustment of pressure for the loading/offloading of the screed ..........17

Screed control pressure with the paver finisher at standstill -

set the floating position with prestressing (o) .......................................17

1.6 Interrupting/terminating operation ............................................................18

During breaks (e.g. the material supply truck is late) ...........................18

During extended interruptions (e.g. lunch break) .................................18

When work is finished ..........................................................................19

2 Malfunctions .............................................................................................21

2.1 Querying the error messages of the traction engine ................................21

Display of the number code .................................................................21

2.2 Error messages ........................................................................................24

2.3 FMI-codes ................................................................................................ 29

2.4 Problems during paving ...........................................................................30

2.5 Malfunctions on the paver finisher or screed ...........................................32

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E01 Set-up and modification .........................................................1

1 Special notes on safety ..............................................................................1

2 Auger .........................................................................................................2

2.1 Height adjustment ......................................................................................2

2.2 Auger crossbeam installed in a fixed position ............................................2

2.3 Mechanical adjustment with ratchet (optional) ...........................................3

2.4 In case of hydraulic adjustment (option) ....................................................3

2.5 Auger extension, auger type I ....................................................................5

2.6 Mounting extension parts ...........................................................................6

2.7 Mounting support tube extensions .............................................................7

2.8 Installing tunnel plates .......................... ......... ......... .......... ......... ......... .......8

2.9 Installing additional braces ............................. ......... .......... ......... ......... .......9

2.10 Auger mounting chart for ø 310 mm auger ..............................................10

2.11 Auger mounting chart for ø 380 mm auger ..............................................11

3 Auger extension, auger type II .................................................................12

3.1 Mounting extension parts .........................................................................13

3.2 Auger modification plan. ..........................................................................15

4 Screed ......................................................................................................17

5 Electrical connections ..............................................................................17

5.1 Remote controls .......................................................................................17

5.2 Grade control ...........................................................................................17

5.3 Auger limit switches .................................................................................17

5.4 Working lights .................... ......... .......... ......... ......... .......... ......... ..............17

F1.0 Maintenance ............................................................................1

1 Notes regarding safety ...............................................................................1

F2.2 Maintenan ce re vie w .............. ................................. .................1

1 Maintenance review ...................................................................................1

F3.0 Mainten ance - Con vey or .......... ..... ..... ..... ..... ................... .......1

1 Maintenance - Conveyor ............................................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................3

Chain tightness of the conveyor (1) .......................................................3

The drive of conveyor (to the left/to the right) (2) ...................................4

F4.1 Maintenan ce - Aug er ........ ..... .... .................... ..........................1

1 Maintenance - auger sub-unit ....................................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................3

Auger - outer bearing (1) .......................................................................3

Auger planetary gear (2) ........................................................................3

Drive chain (3) of the transport augers ..................................................4

Auger case (4) .......................................................................................6

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F5.1 Mainten ance - Engi ne ...... ..... .... ..... ..... ..... ..... ..........................1

1 Maintenance - engine sub-unit ...................................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................4

Engine fuel tank (1) ...............................................................................4

Engine lube-oil system (2) ....................................................................5

Engine fuel system (3) ..........................................................................7

Engine air filter (4) .................................................................................9

Coolant system of the engine (5) .........................................................10

Engine drive belt (6) .............................................................................10

Engine exhaust system (7) .................................................................11

F6.0 Maintenance - Hydraulic system ...........................................1

1 Maintenance - hydraulic system ................................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................3

Hydraulic oil tank (1) ..............................................................................3

Suction/return flow hydraulic filter (2) ....................................................4

Venting the filter: ....................................................................................5

High pressure filter (3) ...........................................................................6

Pump distribution gear (4) .....................................................................7

Hydraulic hoses (5) ................................................................................8

F7.4 Maintenance - travel drive, steering ......................................1

1 Maintenance - travel drive, steering ...........................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................3

Planetary gear (1) ..................................................................................3

Air pressure (driving wheels) (2) ............................................................4

Places of lubrication (3) .........................................................................5

Steering .................................................................................................5

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F8.0 Maintenance - Electronic System ..........................................1

1 Maintenance - Electronic System ..............................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................5

Batteries (1) ........................................................ .......... ......... ................5

Generator (2) .........................................................................................6

Adjustment of belt tightness ...................................................................8

Replacement of belt ...............................................................................9

Electric fuses (3) ..................................................................................11

Type of machine: Conventional electronics .........................................11

Terminal box .......................................................................................11

Fuses in terminal box (B) .....................................................................12

Relays in terminal box (C) ...................................................................13

Fuses on operating panel ....................................................................14

Relays in operating panel ....................................................................15

Type of machine: PLC electronics .......................................................16

Terminal box .......................................................................................16

Fuses in terminal box ..........................................................................17

Relays in terminal box (C) ...................................................................19

Fuses on operating panel ....................................................................20

F9.0 Mainten ance - Po ints of lubric at ion .. ..... ..... .... ..... ..... ............1

1 Maintenance- Points of lubrication .............................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ...............................................................................3

Central lubrication (1) ............................................................................3

Bearings (2) ............................ .......... ............................ ......... ......... .......7

F10.0 Checks, decommissioning .....................................................1

1 Tests, check-up, cleaning, stopping ...........................................................1

1.1 Maintenance intervals ................................................................................2

2 General observation ...................................................................................3

3 Checks by a specialist ...............................................................................3

4 Cleaning ..................................................................................................... 4

5 Conservation of paver finisher ...................................................................5

5.1 Downtime up to 6 months ..........................................................................5

5.2 Downtime between 6 months and 1 year. ..................................................5

5.3 Re-commissioning: ....................................................................................5

F11.3 Lubricants and operating substances ..................................1

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1 Lubricants and operating substances .......................................................1

1.1 Hydraulic oils ......................................... .....................................................2

1.2 Filling volumes ...........................................................................................3

2 Notes on changing over from mineral oil to synthetic oil /

synthetic oil to mineral oil ...........................................................................7

2.1 Track planetary gear ..................................................................................7

VPreface

Safe operation of the machine requires specific knowledge that is imparted by the present operati ng instruction s. The information is pr ovided in a concise, cle arly 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 m aintenance w ork the description appropriate to the machin e option is used.

Safety instructions and important notes are identified by the following pictograms:

f m

Precedes safety inst ructions that must be obser ved in orde r to p revent danger t o personnel.

Precedes notes that must be observed to prevent damage to equipment.

Precedes general notes and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

In the interest of continu ed development, the man ufacturer reserve s the right to make changes to the machine ( which will not, however, change the essential features of the type of m achine descr ibed) wi thou t up dating the pr esent oper ating i nstructi ons at the same time.

Dynapac GmbH Wardenburg

Ammerländer Strasse 93 D-26203 Wardenburg / Germany Telephone:+49 / (0)4407 / 972-0 Fax: +49 / (0)4407 / 972-228 www.dynapac.com

V_01_GB.fm

V 1

1 General safety instructions

1.1 Acts, directives, accident prevention regulations

A A

1.2 Warning instructions

The locally applicable acts, directives and accident prevention regulations shall be obse rved, even if the attenti on is not specifically directed to these. The operator hi mself shall be responsi ble for the observatio n and performa nce 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.

Warning pointing to hazardous place or danger! Not observing the warning instructions may lead to injuries of life and limb!

Warning: risk of pulling in! In this area / with these equipment as a result of rotating or trans-

portation parts, there is a risk of pulling in! Perform each operation only with equipment swicthed 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 load!

Warning: risk of squeezing! Risk of squeezing arises due to the operation of certain parts, use

of some functions and the movement of the machine. Always make sure that no one stays in the areas exposed to risk!

V 2

V_01_GB.fm

Attention: risk of hand injury!

Attention: hot surfaces or hot liquids!

Warning, risk of falling off!

Attention: hazardous batteries!

Attention: materials harmful to health and irritating substances!

Attention: flammable materials!

Attention: gas bottles!

V_01_GB.fm

V 3

1.3 Prohibitive signs

It is prohibited to open / step on / reach into / perform / adjust during operation or when the traction engine is running!

Do not start the engine/drive! Maintenance and repair works can be carried out only with the Diesel engine turned off!

Do not sprinkle with water!

Do not extinguish with water!

Do-it-yourself maintenance is prohibited! Maintenance can be performed by skilled professionals only!

Contact the Dynapac service!

Danger of fire: do not use open flame and no smoking!

Do not turn on!

V 4

V_01_GB.fm

1.4 Protective gear

The applicable local regulations may define the use of different protective gear! Observe these specifications!

Protect your eyes with googles!

Wear appropriate head protection!

Protect your hearing with appropriate ear mufflers!

Protect your feet with safety footwear!

Always wear tight, conforming working coveralls! Wear visibility vest for good visibility!

In case of polluted air, wear respiratory mask!

V_01_GB.fm

V 5

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 cl eanin g, m ainte nance and r epair op erati o n th e mater ial s p olluting water e .g.:

- lubricants (oils, grease)

- hydraulic oil

-gas oil

- coolant

- detergents

may not enter the soil or the sewer system! These materi als shall be colle cted, stored, tran sported in the cor rect

containers until professional disposal!

Material harmful for the environment!

1.6 Fire prevention

The applicable local regulations may specify the mounting of appropriate fire extinguishers! Observe these specifications!

Fire fighting device (optional equipment)

V 6

V_01_GB.fm

1.7 Further instructions

Observe the manufacturer's and other instructions!

e.g. the maintenance instructions of the engine manufacturer

Description / figure in case of an electrically heated design!

V_01_GB.fm

V 7

A Correct use and application

The “Guidelines for the Correct Use and Application of Paver finishers” compiled by Dynapac are included in the scope of delivery for the present machine. The guidelines are part of the present operating instructions and must always be heeded. National regulations are fully applicable.

The road construction machine described in the present operating instructions is a paver finisher that is suited for laying mixed materials, roll-down concrete or leanmixed concrete , track-layi ng ballast and unbound m ineral aggregate s for founda tions for paving. This machine sh all be u sed, operat ed and ma intained for the pu rpose of the intended work as included i n the oper ation manual. A ny other u se is regarded as improper use and can cause injury to persons or damage to the paver finisher or other equipment or property.

Any use going beyond the range of applications described above is regarded as improper use and is expr essly forbidden! E specially in those cases wher e the paver finisher is to be operated on inclines or where it is to be used for special purposes (construction of dump s, dams), it is absolutely necessary to contact the m anufacturer.

Duties of th e u ser : A “ user” wi thin the m eaning of the presen t ope rati ng instru cti ons is defined as any natural or legal person who either uses the paver finisher himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person who, in accordance with existing contractual agreements between the owner and the user of the paver finisher, is charged with the observation of the operating duties. The user must ensure that th e paver finisher is only used in the stipu lated mann er 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 pr evention regulat ions and othe r 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.

Mounting of attachments: The paver finisher must only be operated in conjunction with screeds that have been approved by the manufacturer. Mounting or installation of any attachment s that will interfere with or supple ment the functions of the paver finisher is per mitted only after w ritten a ppro val by the ma nufact urer has bee n obtain ed. 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.

A_01_GB.fm 1-2

A 1

B Vehicle description

1 Application

The Svedala Demag DF115P/D / DF125P/D i s a rubber tyre fitted paver finishe r that is used for layi ng bituminous m ixed materi al, roll-dow n or lean -mixed concre te, tracklaying ballast and unbound mineral aggregates for foundations for paving.

64_ISO_DEM.bmp

B_DF1 15PD_DF125PD_01_GB.fm 1-2 4

B 1

2 Description of assemblies and functions

13 14 19

634_EM_ISO.bmp

Item Designation

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19

Material compartment (hopper)

Truck push rollers

Tube for sensor rod (dir ecti on indicato r) and hol der for levell ing shoe

Rear wheels

Levelling cylinder for paving thickness

Traction roller

Traction arm rail

Paving thickness indicator

Arm

Machine drive

Auger

Screed

Operator’s platform

Operating panel (can be moved to either side)

Protective roof

Working lights

Front tandem axle

Hydraulic front hopper lid

Exhaust of asphalt vapours

4 10

6 7 5

B 2

t = Standard equipment

o = Optional equipment

B_DF1 15PD_DF125PD_01_GB.fm 2-2 4

2.1 Vehicle

Construction

The paver finisher has a welded steel frame on which the individual components are mounted.

The large drive wheels together with the front tandem shaft jointly compensate the irregularities o f the soil and as a re sult of the suspensio n of the screed they gu arantee a particularly high paving precision. The continuously adjustable hydrostatic traction drive allows the speed of the paver finisher to be matched to all work conditions.

The operation of the road construction equipment is considerably facilitated by the automatic mixer device, the independent drives and the transparent operating components and controls.

The following extra equipment (option) is available:

o Automatic levelling/slope control system o Ultrasonic sensors for material transport (controller) o Additional cut-off shoe o Larger working widths o Automatic central lubrication system for the paver finisher and/or the screed o Protective roof o Further equipment and upgrade options on request

Engine: The paver finishe r is dri ven by a water cooled Die sel engine . For furt her de tails see the technical data and the engine's instruction manual. The particl e filter (o) cleans the exhaust gas from the soot particl es produced, reduces the generation of ha rmful carbon -monoxyde and ca rbon-dioxyd e gases, therefor e, it operates as a ca tal yser to minimi ze the load on the envi r onm ent and health . A con trol light indicates the necessity of maintenance operations.

Running gear: The front axle was designed as a tandem swinging axle. As the wheels are not mounted o n non-uniform lifting axles, the second fron t wheel is su bject to a heavier load on the shorter lifting arm. As a result of thi s solution the steer ing possib ility and the lo ad capacity are im proved, especially on soft gro und. Tyr es moun ted with fl exible soli d tyres on the fro nt wheels and large-size, tubeless, air filled tyres on the rear wheels (water filled tyres - o). In case of complementary front wheel drive the second front axle or both front axles can be engaged as additional drive axles.

B_DF1 15PD_DF125PD_01_GB.fm 3-2 4

B 3

Hydraulic system: The diesel engine drives the hydraulic pumps for all main drives of the paver finisher via the attached distribution gear and its auxiliary drive shafts.

Tract ion dri ve: The continuously adjustable traction drive pumps are connected to the traction motors by means of high pressure hydraulic hoses. These hydro-motors can drive the drive wheels through a planetary gear. The multi-st age planetary ge ar produces the various movemen t ranges and th e brake function.

Steering syst em/o pe rat or’s p latf or m: The f ully hydra ulic D anfoss- Orbitr ol steer ing ensures easy maneuverability. The operating panel can be secured in a position at the left-hand or the right-hand side of the paver finisher by means of a latch accessible from above.

Push roller cross bar: The push rollers for material trucks are fastened to a cross bar that is pivoted at its center. This cross bar a llow s to comp ensate for different distance s to the r ear wh eel s of ma terial trucks. The paver finisher thus deviates less from its course and paving in curves is made easier.

Materia l com par tm en t (h op per ): The hopper inlet is equ ipped with a conveyor system that empties the hopper and transfers the material to the auger. The hopper can hold about 13.0 t. To facilitate emptying and to improve material transport, each of the lateral covers of the hopper can be hydraulically moved (option). The hydraul ic fr ont hopp er li d s (o) ensur e t hat n o m ater ial re mai ns at t he fr ont of the feeding hoppers.

Material transfer: The paver finisher is equipped with two conveyors driven separately that transfer the material from the hopper to the augers. By scanning the filling height during the paving procedure, the transfer amount or speed is regulated fully automatically.

Augers: The augers are driven and actuate d independently from the conv eyors. The left-hand and the righ t hand hal f of the aug er can be contr olled separ ately. The drive system is fully hydraulic. The conveying direction can be changed towards the center or towards the outside. This ensures that there is always a sufficient supply with m aterial even i f an excessive amount of material i s required at one side. The auger speed is continuously contr olled by sensors that monitor the material flow.

B 4

B_DF1 15PD_DF125PD_01_GB.fm 4-2 4

Height ad jus tment and e xtens ion of auge rs: Height adjustment and extension of augers ensure optimum adaptation t o a wide ra nge of pavi ng thicknesses and widths.

The basic configuration allows the height to be adjusted by attaching chains to the side arms and by actuating the hydraulic screed lifting device. When using ratchet s for hei g ht adjustm ent ( option) , bar rel nut s at the gui d e suppo rts in the rear wall are used to adjust the height. Another vari ant allows th e height to be reg ulated at the contr ol pane l by means of hydraulic cylinders (option).

Auger segments of different lengths can be attached to easily adapt to the different paving widths.

Automatic levelling/slope control system: The slope control system (option) allows the regulation of the traction point either on the LH or RH sides, by maintaining a difference defined against the opposite side. To determine the actual value, the two traction 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 traction point of the arm (traction roller), the paving height of the material or the laying height of the screed can be controlled. Actuation occurs electro-hydraulically on both sides and can be controlled manually by means o f toggle switch es or automa tically (by me ans of an electr onic grade cont rol system).

The screed lifting system: The screed can be lifted to transport height using the screed lifting system. Lifting occurs electro-hydraulically on both sides by actuating the hydraulic cylinders on the arm s and is cont rolled by mea ns of toggl e switches on the operating panel.

Automatic screed stop and screed charging/relieving device: The automatic screed stop preven ts the screed marks caused by a stopped screed. W hen the pave r finisher is stopped (during a truck change), the screed remai ns in floating posi tion and the relievi ng pressure is turned on, therefore , the sink ing of the s creed can be avoided while stopped.

The screed relieving device puts a higher load on the chassis, thus increasing the traction. Activating the screed charging device can improve the compacting result under certain conditions.

Exhaust of asphalt vapours (o): The asphalt vapours are extracted by a hydrauli- cally driven exhaust head mounted in the material tunnel or over the auger. The vapours collected are discharged together with the exhaust fumes of the internal combustion engine.

Central lubrication unit (o): The central lubrication pump fitted with a large lubricant tank supplies grease to the various lubrication circuits through various flow dividers. They supply lubricant to the service-sensitive points of lubrication (e.g. bearings) by adjustable intervals.

B_DF1 15PD_DF125PD_01_GB.fm 5-2 4

B 5

3 Danger zones

In these areas of the machine there is a danger of pulling in or crushing due to the rotating, transporting or moving parts!

B 6

B_DF1 15PD_DF125PD_01_GB.fm 6-2 4

4 Safety devices

Safe operation is only po ssibl e when all oper ating and co ntrol e l emen ts are function ing correctly and when all safety devices are in position.

Check the function of these devices at regular intervals. (see chapter D, section 2.1).

4.1 Emergency stop button

- on the operating panel

- on t he two remote contr ol units (option)

Pressing the emerge ncy stop button switches off th e engine, the drives and the steer ing system. Corrective measures that might be necessary (anti-collision maneuvers, lifting the screed, etc.) are not possible in this case! Danger!

4.2 Service brake („foot brake“)

F0005_A1.EPS

4.3 Steering

4.4 Horn

- on the operating panel

- on t he two remote contr ol units (option)

4.5 Ignition key / lights

Footbrake.jpg

F0127_A1.tif

Horn.Tif

F0064_A1.EPS

B_DF1 15PD_DF125PD_01_GB.fm 7-2 4

B 7

4.6 Main switch (17)

4.7 Hopper transport sa feguards (18)

(o)

Mainswitch.tif/Mainswitch_SK.eps

(o)

4.8 Screed transport safeguards (19)

4.9 Latch for protective roof (20)

Hopperlock2.tif/Hopperlock_SK.eps

F0083_A1.TIF

B 8

F121Cb.Tif

B_DF1 15PD_DF125PD_01_GB.fm 8-2 4

634_side_DEM.bmp/Feuerlöscher.bmp

Item Designation

25 Fire fighting device 26 Engine hood

26 27

30 31 29 28

27 Lateral flaps 28 Walkway 29 Screed coverings 30 Hazard warning lights of the screed 31 A uger covers

Accessories:

- Wedges

- Warning triangle

- First-aid kit

B_DF1 15PD_DF125PD_01_GB.fm 9-2 4

B 9

5 Technical data, stan dar d config ur atio n

5.1 Dimensions (all dimensions in mm)

1962

2606

3600

3100

1600

925

2020

6500*

634_side_DEM.bmp,634_front_DEM.bmp

For the technical data of the screed, see the operating instructions of the screed.

B 10

2070 2550

3388

*EB51

B_DF1 15PD_DF125PD_01_GB.fm 10-24

5.2 Allowed angle of rise and slope

max 15°

634_side_DEM.bmp,634_front_DEM.bmp

5.3 Allowed angle of driving up

Before oper ating your ma chi ne in an incl ine d po siti on ( gra dient, slope, l ater al incli na tion) which is above the specified limit value , please, consul t with the customer service for your machine!

max 15°

634_side_DEM.bmp,634_front_DEM.bmp

5.4 Turni ng circ l e

Turning circle 12.80 m

B_DF1 15PD_DF125PD_01_GB.fm 11-24

max 14°

max 14,4°

B 11

5.5 Weights DF115P/D (all weights in t) Type DF115P/D

Paver finisher without screed about 14,6 Paver finisher with screed:

- EB 51 about 16,5 Including mounted accessories for max. paving

width plus max. With filled hopper additionally max. about 12,5 max. front axle load for transportation about 3,5 max. rear axle load for transportation about 13,00

5.6 Weights DF125P/D (all weights in t)

For the weigh ts of the scree d and t he scre ed att achme nts, see the op erati n g instru ctions for the screed.

Type DF125P/D Paver finisher without screed about 14,8 Paver finisher with screed:

- EB 51 about 16,7 Including mounted accessories for max. paving

width plus max. With filled hopper additionally max. about 12,5 max. front axle load for transportation about 3,5

about 0,9

max. rear axle load for transportation about 13,00

For the weigh ts of the scree d and t he scre ed att achme nts, see the op erati n g instru ctions for the screed.

B 12

B_DF1 15PD_DF125PD_01_GB.fm 12-24

5.7 Performance data DF115P/D

Screed used

Basic width

(without cut-off shoes)

minimum paving width

(with cut-off shoe)

adjustable up to

continuously hydraulically

(with attachments)

Maximum paving widths EB 51 2,55 2,00 5,10 7,30* m EB 51+ 2,55 2,00 5,10 * m

*The maximum working width depends on the paving conditions!

Travelling speed 0 - 19,5 km/h Transport speed - reversing 0 - 6 km/h Working speed 0 - 29,0 m/min Layer thickness 0 - 300 mm Max. grain size 40 mm Theoretical paving performance 600 t/h

B_DF1 15PD_DF125PD_01_GB.fm 13-24

B 13

5.8 Performance data DF125P/D

Screed used

Basic width

(without cut-off shoes)

minimum paving width

(with cut-off shoe)

adjustable up to

continuously hydraulically

(with attachments)

Maximum paving widths EB 51 2,55 2,00 5,10 8,10* m EB 51+ 2,55 2,00 5,10 * m

*The maximum working width depends on the paving conditions!

Travelling speed 0 - 19,5 km/h Transport speed - reversing 0 - 6 km/h Working speed 0 - 29,0 m/min Layer thickness 0 - 300 mm Max. grain size 40 mm Theoretical paving performance 600 t/h

B 14

B_DF1 15PD_DF125PD_01_GB.fm 14-24

5.9 Traction drive/chassis

Drive Transmission Planetary gear

Speeds (see above) Drive wheels Steering wheels 4 x 560 / 390 - 300 (elastic solid rubber tyres)

Front wheel drive

Brakes Running gear brake, hydraulic brake

5.10 Engine DF115P/D

Make/type Deutz TCD 2013 L04 2V Model 4-cylinder (water cooled) Diesel engine Performance 116 KW / 158 HP (at 2100 rpm)

Volume of fuel tank (see chapter F)

Continuously variable hydrostatic drive, with pump and engine

2 x 14.00 R-25 (air filled tyres) (water filled tyres o)

2 / 4 wheel hub hydro-motor, freely selected, variable drive performance, Anti-spin control (o)

5.11 Engine DF125P/D

Make/type Deutz TCD 2013 L06 2V Model 6-cylinder (water cooled) Diesel engine Performance 140 KW / 190 HP (at 1800 rpm)

Volume of fuel tank (see chapter F)

5.12 Hydraulic system

Pressure build-up

Pressure distribution

Hydraulic oil reservoir - volume (see chapter F)

Hydro-pumps driven by transmission gear (directly connected to the engine)

Hydraulic circuits for:

- Machine drive

- Material conveying and distribution

- Screed drives for tamper / vibration (option)

- Cylinder actuators for steering, hopper, levelling, screed lifting, extending/retracting screed parts, auger lift (option)

B_DF1 15PD_DF125PD_01_GB.fm 15-24

B 15

5.13 Material compartment (hopper)

Volume Minimum inlet height, center 520 mm

Minimum inlet height, outside 600 mm

5.14 Material conveying

Conveyors Left and right side separately controllable Drive Hydrostatic, continuously controllable Conveying volume controller Fully automatic via configurable switching points

5.15 Material di stribution

Augers Left and right side separately controllable

Drive

about 6.0 m3 = about 13.0 t

Hydrostatic external drive, continuously controllable independent from the conveyor Auger halves can be switched to opposite directions

Conveying volume controller Fully automatic via configurable switching points

- mechanically via chain

Auger height adjustment

- mechanically (option) hydraulically (option)

Auger extension With extension parts (see auger extension chart)

B 16

B_DF1 15PD_DF125PD_01_GB.fm 16-24

5.16 Screed lifting device

Special functions

Levelling system

5.17 Electrical system

On-board voltage 24 V Batteries 2 x 12 V, 100 Ah

At standstill:

- Screed stop

- Screed stop with pretensioning

(max. pressure 40 bar) During paving:

- Screed charging

- Screed relieving

(max. pressure 40 bar) Mechanical grade control,

optional systems with and without slope control

17 kVA / 400 V

Alternator (o)

20 kVA / 400 V 28 kVA / 400 V

Fuses see chapter F, section 5

For the filling volumes of lubricating and operating agents, see chapter F.

B_DF1 15PD_DF125PD_01_GB.fm 17-24

B 17

6 Location of instruction labels and identification plates

7 6

11 15

(o)10

B_DF1 15PD_DF125PD_01_GB.fm 18-24

B 18

No. Denomination

1 Label ”Filler neck for diesel fuel” * 2 L abel ”Filler neck for engine oil” * 3 Label „Heed the operating instructions!“ 4 Warning label ”Danger of squeezing!” ** 5 Punched vehicle identification number 6 Label ”Securing or fixing points for crane transportation”** 7 Paver finisher identification label 8 „CE + noise level“ plate (O) 9 „Fan danger!“ warning plate

10 „Spraying with water prohibited“ plate

11 Label „Heed the operating instructions!“*** 12 Label ”High voltage!” 13 Label ”Operating instructions for the engine” 14 „Crossbeam lock“ plate 15 „All switches to STOP“ plate *** 16 Label „Wear Ear Mufflers“ 17 Label „First Aid Box“ (O) 18 Label „20km/h“ (O) 19 Label „Risk of hand injury“ 20 Warning panel: “Seat position while vehicle in transit” 21 Punched vehicle identification number

* Labels are located beneath the engine hood / maintenance flap ** Labels are located on both sides of the paver finisher *** Label is located on the operating panel, above the steering wheel

B_DF1 15PD_DF125PD_01_GB.fm 19-24

B 19

6.1 Identification label for the paver finisher (6)

1 3

Fertiger3.tif

No. Denomination

1 Type of paver finisher 2 Year of manufacture 3 Serial number of the paver finisher series 4 Max. permissible operating weight, incl. all attachments, in kg 5 Max. permissible load on the front axle, in kg 6 Max. permissible load on the rear axle, in kg

7 Rated performance in kW 8 Product identification number (PIN)

The punched vehi cle identification nu mber on the paver finisher must match th e product identification number (8).

B 20

B_DF1 15PD_DF125PD_01_GB.fm 20-24

7 EN standards

7.1 Continuous sound level DF115P/D, Deutz TCD2013L04

The operator always mu st use ear protection. The imission value at the ear of the dr iver varies depen ding on the mater ials used fo r paving and may e ven rise ab ove 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 EN 500-6 draft, dated March, 1997, and ISO 4872.

Sound pressure level at the operator’s position (at the height of the head): LAF = 84,2 dB(A)

Sound capacity level: LWA = 108,0 dB(A) Sound pressure level at the machine

Measuring point 2 4 6 8 10 12 Sound pressure level L

AFeq

(dB(A))

73,9 73,5 72,9 75,6 72,5 73,6

7.2 Operating conditions during measurement

The diesel engine was running at maximum speed. The screed was in working position, lowered to a rubber mat . The tamp er and the vibrator were running at min. 50% of their maximum speed, the augers at min. 40% and the conveyors at min. 10% of their maximum speed.

7.3 Measuring point configuration

Semispheric al measuring surfa ce with a radi us of 16 m. T he machine was at t he center. The measuring points had been assigned the following coordinates:

Measuring points 2, 4, 6, 8 Measuring points 10, 12

Coordinates 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_DF1 15PD_DF125PD_01_GB.fm 21-24

SCHALL.TIF

B 21

7.4 Continuous sound level DF125P/D, Deutz TCD2013L06

Sound pressure level at the operator’s position (at the height of the head): L

Sound capacity level: L Sound pressure level at the machine

Measuring point 2 4 6 8 10 12 Sound pressure level L

AFeq

(dB(A))

75,6 73,9 73,4 75,4 73,2 74,7

7.5 Operating conditions during measurement

= 84,1 dB(A)

= 109,0 dB(A)

7.6 Measuring point configuration

Semispheric al measuring surfa ce with a radi us of 16 m. T he machine was at t he center. The measuring points had been assigned the following coordinates:

Measuring points 2, 4, 6, 8 Measuring points 10, 12

Coordinates 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 22

SCHALL.TIF

B_DF1 15PD_DF125PD_01_GB.fm 22-24

7.7 Vibration acting on the entire body

When the machine i s used prope rly, the weighted effe ctive acceler ation values at the driver’s seat of aw = 0.5 m/s2 according to prEN 1032-1995 draft are not exceeded.

7.8 Vibrations acting on hands and arms

When the machine i s used prope rly, the weighted effe ctive acceler ation values at the driver’s seat of ahw = 2.5 m/s2 according to prEN 1033-1995 draft are not exceeded.

7.9 Electromagnetic compatibility (EMC)

The following limit values are observed according to the stipulations of the EMC directive 89/336/EEC/08.95:

- Interference emission according to DIN EN 50081-1/03.93: < 40 dB µV/m for frequen cies of 30 M Hz - 230 MHz measur ed at a distance o f 3 m < 47 db µV/m for frequencies of 20 MHz - 1 GHz measured at a distance of 3 m

- Interference immunity against electrostatic discharge according to DIN EN 610004-2/03.96 (ESD): The paver finisher did not show any discernible reactions to contact discharges of ± 4 KV and to air discharges of ± 8 KV. The modifications accor ding to test crite rion „A“ are being me t, i.e. the paver finisher continues to work without malfunction during the test.

Electrical or electron ic comp onents an d their arrangem ent may only be modified after written approval by the manufacturer has been obtained.

B_DF1 15PD_DF125PD_01_GB.fm 23-24

B 23

C 1.0 Transportation

1 Safety regulations for transportation

Accidents can happen when the paver finisher and the screed are not properly prepared for transportation or when transportation is carried out improperly!

Reduce both the paver finisher and the screed to their basic widths. Remove all protruding parts (such as the levelling device, 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 safe guards. C onvert the pr otective roof and engage the latch.

Check that the clampin g device for the auger frame is fastened and that the telescopic tube cannot slide out (see chapter E, section 2.5).

Pack all parts tha t are n ot per mane ntly fixed to the paver finisher and th e screed into the appropriate boxes and into the hopper. Close all coverings and check that they are securely seated.

In Germany, gas bottles must not be transported on the paver finisher or on the screed. Disconnect the gas bottles from the gas system and protect th em with t heir caps. Use a separate vehicle to transport them.

When loading via ramps, the paver finisher may slip aside, tilt or topple over. Drive carefully! Keep the danger area free of persons!

Additional stipulations for transportation on public roads:

Wheel type pa ver fin ishers may travel on public roads along shor t sections o nly in the Federal Republic of Germany. On machines with a gas screed, the two lower floorboards of the screed need to be removed and placed in the front hopper. On machines with an el ectric scre ed, the t wo lower floorboar ds of the screed a nd ladder need to be removed and placed in the front hopper.

Note that in other countries different regulations may apply. The operator must be in the possession of a valid permit for vehicles of this type.

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 accessories may be transported in the hopper, no material or gas bottles!

C_1.0_01_GB.fm 1-12

If necessary, t he operato r must be assi sted by a se cond person when driving o n public roads – especially at road crossings and junctions.

C 1.0 1

2 Transportation on low-bed trailers

2.1 Preparations

Reduce the paver finisher and the screed to their basic widths; also remove any attached side plates. The maximum drive-on angle is included in Chapter „Technical Specifications“!

- Prepare the paver finisher for transportation (see chapter D).

- Remove all protruding or loose parts from the paver finisher and the screed (see also the operating instructions of the screed). Store these parts in a safe place.

When screed is operated with the optional gas heating system:

- Remove the gas bottles of the screed heating system:

- Close the main shut-off valves and the bottle valves.

- Unscrew the valves on the bottles and remove the

gas bottles from the screed.

- Transport the gas bottles on a second vehicle; heed all pertaining safety regula-

tions.

C 1.0 2

C_1.0_01_GB.fm 2-12

Operation Switch Buttons

- Disabling the interlocking of operation

- Close the hopper halves.

- Engage both hopper transport safeguards.

- Lift the screed.

- Insert the transportation safeguards of the hopper!

- Turn the pre selecting r egulator to zero.

- Move the drive lever forward.

- The levelling cylinders are completely extended.

Only in case of not connected

remote control

- Set the drive lever to mid-position.

C_1.0_01_GB.fm 3-12

- Retract the screed to the basic width of the paver.

C 1.0 3

2.2 Drive onto the low-bed trailer

Make sure that there are no persons in the danger area during loading.

1 2

( )

634_side3_Dyn.bmp

- Use the work gear and low engine speed to drive onto the low-bed trailer.

- Lower the screed onto wooden blocks on the low-bed trailer.

- Switch off the paver finisher.

- Attach and secure the protective hood to protect the operating panel.

- If necessary, swing down the protective roof:

- Take out the bolts and pull the roo f to

the front by gripping it with the bowtype handle. When it is in the lower position, secure it with the bolts.

Roof.tif

C 1.0 4

C_1.0_01_GB.fm 4-12

2.3 Secure the paver finisher in its position to the low-bed trailer:

- Use only proper and permitted load fastening devices.

- Use the four securing points provided (1, 2).

Depending on the equipment of the machine there can be further support points (3) on the auger frame (3).

- Wait until the exhau st exten sion pi p e has cooled d own; th en r emove it and stor e i t.

2.4 After transportation

- Remove the attachment devices.

- Swing up the protective roo f: take out the bolts, push the protect ive roof forw a rd to raise it and insert the bolts to lock it again.

- Mount the protective tarpaulin if it has been removed.

- Lift the screed to the transportation position and lock it.

- Start the engine and drive from the trailer at a low engine/traction speed.

- Park the paver finish er in a secure spo t, lower th e screed and switch of f the eng ine.

- Remove the key and/or cover the operating panel with the pr otecti ve h ood and secure it.

C_1.0_01_GB.fm 5-12

C 1.0 5

3Transportation

3.1 Preparations

Reduce the paver finisher and the screed to their basic widths; also remove any attached side plates.

- Prepare the paver finisher for transportation (see chapter D).

- Remove all protruding or loose parts from the paver finisher and the screed (see also the operating instructions of the screed). Store these parts in a safe place.

When screed is operated with the optional gas heating system:

- Remove the gas bottles of the screed heating system:

- Close the main shut-off valves and the bottle valves.

- Turn off the valves on the bottles and remove the gas

bottles from the screed.

- Transport the gas bottles on a second vehicle; heed all pertaining safety regula-

tions.

C 1.0 6

C_1.0_01_GB.fm 6-12

Operation Switch Buttons

- Disabling the interlocking of operation

- Close the hopper halves.

- Engage both hopper transport safeguards.

- Lift the screed.

- Insert the transportation safeguards of the screed.

- Turn the preselecting regulator to zero.

- Move the drive lever forward.

- The levelling cylinder are in fully extended position.

Only when

remote control is not connected

- Set the drive lever to mid-position.

C_1.0_01_GB.fm 7-12

- Retract the screed to the basic width of the paver finisher.

C 1.0 7

3.2 Traction drive:

Warning Marking Marking

- Set the Fast/Slow switch to „Hare“.

- Turn the preselecting regulator to maximum.

- Use the drive lever to regulate the speed.

Risk of accident!

- In tight curves avoid sudden steering movements. Moving the steered wheels to locking position requires about 2.5 - 3 full steering wheel turns.

- Press the emergency stop button when a dangerous situation arises!

When pressing the emergency button the paver, the engine stops and steering becomes very difficult. This may lead to accidents!

C 1.0 8

C_1.0_01_GB.fm 8-12

4 Loading by crane

Use only lifting gear that can bear the load. (See Chapter B for weights and dimensions).

1 2

634_side3_Dyn.bmp/634_front2.bmp

Four lifting eyes (1.2) are provided for loading the vehicle with a crane.

- Park the paver finisher and render it safe.

- Engage the transport safeguards.

- Remove any attachments and accessories from the paver finisher and the screed until the basic width has been attained.

- Take off all protrud i ng or loose p arts and the gas b ottles of the scr eed h eating system (see Chapters E and D).

- Swing down the protective roof.

- Attach the lifting gear to the four lifting eyes (1,2).

Make sure that the paver finisher remains in a horizontal position during transport!

C_1.0_01_GB.fm 9-12

C 1.0 9

5Towing

f m

Heed 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.

The engine compartme nt holds a hand-pump on the LH side, which must be actuated to permit the towing of the machine. Pressure for releasing the traction system brakes is built up with the hand pump.

Only release the traction system brakes when the machine is sufficien tly secured against accidental rolling or is already properly connected to the towing vehicle.

- The two high pressure cartridges (1) of the pumps of the traction drive m ust be driven out by about 3 turns.

- Release lock nut (2), screw threaded dowel (3) into pump as far as possible and secure with lock nut.

- Actuate lever (4) of hand pump until sufficient pressure has been built up and traction system b rakes have be en released.

- Attach the tow bar to the coupling (5) located in the bumper.

Now carefully and slowly tow the paver finisher out of the construction area.

Always only tow the shortest distance to the means of transport or the next parking possibility.

Pump634.jpg

C 1.0 10

Pump

C_1.0_01_GB.fm 10-12

Following towing, unscrew the threaded dowel (3) a few tur ns again a nd lock with the lock nut (2). The high pressu re car tridge s (1) ha ve to be fully screwed ba ck in to make the machine usable again. The brakes of the traction drive are now active again a nd the machine is secur ed against accidental rolling away.

634_Dyn_Iso_1.bmp

C_1.0_01_GB.fm 11-12

C 1.0 11

6 Safely parking the vehicle

When the equipme nt is par ked at a location accessible to the public, it must be secured in su ch a way t hat unauthoriz ed persons or pla ying chi ldre n cann ot dam age the vehicle.

- Pull off the ignition key and the main switch (1) and take it with you – do not hide them somewhere on the machine.

F0077/0078_A1.EPS

Do not turn off main switch (1) until 15 seconds after the ignition has been turned off!

The engine electronics need this length of time to back up data.

- Protect the operating panel with the dust cover (2) and lock it.

- Store loose parts and accesso ries in a safe place.

Bedienpult_SPS_Rad_634_2.wmf/Vandalism.bmp

Secure the dust cover (2) during operation with the lock on the term inal b ox un der the maintenance flap on the RH side!

C 1.0 12

Dieseltank.eps/Vandalism.bmp

C_1.0_01_GB.fm 12-12

D 1.3 Operation

1 Safety regulatio ns

Starting the engin e, the traction drive, the conveyor, the auger, the scree d or the lifting devices can cause injuries or even the death of persons. Make sure before starting any of these devices that no-one is working at, in or beneath the paver finisher or within its danger area!

- Do not start the engine or do not actuate any controls when this is expressly forb idden! 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 damages are detected, eliminate them 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 drivers’s position that is opposi te to the flowing traffic! Lock the operating panel and the driver’s seat.

- Keep a sufficient safety clearance to overhanging objects, other machines and points of danger!

- Be careful when travelling on roug h terrain to keep the paver finisher from slipp ing, tipping or turning over.

Always be the master over the machine; never try to use it beyond its capacities!

D_1.3_01_GB.fm 1-24

D 1.3 1

2 Operati ng elem ent s

2.1 Operati ng pan el

B A

Bedienpult_konv_Rad_634_2.bmp/Element3_konv_Rad_634.bmp/Element1_konv_Kette_635.bmp/Element2_konv_Rad_634.bmp

D 1.3 2

D_1.3_01_GB.fm 2-24

Item Designation Brief description

Steering is transmitted to the front wheels hydraulically.

1 Steering

Retaining bracket

for operating panel

Latch for operat-

ing panel

For securing the movabl e op eratin g panel against inadvertent movement at the desired paver finisher height.

- Turn the knurled screw at the desired location into the des-

In the case of seats which can be swung out beyond the machine contour ( option), the o perating pa nel can a lso be moved beyond the basic width of the paver finisher. Pull out the latch and move the operating panel; let the latch engage again.

When travelling in tight curves, take care of the special steering ratio (about 3 turns for changing between steering locks) Risk of accident!

ignated notch and secure with the knurled nut.

When not secured, the operating panel can move. Danger of accidents during transportation!

An unlatched operating panel can slide out of position. Danger of accidents during transportation!

4 Lights

Lights up instrument panel A / B when the parking light is switched on.

D_1.3_01_GB.fm 3-24

D 1.3 3

8 14

Element2_konv_Rad_634.bmp

D 1.3 4

9129a

D_1.3_01_GB.fm 4-24

Item Designation Brief description

Starting is only possible when the drive lever is in the neutral

5Starter

position. All emergency stop buttons (on the operating panel and the remote controls) must be pulled up.

Hare: Travelling speed Tortoise: Working speed for laying

Machine drive

fast/slow

7Horn

Preselector of trac-

tion drive

9 Drive lever (feed)

Use it as a sound alarm in case of imminent danger and before starting!

This sets the speed, which the machine must ach ieve with the full swing of the drive lever.

For switching on the paver finisher functions and for continuously regulating the traction speed – forward or reverse. Zero position: Starting is possible; engine at idling speed; no traction drive; secured against inadvertent starting. For turning out, pull up the ring (9a). Depending on the position of the drive lever, the following functions can be activated:

- Position 1: the engine runs at the preset speed

- Position 2: feeder and auger On.

- Posi tion 3: screed moveme nt ( tamp er/vibr ator ) ON; traction Use the preselector to set the maximum speed.

When the working speed is selected, the differential lock is automatically engaged!

When the travelling speed is engaged, the front wheel drive is automatically switched off!

The scale approximately corresponds to the speed in m/min (when laying).

(See engine speed setting).

drive ON; increase speed until impact.

10 Warning signal Switch on for safety on roads.

Travelling direc-

D_1.3_01_GB.fm 5-24

tion indicator („Direction indicator“)

Use it when changing direction along public road.

When the machine is stopped, the parking brake is automatically engaged.

When the drive leve r is move d, the parki ng brake is automatically released.

If the machine was stopped by the service brake, it cannot be started again, before the drive lever is set to neutral position.

D 1.3 5

8 14

Element2_konv_Rad_634.bmp

D 1.3 6

9129a

D_1.3_01_GB.fm 6-24

Item Designation Brief description

Key inserted: Ignition on Key pulled out: Ignition, engine off. Key positions: 0 Lights switched off

Ignition switch and

lighting switch

1 Parking lights / rear lights, instrument panel light, working floodlight as applicable 2 Driving lights 3 Headlights

Query of fault / fail-

ure

Emergency stop

button

If one of the control lights indicates the fault in the traction engine, then a code can be queried from the machine, which means a specific fault. Keep pressing the button, until a three digit error code is displayed.

In case of danger (persons are exposed to risk, danger of collision etc.), press it!

- Pressing the emergency stop button switches off the en-

- The emergency stop button does not shut off the gas heat-

- To restart the engine, the button must be pulled out again.

Override the interlocking between 1 and 2 by depressing them.

See Chapter „Operati n g Fail ur es“ fo r que rying th e err or code.

gine, the drives and the steering system. Steering away, lifting the screeds and other maneouvers are not possible in such cases! Risk of accident!

ing system. Manually close the main shutoff valve and both cylinder valves!

15 has no function

D_1.3_01_GB.fm 7-24

D 1.3 7

23 24

20 21 22

Element1_konv_Kette_635.bmp

D 1.3 8

D_1.3_01_GB.fm 8-24

Item Designation Brief description

The transport direction of the conveyor, applicable separately to both sides of the conveyo r, can be switched to the opposite direction so that over a short distance it retracts the material directly before the auger. In this way the loss of material can

(o)

Reverse selection Feeder

be avoided during transport. The conveyor travels about 1 m in the direction of the hopper.

Conveyor modes of operation on the right/left sides

Tamper (depends on the screed)

A - auto: drive lever turned on and continuously regulat- B - stop: turned off

C - manual: continuously turned on (full delivery capacity,

- If the conveyor is to be remote controlled (o), then both

A - auto: drive lever turned on, in normal position turned B - stop: completely turned off

C - manual: continuously turned on

Use „auto“ mode for laying in the basic case.

If necessary, press the butt on as m any tim es as n ecessary, so that the feeder operates in the opposite direction over a longer section.

ed in the tunnel using the material limit switch

(without material mix regulation)

switches shall be set to „auto“ position.

off

If the switch is in „manual“ position when laying, then it must be set to „stop“ in normal position. In the opposite case excessive tampering may take place.

Vibration (depends on the screed)

Operation and application similarly to the (tamper) switch.

Speed regulation (see „Operation manual of screed“)

Speed regulation (see „Operation manual of the screed“).

D_1.3_01_GB.fm 9-24

D 1.3 9

23 24

20 21 22

Element1_konv_Kette_635.bmp

D 1.3 10

D_1.3_01_GB.fm 10-24

Item Designation Brief description

Screed position

Screed control in case of stopped paver finisher

A B

A Lift the screed. B Lock the screed (the position appropriate for inserting the

transportation safeguard of the screed)

C: Lower the screed and set it to „Floating position“

With this function the hydraulic unit of the screed can be controlled to pre vent the low ering of the screed, when the pave r is stopped (temporary stoppi ng). A automatic- if th e drivea rm (9 ) i s in centra l position, i n case

- Position C can be used for setting the paver, position A C: switched off- if the drivearm (9) is in central position, in

During paving, the screed must always be in the floating position. The same applies to temporary stops and the case of changing trucks.

of stopping the pa ver, the screed is controlled b y abou t 20 bar preliminary pressure.

can be used for paving.

case of stopping the paver, the screed is only maintained in floating position / controlled.

In case of transportation or maintenance operations always insert the mechanical transportation safeguard of the screed.

creed loading / unloading

Starter switch „Temporary pres-

sure load when laying is started“

A 



The screed can be thus loaded or offloaded to change the traction force or compacting.

A: Relieving (screed ‘lighter’) B: Function Off C: Charging (screed ‘heavier’)

- With the help of pr essure reg ulating valve (93) th e heigh t of loading and offloading must be adjusted.

- For the function „Stop screed with prestressing“ select position A (see switch (21b) and pressure regulator valve (93a)).

To start the screed with preselected pressure load.

- The time limit can be set between 0.5 and 30 sec.

After the expiry of the preset delay time of the pressure load, the machine automatically switches to floating position.

This function prevents the floating of the screed, e.g. in case of temporary stopping or changing trucks.

D_1.3_01_GB.fm 11-24

D 1.3 11

23 24

20 21 22

Element1_konv_Kette_635.bmp

D 1.3 12

D_1.3_01_GB.fm 12-24

Item Designation Brief description

It sets the delay time of the prestressed start of the screed.

Preselecting regulator „Pressure

load delay time to start paving“

Auger modes of operation on the right/left sides

- High working speed - short delay time

- Low working speed - longer delay time

A auto: wi th th e driv e le ver tur ned o n and u sin g the m a-

Bstop: turned of f C manual: turned on, transport direction inward/outward.

If you wish to switch the auger with automatically with the mechanical limit switch and the (o) ultrasonic sensor, both switches must be in „auto“ position.

The delay time must be set depending on the working speed.

terial limit switch at the auger for continuous regulation

(The direction set by switch (26))

In position (C), when the switch (26) is turned on, the half-augers work continuously (full transport capacity, without automatic material regulation).

Adjustment of au-

ger beams on the LH/RH sides (o)

Conveying direc-

tion of the auger

Screed extension

retraction (o)

Opening/closing o f

the feeding hopper

In case of hydraulically adjustable auger beams, this is the way to change the height of the auger.

- The height can be read on the scale on the LH/RH sides of the auger beam support. Basic rule: Laying thickness + 5 cm (2 inches) = auger beam height.

For setting / switching over the transport direction of the two auger halves in „manual“ mode.

With this the extendable parts of the Vario screeds can be hydraulically extended or retracted.

top: Opening of hopper middle: has no function bottom: Opening of hopper

Separate actuation (o): Necessary when laying in a tight place on one side or when filling from the truck is hindered.

Operate both switches at the same time, or else the auger beams will go slant.

In the EU countries this is permitted with the remote control switch only.

D_1.3_01_GB.fm 13-24

D 1.3 13

5453

49505152

40 4138 3937

45 4642 43 44

lmnt3konvad634bmpuchtmodultt635bmp

D 1.3 14

D_1.3_01_GB.fm 14-24

Item Designation Brief description

Levelling cylinder

on the right/left sides

Engine speed

adjustment (o)

32 has no function 33 has no function

With this the levelling cylinders can be controlled manually, if the levelling automatic system is switched off. For this, the switch on the remote control shall be in „manual“ position.

Continuously va riable a djustme nt of speed (in case of moving the drive lever). Min. position: idling speed Max. position: rated speed

In the upper position the supplementary front-wheel drive is engaged.

During laying in a normal case the rated speed is selected, while in case of travel the RPM shall be reduced.

The automatic RPM control keeps the set RPM constant even under a load.

Front wheel drive

On/Off (o)

35 has no function

Front wheel drive can be engaged only with the switch in working speed position.

See the valve and the pressure gauge for the adjustment of the drive pressure.

D_1.3_01_GB.fm 15-24

D 1.3 15

5453

49505152

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Element3_konv_Rad_634.bmp/Leuchtmodul_KONV_Kette_635.bmp

D 1.3 16

45 4642 43 44

D_1.3_01_GB.fm 16-24

Item Designation Brief description

Normal display up to 85 °C = 185 °F.

Hydraulic oil ther-

mometer

Alarm light (red)

„Water in the fuel“

This light is on, if the water separator of the fuel system has established a too high water level.

In case of higher temperature stop the machine, (set drive lever to neutral position), and let the engine cool at idling speed. Find the cause and eliminate the fault.

In order to avoid the damage of the traction engine drain the separated water imm edi ately accor ding to the operation manual.

Fault message

(yellow)

High beam head-

light control lamp (blue)

Front wheel drive

(o)

Stopping the en-

gine

It indicates that a fault has occurred in the tra ction eng ine. D epending on the type of the fault the operation of the machine can be continued temporarily, or in case of a major fault it must be stopped immediately to prevent further faults. All the faults shall be eliminated as soon as possible!

A A

It is on, when the high beam headlight is switched on (at the ignition switch).

It is on, when the front wheel drive is engaged.

It is on if the engine cannot be started (e.g. the emergency stop button was depressed).

The fault is indicated together with the „Error message“ light.

The error code can be queried using button (13).

After the ignition is turned on, the light is on for a few seconds for check-up.

Avoid blinding the oncoming traffic!

In such a case see Chapter „Operating failures“.

It is lit on, when the engine temperature is too high.

Indicator light of

engine temperature (red)

D_1.3_01_GB.fm 17-24

The output of the engine drops automatically. (Further travel remains possible). Stop the paver, (set drive lever to neutral position), and let the engine cool at idling speed. Find the cause and if necessary eliminate it (see Chapter „Operating Faults“). Upon cooling down to normal temperature, the engine will work a gain at fu ll capacity.

The fault is indicated together with the „Error message“ light.

D 1.3 17

5453

49505152

40 4138 3937

Element3_konv_Rad_634.bmp/Leuchtmodul_KONV_Kette_635.bmp

D 1.3 18

45 4642 43 44

D_1.3_01_GB.fm 18-24

Item Designation Brief description

It must go out soo n after start-up. Co nsider the time of warm-

Oil pressure indica-

tor for the hydraulic traction drive (red)

ing up. The hydraulic oil may be too cold and rigid.

If the light does not go dark, do not turn on the traction drive.

Oil pressure indica-

tor for the Diesel engine (red)

Control light

differential lock

Battery indicator ligh t

(red).

„Parking brake“ light

(red)

It is on, when the differential lock is engaged.

It must go out after start-up at a higher speed.

- Stop the engine. It is on when parking brake is active.

The lamp goes out at a pressure of 2.8 bar = 40 psi. It is on, when the oil pressure is too low.

Stop the engine immediately! For additional fa ults, see operating instr uctions for th e engine.

The fault is indicated together with the „Error message “ light.

In working speed the differential lock is automatically engaged.

When the machine is stopped, the parking brake is automatically engaged.

When the drive lever is moved, the parking brake is automatically released.

48 has no function

49 Service hour meter

50 Fuel gauge

51 has no function

52 RPM meter (o)

53 Fuse box I. 54 Fuse box II.

The service hours are counted by the machine with running engine. Daily maintenance of the paver finisher (see chapter F)

Continuously observe the fuel gauge.

The speed is displayed in revolutions per minute (rev/min).

A A A

The gas oil tank may never go empty! Otherwise, the entire fuel system must be bled (vented).

The RPM can be modified with the speed regulator. For assignment of fuse strips, refer to chapter F. For assignment of fuse strips, refer to chapter F.

D_1.3_01_GB.fm 19-24

D 1.3 19

5453

49505152

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Element3_konv_Rad_634.bmp/Leuchtmodul_KONV_Kette_635.bmp

D 1.3 20

45 4642 43 44

D_1.3_01_GB.fm 20-24

3 Remote control

61 57

D_1.3_01_GB.fm 21-24

Remote_konv_neu1.bmp

With the help of the two re mote co ntro ls - on t he RH and LH sides of the screed - the functions available on the specific side of the paver can be controlled.

D 1.3 21

Front side

Item Designation Brief description

Its function and use are similar to those of the emergency

Emergency stop

button (o)

56 Horn Its function is similar to the button (7) on the control panel.

57 Levelling cylinder

58 Feeder

59 Auger

stop button on the operating panel (14). It is important in such dan gero us situati on s, which cannot b e observed by the driver.

Its function and use are similar to the function of the switch (30) on the control panel. Switch (61) must be set „manual“ position.

Its function and use are similar to the function of the switch (17) on the control panel. The switch must be set to „auto“.

Its function and use are similar to the function of the switch (25) on the control panel.

- The switch must be set to „auto“.

Screed extension/

retraction

Levelling automatic

system

Levelling „cross-

connection“ (o)

With this the extendable parts of the Vario screeds can be hydraulically extended or retracted.

manual:Height adjustment is possible with switch (57) (or

switch (30) on the operating platform)

auto: automatic height adjustment with grade signal

transmitter

To control the levelling cylinder on the other side of the machine.

A A

The „other side“ at any time must be set to „manual“.

It overrides the „manual“ switch position.

D 1.3 22

D_1.3_01_GB.fm 22-24

Reverse side

6766 68

Remote_konv_neu1.bmp

Item Designatio n Brief description

Connection to the

levelling automatic

Connect the cable for the grade control unit here.

system Connection to the

end position switch of

Connect the cable for the material limit switch here.

the auger

Cable for the remote control

Connect to the socket on the screed (See the operation manual of the screed).

D_1.3_01_GB.fm 23-24

D 1.3 23

D 1.3 24

D_1.3_01_GB.fm 24-24

D 3.0 Operation

1 Operating elements on the paver finisher

Batteries (71)

The batteries of the 24 V system are located under the left maintenance flap.

For the sp ecifications, refer to chapter B, ”Technical Data”. For servicing, see chapter F.

Heed the instructions when starting the paver finisher externally. (see section “Starting the paver finisher, External starting (starting aid)“.

Battery main switch (72)

The main switch interrupting the circuit between the battery a nd the m ain fuse is located under the left maintenance flap.

For the assignment of all fuses, see chapter F.

- For switching off, turn the key (72) to the left and pull it out.

Tankhood_LH.eps

D_3.0_01_GB.fm 1-16

Do not lose the key as in this case the paver finisher can no longer be moved!

Tankhood_LH.eps

F0077_A1.EPS/F0078_A1.EPS

D 3.0 1

Transport safeguards for the hopper (73)

Before parking or transporting the paver finisher, the hopper halves must be swung upwards and the transport safeguards for the ho pper must be inser ted.

Item:

- (a) - outside on the two half-hoppers

- (b) - in the feeding hopper (o)

Do not enter the hopp er while the engine is running! Danger of being caught by the conveyor! Without transport safeguards inserted, the hopper halves will slowly open; danger during transportation!

(o)

Hopperlock2.tif/Hopperlock_SK.eps

D 3.0 2

D_3.0_01_GB.fm 2-16

Mechanical screed transport safeguard (to the left and the right beneath the driver’s seat) (74)

Used to protect the lifted screed from inadvertent lower ing. The screed tr ansport safeguard must be inser ted before transportation and when work is finished.

Transportation with an unsecured screed bears the danger of accidents!

- Lift the screed.

- Actuate the levers.

- Check that the latches (to the left and to the right) engage in the crossbeams.

ATTENTION!

Insert screed lo ck only at crown adjustment „ zero“! Screed lo ck only for transporta tion Use the interlocking of the main girder for transportation only! Do not enter or work under screed only secured with screed lock for transportation!

Danger of accident!

Seat lock (behind the driver’s seat) (75)

Telescoping seats (o) can be extended beyond the basic width of the paver finisher. They must be locked.

F0083_A1.TIF

The seats must not protrude from the vehicle during transportation. Push the seats back to the basic width of the paver finisher!

- Pull out t he lo cking b utton and m ove t he se at; l et th e lo cking b utton eng age agai n.

The driver’s se at can move w h en the locking bu tton i s no t enga ged p rope rly. D ange r of accidents during transportation!

F0169_A1.EPS

D_3.0_01_GB.fm 3-16

D 3.0 3

Service brake („foot brake“) (76)

There is a brake pedal before each driver's seat on the LH and RH sides. The service brake acts within the machine drive.

Upon operating the brake, the machine drive is regulated to stop automatically (regardle ss of the position of the drive lever).

If the machine was stopped with the service brake, it cannot be started if the drive lever was not set to neu tral b efore hand!

Footbrake.eps

D 3.0 4

D_3.0_01_GB.fm 4-16

Separator fluid spraying system (80) (o)

Used to spray the parts com ing into contact with asphalt with a separator emulsion.

- The indicator lamp (A) lights up when the emulsion pump is running

- On/off switch (B) for the emulsion pump

- Quick-release coupling (C) for hose connection

(o)

Only switch on the spraying system when the diesel en gine is running; otherwise, the battery will be discharged. Switch off after use.

A permanent installed hose guide ( D) fo r the fluid spraying system is available as an option.

Pull hose out of the guide till there is an audible creak. The hose will engage in this position after discharging.The hose will be retracted automatically into the guide after pulling and discharging again.

Don’t spray into open flame or on hot surface! Danger of explosion!

Emu2.tif

(o)

D_3.0_01_GB.fm 5-16

The spraying system is feeded by a can (E) under the side flap on R.H. side.

Refill the can only while standstill of the paver finisher!

Emul1.Tif

(o)

Emu3.tiff

D 3.0 5

Further switch options for optional equipment features may be located on the central panel:

(o)

on / off swit ch for ad ditional h eadlight in the roof (85):

Actuate switch (a) to activate.

On / off switch for fuel tank filler pump (85a)

If the pump is actuated with the switch (a), the indicator lamp (b) lights up.

When fuelling, ensure that no fuel penetrates the earth. Switch off the engine and do not smoke. Do not fuel in enclosed spaces. Danger to hea lth! Have a fire extinguisher ready.

On / off switch special lighting (85b)

85a

85b

If the mach ine i s e quippe d w ith additi on al headlights, these are actuated by means of the switch (a). When switched to the „ON“ position, the indicator lamp (b) lights up.

Switch the additional headlights and special lighting off when the engine is not running, as the battery is otherwise discharged!

On / Off swi tch Exha ust of asph alt vapours (85c)

In case of the availability of optional asphalt vapour exhaust system, this can be turned on by switch (a). In the switch position „ON“ the control light (b) is on.

b a

85c

b a

85d

b a

D 3.0 6

85e

b a

D_3.0_01_GB.fm 6-16

On/Off switch of work headlights (85d):

Actuate switch (a) to switch on. In the switch position „ON“ the control light (b) is on.

On/Off switch of flasher (85e):

Actuate switch (a) to switch on. In the switch position „ON“ the control light (b) is on.

If optionally ava ilable 23 0 V syste ms are installed, an additional switch cabinet is mounted on the paver finisher:

230 V On / Off switch Connection sockets (85f)

In case of being equ ipped w ith 230 V accessories, the connection sockets can be powered through switches. In the switch position „I“ the control light (b) is on.

Locking of the collapsible roof (LH and RH on the roofs console) (86):

To lower the roof (for example during transport on a low bed trailer):

- Loose the twistlock (A)

- Pull the roof fram e forward holdi ng the clevis or the frame

- Arrest the twistl ock in the se cond locking hole.

(o)

85f

b a

Schalt_230V.wmf

D_3.0_01_GB.fm 7-16

Dachkons.bmp

D 3.0 7

Hydraulic folding roof (87) (o)

The hydraulically folding roof is secured by means of a latch (A) at the rear suspension on the left and right sides of the machine. This must be released prior to lowering and raising. Once it has reached its terminal position, the roof must be secured with the latch again. The hydraulic unit and the key-operated switch (A) for actuating the folding roof hydraulic system are located on the left side of the paver finisher's rear panel.

The roof can be raised and lowe red with-

out having to start the drive motor.

- In order to lower the roof, turn the keyoperated switch (B) to the right until the roof has been lowered to its minimum level.

Danger of crushing! Ensure that nobody inserts their fingers or hands into the joint areas or are placed at risk by the lowering roof during the folding procedure.

- In order to raise the roof again, turn the key-operated switch (B) to the left

Dachkons.bmp/Dach_Hydr.wmf

until the roof has been raised to its maximum height.

If it is necessary to raise the roof whilst the battery is discharged, a manual pump is available on the hydraulic unit.

D 3.0 8

- Actuate the pump l ever (C) until the roof can be secured w ith the latch bo lt (A) i n its uppermost position.

Two throttles are installed to adjust the raising and lowering speed:

- Throttle valve (D): Adjust roof raising speed. Turning the adjusting knob in the clockwise direction = lower speed. Turning anti-clockwise = higher speed.

- Throttle valve (E): Adjust roof lowering speed. Turning the adjusting knob in the clockwise direction = lower speed. Turning anti-clockwise = higher speed.

D_3.0_01_GB.fm 8-16

Electric setting of the transportation volume of the conveyor (o) (88)

With this the transport volume of the conveyor can be adjusted when mechanical limit switch o r ultra sonic senso r is used.

- The „0“ position of the scale corresponds to the smallest adjustable volume.

- RH-side conveyor: (88a)

- LH-side conveyor: (88b)

(o)

88a

85d

88b

F0091_A1.EPS

Conveyor limit switches (89)

The mechanical conveyor limit switches (89) or the ultrasonic conveyor limit switches (89ao) control the material flow at the respective conveyor half. The conveyors should stop when the material has roughly reached the area below the auger tube.

This requires that the auger height has been adjusted correct ly (see chapter E).

89a

D_3.0_01_GB.fm 9-16

F0114_A1.EPS/Ultra3.EPS

D 3.0 9

Ultrasonic auger limit switches (90) (left and right)

The limit switches control the material flow at the respective auger half.

The ultrasonic sensor is mounted by means of an appropriate leverage to the side plate. Loose clamping lever for adjustment and modify an gle / height of t he sensor. The cables mu st be con nected to the re mote control units located at the sides of the screed (socket (62)).

We recommend to ad just the limit switch positions while the material is distributed.

Sockets for working lights (left and right) (92)

Connect the working lights (24 V) here.

- Power is present when the main switch (72) is switched on.

Ultra_Auger.bmp

As an option, one socket can be used to provide power for an electrically heated seat.

F0124_A1.TIF

D 3.0 10

D_3.0_01_GB.fm 10-16

Pressure control valve for screed charging/relieving (93)

Used to adjust the pressure for addition al charging/relieving of the screed.

- See ”screed charging/relieving device”. (Chapters „Operating Panel“, „Operation“).

- Pressure display: see pre ssure gau ge (93b).

Pressure control valve for screed stop with pretensioning (93a)

This valve is located beneath the righthand bottom flap of the operator´s platform.

It is used to adjust the pressure for ”screed stop with pretensioning”.

93b

93a

- Activation: see “screed charging/relieving device”.

- Pressure display: see “pressure gauge” (93b).

93b

Pressure gauge for screed charging/ relievi ng and s creed stop with p retensioning (93b)

Displays the pressure for

- Screed stop w ith preten sioning scre ed

F0184_A1.TIF/Screed_Valve.eps/F0105_A1.TIF

stop with pr etensioning when the dr ive lever is set to the neutral position (pressure to be adjusted using valve (93a));

Screed charging /relieving devi ce when the drive l ever is in the thi rd position (p ressure to be adjusted using valve (93)).

D_3.0_01_GB.fm 11-16

D 3.0 11

Front wheel drive pressure regulating valve (94) (o)

The drive pressure of the supplem entary front wheel drive can be adjusted here.

F0105_A1.TIF

- Engage the front wheel drive with the switch (30).

- Pressure display: see pressure gauge (94a).

Adjust the pressure on the moving paver so that the driven front wheels do not spin.

Pressure gauge of the front wheel drive (94a) (o)

It shows the drive pressure of the sup-

94a

plementary front wheel drive. Pressure adjustment with valve (94)

Experimen tal val ue : abo ut 110 - 1 40 bar Maximum value: about 200 bar)

In case of the engagement of the anti-

F0104_A1.EPS

spin regulator (ASR - o) the optimum value is automatically adjusted to the variable adhesion relations. This requires the adjustment of about 200 bar maximum pressure.

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D_3.0_01_GB.fm 12-16

Central lubrication unit (o) (100)

The central lubrication unit turns on in automatic mode when the drive engine starts.

- Pumping time: 12 min

- Duration of the break: 2 h

It is prohibited to change the factory-set durations of pumping and break without consulting the technical customer service!

Changing the duration of lubrication and breaks may be necessary when placing mineral or cement bound material mix.

Manual start of lubr ication (pumpi ng time):

- Remove the cover lid (a).

- Keep the starting button (b) depressed for at least 2 sec.

- Replace the cover lid (a).

Observe the instructions of chapter „Maintenance“!

Lincoln3.jpg/Lincoln9.jpg

D_3.0_01_GB.fm 13-16

D 3.0 13

Particle filter - control light (102) (o)

The control light of the particle filter is found under the control track of the operating panel.

When observing the control light (a) it is essential:

Partikellight.tif

Indicator colour

yellow No counterpressure

Operating condition Cause / action

No counterpressure Check the tightness of the system.

green Within the measuring range There is no fault flashing

green

Treshold range Counterpressure in the warning range

Increase of engine speed to raise the temperature of the exhaust fume.

Increase of engine speed to raise

red

Set value achieved / exceeded

the temperature of the exhaust fume. If necessary, clean / replace the particle filter.

flashing red

The temperature or pressure sensor failed

Check and replace, as required, the temperature / pressure sensor

With the brie f increase of the e ngine speed to th e max. range , the filter is cleaned automatically due to the higher temperature of the exhaust fume. If the control light still fails to turn on for this action, the filter needs to be cleaned.

See chapter „Maintenance“ for cleaning the particle filter.

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D_3.0_01_GB.fm 14-16

Front and side window (o) (103)

The front window can be folded up for the maintena nce works perf ormed at t he tank.

- Fold the front wind ow by its hand le (A) and lock it on the RH and LH sides with the two locks (B) in the upper position.

(o)

Additional functions:

- If necessary, turn on the windscreen wipers on the RH and LH sides (C).

- Fold up the side window (D) at its clevis (window frame) and the push the driver's seat out.

Wetterhaus.eps

D_3.0_01_GB.fm 15-16

D 3.0 15

Adjustment of screed eccentric (o) (104)

(o)

To pave thicker layers of material, if the piston rods in the levelling cylinder are operating clo s e to their li mit po sition and

III

if the desired paving thickness cannot be reached, it is possible to alter the ap-

proach angle of the screen by adjusting the eccentric.

- Pos I: Paving thickness of up

to approx. 7cm

- Pos II: Paving thickness of approx.

7 cm to approx. 14cm

- Pos III: Paving thickness above

Wetterhaus.eps

approx. 14 cm

- The spindle (A) is not adjusted.

- Unfasten lock nuts (B) for eccentric adjustment.

- Swivel screed into desired position using lever (C) then engage the locking knob once again.

If the levelling unit is connected to a height con troller , this has th e functio n of balan cing out any rapid rise in the screed position: T he level ling cylinder s are extende d until the correct height is reached.

The change in app roach angle can only take place sl owly and uniformly on bo th sides at once during paving operation, and involves the use of the eccentric adjustment. Failing this, any rapi d re sponse in the screed could easil y cause wave s to appea r on the road surface. The setting process should therefore take place before work starts!

D 3.0 16

D_3.0_01_GB.fm 16-16

D 4.5 Operation

1 Preparation of operation

Required devices and aids

To avoid delays on site, check before starting work whether or not the following devices and aids are present:

- Wheel loader for transporting heavy extendable parts

- Diesel fuel

- Engine oil and hydraulic oil, lubricants

- Separating agents (emulsion) and manual injector

- Two filled propane gas bottles

- Shovel and broom

- Scraper (spatula) for cleaning the auger and the hopper infeed area

- Parts that may become necessary for extending the auger

- Parts that may become necessary for extending the screed

- Percentage spirit level and levelling rail, +4-m- long

- Levelling wire

- Protective clothing, signal vest, gloves, ear protection

Before starting work

(in the morning or when starting paving)

- Heed the safety instructions.

- Check the personal protective equipment.

- Take an in spection wal k arou nd t he p aver fini sher a nd ch eck fo r leaks a nd d amag es.

- Install parts removed for transportation or for the night.

- When screed is operated with the optional gas heating system, open the closing valves and the main shut-off valve.

- Perform the check according to the ”Checklist for the machine operator” given below".

D_4.5_01_GB.fm 1-34

D 4.5 1

Checklist for the machine operator

Check! How?

Emergency stop button

- on the operating panel

- on both remote control units o

Steering

Horn

- on the operating panel

- on both remote control units o

Lights

Hazard warning lights of the screed (with vario screeds)

Gas heater system (o):

- Bottle holders

- Bottle valves

- Pressure reducer

- Hose break safety devices

- Shut-off valves

- Main shut-off valve

- Connections

- Indicator lamps of the switch box

Push in the button. The diesel en gine and a ll run ning dri ves must stop immediately.

The paver finishe r must immed iately fol low every ste ering wheel mo vement in a precise man ner. Check st raight r unning.

Briefly press the horn button. The horn must sound.

Switch on with the ignition key, walk around the paver finisher to check and switch off again.

With the ignition switched on, press the switches for extending/retracting the screed parts. The rear lights must flash.

Check:

- Secure seat

- Cleanliness and tightness

- Working pressure 1.5 bar

- Function

- Tightness

- All lamps must light up when the system is switched on

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D_4.5_01_GB.fm 2-34

Check! How?

Auger covers

Screed covers and walkways

Screed transport safeguard

Hopper transport safeguard

For larger working widths, the walkway plates must be extended and the auger tunnels must be covered.

For larger working widths, the walkway plates must be extended. Hinged walkway plates must be swung down. Check that the side shields, the side plates and the covers ar e secur ely seated.

When the screed is lifted, it must be possible to push the locking rods sideways into the recesses in the crossbeams using the lever beneath the seat.

When the hopper is closed, it must be possible to fold the catches over the lock studs on the two halves of the hop-

per. Protective roof Miscellaneous:

- Engine hood

- Lateral flaps Accessories:

- Wedges

- Warning triangle

- First-aid kit

Both locking bolts must be in the

provided bore hole.

Check that the hoods and flaps are

securely seated.

The accessories must be in the

provided holders.

D_4.5_01_GB.fm 3-34

D 4.5 3

1.1 Starting the paver finisher

Before starting the paver finisher

Before starting the di esel engine and beginning operation, the following steps must be performed:

- Daily maintenance of the paver finisher (see chapter F)

Check the operating hour counter to determine whether or not additional maintenance work (such as m onthly or yearly maintenance) must be performed.

- Check the safety devices and protective devices.

„Normal” starting

Set the drive l ever ( 1) to the center position and the speed adjuster (2) to minimum.

- Insert the ignition key (3) 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 mo-

tor stop control light (4) is On (the emergency stop button (5) or the one on the

remote contro l (o) is depressed, the auger and the conveyor switches are turned).

Element2_konv_Rad_634.bmp/Element3a_konv_Rad_634.bmp

- Press the sta rter bu tton (7) to start the engin e. Do no t let the sta rter run permanen tly for more than 20 seconds; allow for a break of 1 minute after every attempt

D 4.5 4

D_4.5_01_GB.fm 4-34

Dynapac Svedala Demag DF 115 P/D, Svedala Demag DF 125 P/D Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual