OPERATION

&
MAINTENANCE
Paver finisher

F 121 W/D
F 141 W/D
Type 634

Keep this manual for future reference

Order number for this manual: D900981402
04-0107

634........................
VALUE QUALITY
THE ORIGINAL

Your Authorized Dynapac Dealer:

 Table of contents
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
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5.5 Weights F121W/D (all weights in t) .......................................................... 12

5.6 Weights F141W/D (all weights in t) .......................................................... 12
5.7 Capacity data F121W/D ........................................................................... 13
5.8 Capacity data F141W/D ........................................................................... 14
5.9 Traction driv/De/chassis ........................................................................... 15
5.10 Motor F121W/D ........................................................................................ 15
5.11 Engine F141W/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
8

1
 7 EN standards ........................................................................................... 21
7.1 Continuous sound level F121W/D, Deutz TCD 2012L06 ......................... 21
7.2 Operating conditions during measurement .............................................. 21
7.3 Measuring point configuration .................................................................. 21
7.4 Continuous sound level F141W/D, Deutz TCD 2013L0 ........................... 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 Transportation ......................................................................... 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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2
 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 drivers seat) (74) ......................... 3
Seat lock (behind the drivers 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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3
 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
634_F121WD_F141WD_OMM_CON_04_GBIVZ.fm 4-8

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

4
 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 310 mm auger .............................................. 10
2.11 Auger mounting chart for 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 Maintenance review ................................................................ 1

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

F3.0 Maintenance - Conveyor ........................................................ 1

1 Maintenance - Conveyor ............................................................................ 1
1.1 Maintenance intervals ................................................................................ 2
1.2 Points of maintenance ............................................................................... 3
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Chain tightness of the conveyor (1) ....................................................... 3

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

F4.2 Maintenance - Auger ............................................................... 1

1 Maintenance - Auger sub-unit I .................................................................. 1
1.1 Maintenance intervals ................................................................................ 2
1.2 Points of maintenance ............................................................................... 3
Auger - outer bearing (1) ...................................................................... 3
Auger middle bearing (2) ....................................................................... 3
Auger - drive gear neck bearing (3) ....................................................... 4
Auger bevel gear (on the RH and LH sides) (4) .................................... 5
8

5
 F5.1 Maintenance - Engine ............................................................. 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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6
 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 Maintenance - Points of lubrication ...................................... 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
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5.1 Downtime up to 6 months .......................................................................... 5

5.2 Downtime between 6 months and 1 year. .................................................. 5
5.3 Re-commissioning: .................................................................................... 5

F11.0 Lubricants and Fuels .............................................................. 1

1 Lubricants and fuels ................................................................................... 1
1.1 Hydraulic oil ............................................................................................... 2
1.2 Instructions referring to the oil types applied ............................................. 3
1.3 Filling volumes ........................................................................................... 4
2 Instructions to change from mineral oil to synthetic oil /
from synthetic oil to mineral oil ................................................................... 8
2.1 Caterpillar drive - planetary gear ................................................................ 8
8

7
 V Preface
Safe operation of the machine requires specific knowledge that is imparted by the
present operating instructions. The information is provided in a concise, clearly struc-
tured form. The individual chapters are arranged in alphabetical order and every
chapter starts with page 1. The individual pages are identified by the chapter letter
and the page number.
Example: Page B 2 is the second page of chapter B.

These operating instructions cover various machine options. Make sure that during
operation and maintenance work the description appropriate to the machine option is
used.

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

f Precedes safety instructions that must be observed in order to prevent danger to per-
sonnel.

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

A Precedes general notes and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

In the interest of continued development, the manufacturer reserves the right to make
changes to the machine (which will not, however, change the essential features of the
type of machine described) without updating the present operating instructions at the
same time.

Dynapac GmbH
Wardenburg

Ammerlnder 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

V1
1 General safety instructions

1.1 Acts, directives, accident prevention regulations

A The locally applicable acts, directives and accident prevention regulations shall be
observed, even if the attention is not specifically directed to these.
The operator himself shall be responsible for the observation and performance of the
related regulations and actions!

A The following alerts, prohibitions and instructions refer to the risks to which people,
machinery and environment are exposed.

A Ignoring these instructions, bans and commands may lead to fatal injuries!

A Furthermore, the Dynapac publication "Directives for the correct and specified appli-
cation of pavers" shall also be observed.

1.2 Warning instructions

Warning pointing to hazardous place or danger!

Not observing the warning instructions may lead to injuries of life
and limb!

Warning: risk of pulling in!

m 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!

m All maintenance and repair work on the screed's electrical system

must always be carried out by an electrician!

Attention: suspended load!

m Never stand under suspended load!

Warning: risk of squeezing!

m 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_01_GB.fm

V2
 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

V3
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 Die-
sel 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!

A Contact the Dynapac service!

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

Do not turn on!

V_01_GB.fm

V4
 1.4 Protective gear

A 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

V5
1.5 Environmental protection

A The locally applicable acts, directives and waste disposal regulations shall be ob-
served, even if the attention is not specifically directed to these.
During cleaning, maintenance and repair operation the materials polluting water e.g.:

- lubricants (oils, grease)

- hydraulic oil
- gas oil
- coolant
- detergents

may not enter the soil or the sewer system!

These materials shall be collected, stored, transported in the correct

containers until professional disposal!

Material harmful for the environment!

1.6 Fire prevention

A The applicable local regulations may specify the mounting of appropriate fire extin-
guishers!
Observe these specifications!

Fire fighting device

(optional equipment)

V_01_GB.fm

V6
 1.7 Further instructions

m Observe the manufacturer's and other instructions!

A e.g. the maintenance instructions of the engine manufacturer

m Description / figure in case of an electrically heated design!

m Description / figure in case of an electrically heated design!

V_01_GB.fm

V7
 A Correct use and application
A The Guidelines for the Correct Use and Application of Paver finishers compiled by
Dynapac are included in the scope of delivery for the present machine. The guide-
lines are part of the present operating instructions and must always be heeded. Na-
tional regulations are fully applicable.

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 lean-
mixed concrete, track-laying ballast and unbound mineral aggregates for foundations
for paving.
This machine shall be used, operated and maintained for the purpose of the intended
work as included in the operation manual. Any other use is regarded as improper use
and can cause injury to persons or damage to the paver finisher or other equipment
or property.

Any use going beyond the range of applications described above is regarded as im-
proper use and is expressly forbidden! Especially in those cases where the paver fin-
isher is to be operated on inclines or where it is to be used for special purposes
(construction of dumps, dams), it is absolutely necessary to contact the manufacturer.

Duties of the user: A user within the meaning of the present operating instructions
is defined as any natural or legal person who either uses the paver 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 be-
tween the owner and the user of the paver finisher, is charged with the observation
of the operating duties.
The user must ensure that the paver finisher is only used in the stipulated manner and
that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance guide-
lines are observed. The user must also ensure that all persons operating the equip-
ment 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 attachments that will interfere with or supplement the functions of the paver fin-
isher is permitted only after written approval by the manufacturer has been obtained.
If necessary, the approval of local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
A_01_GB.fm 1-2

A1
 B Vehicle description
1 Application

The DYNAPAC F 121 W/D / F 141 W/D road construction machine is a rubber tyre
type paver, which can be applied for laying mixed materials, roll-down concrete or
lean-mixed concrete, track-laying ballast and unbound mineral aggregates for foun-
dations for paving.

634_DYN_ISO_1.bmp
B_F121WD_F141WD_02_GB.fm 1-24

B1
2 Description of assemblies and functions
15

13
16
14

19

18

8 4 10 11 12

2
6 7 5 9
634_DYN_ISO_1.bmp
3 17

Item Designation
1 t Material compartment (hopper)
2 t Truck push rollers
3 t Tube for sensor rod (direction indicator) and holder for levelling shoe
4 t Rear wheels
5 t Levelling cylinder for paving thickness
6 t Traction roller
7 t Traction arm rail
8 t Paving thickness indicator
9 t Arm
10 t Machine drive
11 t Auger
12 t Screed
B_F121WD_F141WD_02_GB.fm 2-24

13 t Operators platform
14 t Operating panel (can be moved to either side)
15 o Protective roof
16 o Working lights
17 o Front tandem axle
18 o Hydraulic front hopper lid
19 o Exhaust of asphalt vapours

t = Standard equipment o = Optional equipment

B2
 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 of the soil and as a result of the suspension of the screed they guarantee
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 com-
ponents 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 finisher is driven by a water cooled Diesel engine. For further de-
tails see the technical data and the engine's instruction manual.
The particle filter (o) cleans the exhaust gas from the soot particles produced, reduc-
es the generation of harmful carbon-monoxyde and carbon-dioxyde gases, therefore,
it operates as a catalyser to minimize the load on the environment 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 on non-uniform lifting axles, the second front wheel is subject
B_F121WD_F141WD_02_GB.fm 3-24

to a heavier load on the shorter lifting arm.

As a result of this solution the steering possibility and the load capacity are improved,
especially on soft ground. Tyres mounted with flexible solid tyres on the front 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.

B3
 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.

Traction drive: 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-stage planetary gear produces the various movement ranges and the brake
function.

Steering system/operators platform: The fully hydraulic Danfoss-Orbitrol steering

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 allows to compensate for different distances to the rear wheels of ma-
terial trucks. The paver finisher thus deviates less from its course and paving in
curves is made easier.

Material compartment (hopper): The hopper inlet is equipped with a conveyor sys-
tem 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 hydraulic front hopper lids (o) ensure that no material remains at the front of the
feeding hoppers.

Material transfer: The paver finisher is equipped with two conveyors driven sepa-
rately 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 actuated independently from the conveyors. The
left-hand and the right hand half of the auger can be controlled separately. 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 material even if an excessive
amount of material is required at one side. The auger speed is continuously controlled
by sensors that monitor the material flow.
B_F121WD_F141WD_02_GB.fm 4-24

B4
 Height adjustment and extension of augers: Height adjustment and extension of
augers ensure optimum adaptation to a wide range of paving 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 ratchets for height adjustment (option), barrel nuts at the guide supports
in the rear wall are used to adjust the height.
Another variant allows the height to be regulated at the control panel by means of hy-
draulic 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) al-
lows 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 ad-
justment 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 of toggle switches or automatically (by means of an electronic grade control
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 arms and is controlled by means of toggle switches on
the operating panel.

Automatic screed stop and screed charging/relieving device: The automatic

screed stop prevents the screed marks caused by a stopped screed. When the paver
finisher is stopped (during a truck change), the screed remains in floating position and
the relieving pressure is turned on, therefore, the sinking of the screed 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 cer-
tain conditions.
B_F121WD_F141WD_02_GB.fm 5-24

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 va-
pours 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.

B5
3 Danger zones

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

B_F121WD_F141WD_02_GB.fm 6-24

B6
 4 Safety devices

Safe operation is only possible when all operating and control elements are function-
ing correctly and when all safety devices are in position.

A 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 the two remote control units F0005_A1.EPS

(option)

m Pressing the emergency stop button switches off the 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)

Footbrake.jpg

4.3 Steering

F0127_A1.tif

4.4 Horn

- on the operating panel

- on the two remote control units
Horn.Tif
(option)

4.5 Ignition key / lights

B_F121WD_F141WD_02_GB.fm 7-24

F0064_A1.EPS

B7
4.6 Main switch (17)

17

(o)
Mainswitch.tif/Mainswitch_SK.eps

4.7 Hopper transport safeguards (18)

(o)
18

Hopperlock2.tif/Hopperlock_SK.eps

4.8 Screed transport safeguards (19)

19

F0083_A1.TIF

4.9 Latch for protective roof (20)

B_F121WD_F141WD_02_GB.fm 8-24

20

F121Cb.Tif

B8
 26 27

25

30

31
29

28

634_side_Dyn.bmp/Feuerlscher.bmp

Item Designation
25 Fire fighting device
26 Engine hood
27 Lateral flaps
28 Walkway
29 Screed coverings
30 Hazard warning lights of the screed
31 Auger covers

Accessories:

- Wedges
- Warning triangle
- First-aid kit
B_F121WD_F141WD_02_GB.fm 9-24

B9
5 Technical data, standard configuration

5.1 Dimensions (all dimensions in mm)

1962

3600
3100
2606

1600
925 2020
6500*

2054
B_F121WD_F141WD_02_GB.fm 10-24

2550

3386

*VB510 T/TV
634_side_DYN.bmp,634_front_DEM.bmp

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

B 10
 5.2 Allowed angle of rise and slope

max 15 max 15 max 15

634_side_Dyn.bmp,634_front_DEM.bmp

A Before operating your machine in an inclined position (gradient, slope, lateral inclina-
tion) which is above the specified limit value, please, consult with the customer serv-
ice for your machine!

5.3 Allowed angle of driving up

max 14

max 14,4
634_side_Dyn.bmp,634_front_DEM.bmp
B_F121WD_F141WD_02_GB.fm 11-24

5.4 Turning circle

Turning circle 12.80 m

B 11
5.5 Weights F121W/D (all weights in t)

Type F 121W/D
Paver finisher without screed about 14,6
Paver finisher with screed:
- VB 510T/TV about 16,5
Including mounted accessories for max. paving
about 0,9
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

A For the weights of the screed and the screed attachments, see the operating instruc-
tions for the screed.

5.6 Weights F141W/D (all weights in t)

Type F 141W/D
Paver finisher without screed about 14,8
Paver finisher with screed:
- VB 510T/TV about 16,7
Including mounted accessories for max. paving
about 0,9
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

A For the weights of the screed and the screed attachments, see the operating instruc-
tions for the screed.

B_F121WD_F141WD_02_GB.fm 12-24

B 12
 5.7 Capacity data F121W/D

continuously hydraulically

Maximum paving widths

minimum paving width
(without cut-off shoes)

(with attachments)
(with cut-off shoe)

adjustable up to
Screed used

VB 510 T/TV 2,55 Basic width 2,00 5,10 7,30* m

VB 510 T/TV+ 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_F121WD_F141WD_02_GB.fm 13-24

B 13
5.8 Capacity data F141W/D

continuously hydraulically

Maximum paving widths

minimum paving width
(without cut-off shoes)

(with attachments)
(with cut-off shoe)

adjustable up to
Screed used

VB 510 T/TV 2,55 Basic width 2,00 5,10 8,10* m

VB 510 T/TV+ 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 750 t/h

B_F121WD_F141WD_02_GB.fm 14-24

B 14
 5.9 Traction driv/De/chassis

Continuously variable hydrostatic drive, with

Drive
pump and engine
Transmission Planetary gear
Speeds (see above)
2 x 14.00 R-25 (air filled tyres) (water filled tyres
Drive wheels
o)
Steering wheels 4 x 560 / 390 - 300 (elastic solid rubber tyres)
2 / 4 wheel hub hydro-motor, freely selected, vari-
Front wheel drive able drive performance,
Anti-spin control (o)
Brakes Running gear brake, hydraulic brake

5.10 Motor F121W/D

Make/type Deutz TCD 2012 L06 2V

Model 6-cylinder diesel engine (water-cooled)
Performance 120 KW / 163 HP (at 1800 rpm)
Volume of fuel tank (see chapter F)

5.11 Engine F141W/D

Make/type Deutz TCD 2013 L06 2V

Model 6-cylinder (water cooled) Diesel engine
Performance 140 KW / 188 HPc (at 1800 rpm)
Volume of fuel tank (see chapter F)

5.12 Hydraulic system

Hydro-pumps driven by transmission gear

Pressure build-up
(directly connected to the engine)
Hydraulic circuits for:
- Machine drive
- Material conveying and distribution
Pressure distribution - Screed drives for tamper / vibration (option)
- Cylinder actuators for steering, hopper, level-
ling, screed lifting, extending/retracting screed
B_F121WD_F141WD_02_GB.fm 15-24

parts, auger lift (option)

Hydraulic oil reservoir - volume (see chapter F)

B 15
5.13 Material compartment (hopper)

Volume about 6.0 m3 = about 13.0 t

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 distribution

Augers Left and right side separately controllable

Hydrostatic external drive, continuously controlla-
ble independent from the conveyor
Drive
Auger halves can be switched to opposite direc-
tions
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_F121WD_F141WD_02_GB.fm 16-24

B 16
 5.16 Screed lifting device

At standstill:
- Screed stop
- Screed stop with pretensioning
(max. pressure 40 bar)
Special functions
During paving:
- Screed charging
- Screed relieving
(max. pressure 40 bar)
Mechanical grade control,
Levelling system optional systems with and without
slope control

5.17 Electrical system

On-board voltage 24 V
Batteries 2 x 12 V, 100 Ah
17 kVA / 400 V
Alternator (o) 20 kVA / 400 V
28 kVA / 400 V
Fuses see chapter F, section 5

A For the filling volumes of lubricating and operating agents, see chapter F.
B_F121WD_F141WD_02_GB.fm 17-24

B 17
6 Location of instruction labels and identification plates

9
12
1 2 3 19

8
14

17
13
20

11

7 6 15

16

4
18

5
10

21 5
B_F121WD_F141WD_02_GB.fm 18-24

10 (o)

B 18
 No. Denomination
1 Label Filler neck for diesel fuel *
2 Label 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_F121WD_F141WD_02_GB.fm 19-24

B 19
6.1 Identification label for the paver finisher (6)

1 2
3
4
5
6
7
8

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)

A The punched vehicle identification number on the paver finisher must match the prod-
uct identification number (8).

B_F121WD_F141WD_02_GB.fm 20-24

B 20
 7 EN standards

7.1 Continuous sound level F121W/D, Deutz TCD 2012L06

m The operator always must use ear protection. The imission value at the ear of the driv-
er varies depending on the materials used for paving and may even rise above 85 dB
(A). If no ear protection devices are used, hearing can be impaired.
The noise emission level of the paver finisher was measured under free-field condi-
tions according to EN 500-6 draft, dated March, 1997, and ISO 4872.

Sound pressure level at the operators position

(at the height of the head): LAF = 84,3 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 LAFeq (dB(A)) 74,8 73,1 72,2 74,4 72,5 73,8

7.2 Operating conditions during measurement

The diesel engine was running at maximum speed. The screed was in working posi-
tion, lowered to a rubber mat. The tamper 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

Semispherical measuring surface with a radius of 16 m. The machine was at the cent-
er. 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
- 4,32 +10,4 11,36
11,2 11,2 1,5
+4,32 -10,4 11,36
B_F121WD_F141WD_02_GB.fm 21-24

SCHALL.TIF

B 21
7.4 Continuous sound level F141W/D, Deutz TCD 2013L0

m The operator always must use ear protection. The imission value at the ear of the driv-
er varies depending on the materials used for paving and may even rise above 85 dB
(A). If no ear protection devices are used, hearing can be impaired.
The noise emission level of the paver finisher was measured under free-field condi-
tions according to EN 500-6 draft, dated March, 1997, and ISO 4872.

Sound pressure level at the operators position

(at the height of the head): LAF = 84,1 dB(A)

Sound capacity level: LWA = 109,0 dB(A)

Sound pressure level at the machine

Measuring point 2 4 6 8 10 12
Sound pressure level LAFeq (dB(A)) 75,6 73,9 73,4 75,4 73,2 74,7

7.5 Operating conditions during measurement

The diesel engine was running at maximum speed. The screed was in working posi-
tion, lowered to a rubber mat. The tamper 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.

7.6 Measuring point configuration

Semispherical measuring surface with a radius of 16 m. The machine was at the cent-
er. 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
- 4,32 +10,4 11,36
11,2 11,2 1,5
+4,32 -10,4 11,36
B_F121WD_F141WD_02_GB.fm 22-24

SCHALL.TIF

B 22
 7.7 Vibration acting on the entire body

When the machine is used properly, the weighted effective acceleration values at the
drivers 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 is used properly, the weighted effective acceleration values at the
drivers 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 di-
rective 89/336/EEC/08.95:

- Interference emission according to DIN EN 50081-1/03.93:

< 40 dB V/m for frequencies of 30 MHz - 230 MHz measured at a distance of 3 m
< 47 db V/m for frequencies of 20 MHz - 1 GHz measured at a distance of 3 m

- Interference immunity against electrostatic discharge according to DIN EN 61000-

4-2/03.96 (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 according to test criterion A are being met, i.e. the paver finish-
er continues to work without malfunction during the test.

A Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
B_F121WD_F141WD_02_GB.fm 23-24

B 23
 C 1.0 Transportation
1 Safety regulations for transportation

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

Reduce both the paver finisher and the screed to their basic widths. Remove all pro-
truding parts (such as the levelling device, auger limit switches, aprons, etc.). When
transporting under a special permit, secure these parts!

Close the hopper lids and engage the hopper transport safeguards. Lift the screed
and engage the screed transport safeguards. Convert the protective roof and engage
the latch.

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

Pack all parts that are not permanently fixed to the paver finisher and the screed into
the appropriate boxes and into the hopper.
Close all coverings and check that they are securely seated.

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 them with their 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:

m Wheel type paver finishers may travel on public roads along short sections only 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 electric screed, the two lower floorboards of the screed and lad-
der need to be removed and placed in the front hopper.

m 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.
C_1.0_01_GB.fm 1-12

Only attachments and accessories may be transported in the hopper, no material or

gas bottles!

If necessary, the operator must be assisted by a second person when driving on pub-
lic roads especially at road crossings and junctions.

C 1.0 1
2 Transportation on low-bed trailers

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

2.1 Preparations

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

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

f 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_01_GB.fm 2-12

C 1.0 2
 .

Operation Switch Buttons

- Disabling the interlocking of oper-

ation

- Close the hopper halves.

- Engage both hopper transport

safeguards.

- Lift the screed.

- Insert the transportation safe-

guards of the hopper!

- Turn the preselecting regulator to

zero.
Only in case of not connected

- Move the drive lever forward.

remote control

- The levelling cylinders

are completely extended.

- Set the drive lever to mid-posi-

tion.
A

- Retract the screed to the basic

width of the paver.
C_1.0_01_GB.fm 3-12

C 1.0 3
2.2 Drive onto the low-bed trailer

f 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 protec-
tive roof:
- Take out the bolts and pull the roof to
the front by gripping it with the bow-
type handle. When it is in the lower
position, secure it with the bolts.

Roof.tif
C_1.0_01_GB.fm 4-12

C 1.0 4
 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).

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

- Wait until the exhaust extension pipe has cooled down; then remove it and store it.

2.4 After transportation

- Remove the attachment devices.

- Swing up the protective roof: take out the bolts, push the protective roof forward to
raise it and insert the bolts to lock it 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 finisher in a secure spot, lower the screed and switch off the engine.
- Remove the key and/or cover the operating panel with the protective hood and se-
cure it.
C_1.0_01_GB.fm 5-12

C 1.0 5
3 Transportation

m Reduce the paver finisher and the screed to their basic widths; also remove any at-
tached side plates.

3.1 Preparations

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

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

f 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_01_GB.fm 6-12

C 1.0 6
 .

Operation Switch Buttons

- Disabling the interlocking of operation

- Close the hopper halves.

- Engage both hopper transport safe-

guards.

- Lift the screed.

- Insert the transportation safeguards

of the screed.

- Turn the preselecting regulator to ze-

remote control is not connected

ro.

- Move the drive lever forward.

- The levelling cylinder are

Only when

in fully extended position.

- Set the drive lever to mid-position.

A

- Retract the screed to the basic width

of the paver finisher.
C_1.0_01_GB.fm 7-12

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.

f 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!

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

C_1.0_01_GB.fm 8-12

C 1.0 8
 4 Loading by crane

m 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

A 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 protruding or loose parts and the gas bottles of the screed heating sys-
tem (see Chapters E and D).
- Swing down the protective roof.
- Attach the lifting gear to the four lifting eyes (1,2).

m 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
5 Towing

f Heed all regulations and apply all safety measures applicable for towing heavy con-
struction machines.

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

m Only release the traction system brakes

when the machine is sufficiently secured
against accidental rolling or is already
properly connected to the towing vehi-
cle.

- The two high pressure cartridges (1)

of the pumps of the traction drive must
be driven out by about 3 turns.

Pump634.jpg

- Release lock nut (2), screw threaded

dowel (3) into pump as far as possible
and secure with lock nut. 4
- Actuate lever (4) of hand pump until
sufficient pressure has been built up
and traction system brakes have been
3
released.
- Attach the tow bar to the coupling (5)
located in the bumper. 2

A Now carefully and slowly tow the paver

finisher out of the construction area.

m Always only tow the shortest distance to

the means of transport or the next park-
ing possibility.
C_1.0_01_GB.fm 10-12

Pump

C 1.0 10
 Following towing, unscrew the threaded
dowel (3) a few turns again and lock with
the lock nut (2).
The high pressure cartridges (1) have to
be fully screwed back in to make the ma-
chine usable again.
The brakes of the traction drive are now
active again and the machine is secured
against accidental rolling away.

5
634_Dyn_Iso_1.bmp
C_1.0_01_GB.fm 11-12

C 1.0 11
6 Safely parking the vehicle

m When the equipment is parked at a loca-

tion accessible to the public, it must be
secured in such a way that unauthorized
persons or playing children cannot dam-
age the vehicle.

- Pull off the ignition key and the main 1

switch (1) and take it with you do not
hide them somewhere on the ma-
chine.
F0077/0078_A1.EPS

m Do not turn off main switch (1) until 15

seconds after the ignition has been turned off!

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

- Protect the operating panel with the

dust cover (2) and lock it.
- Store loose parts and accessories in a
safe place.

Bedienpult_SPS_Rad_634_2.wmf/Vandalism.bmp

A Secure the dust cover (2) during opera-

tion with the lock on the terminal box un-
der the maintenance flap on the RH
side!

2
C_1.0_01_GB.fm 12-12

Dieseltank.eps/Vandalism.bmp

C 1.0 12
 D 1.3 Operation
1 Safety regulations

f Starting the engine, the traction drive, the conveyor, the auger, the screed or the lifting
devices can cause injuries or even the death of persons.
Make sure before starting any of these devices that no-one is working at, in or be-
neath the paver finisher or within its danger area!

- Do not start the engine or do not actuate any controls when this is expressly forbid-
den!
Unless otherwise specified, the controls may only be actuated when the engine is
running!

f Never crawl into the auger tunnel or step into the hopper or onto the conveyor. Dan-
ger 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 driverss position that is opposite to the flowing traffic! Lock
the operating panel and the drivers seat.
- Keep a sufficient safety clearance to overhanging objects, other machines and
points of danger!
- Be careful when travelling on rough terrain to keep the paver finisher from slipping,
tipping or turning over.

f 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 Operating elements

2.1 Operating panel

1 C
2

4 3

B A
D_1.3_01_GB.fm 2-24

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
 Item Designation Brief description

Steering is transmitted to the front wheels hydraulically.

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

For securing the movable operating panel against inadvertent

movement at the desired paver finisher height.
Retaining bracket - Turn the knurled screw at the desired location into the des-
2
for operating panel ignated notch and secure with the knurled nut.
f When not secured, the operating panel can move.
Danger of accidents during transportation!

In the case of seats which can be swung out beyond the ma-
chine contour (option), the operating panel can also be moved
beyond the basic width of the paver finisher.
Latch for operat-
3 Pull out the latch and move the operating panel; let the latch
ing panel
engage again.
f An unlatched operating panel can slide out of position.
Danger of accidents during transportation!

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

4 Lights
switched on.
D_1.3_01_GB.fm 3-24

D 1.3 3
 A

8 14

10 11

12

13

7
5

9 9a
D_1.3_01_GB.fm 4-24

Element2_konv_Rad_634.bmp

D 1.3 4
 Item Designation Brief description

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

5 Starter 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 A When the working speed is selected, the differential

6 lock is automatically engaged!
fast/slow

A When the travelling speed is engaged, the front wheel

drive is automatically switched off!

Use it as a sound alarm in case of imminent danger and be-

7 Horn
fore starting!

This sets the speed, which the machine must achieve with the
Preselector of trac- full swing of the drive lever.
8
tion drive The scale approximately corresponds to the speed in
A
m/min (when laying).

For switching on the paver finisher functions and for continu-

ously regulating the traction speed forward or reverse.
Zero position: Starting is possible; engine at idling speed; no
traction drive; 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
(See engine speed setting).
- Position 2: feeder and auger On.
- Position 3: screed movement (tamper/vibrator) ON; traction
9 Drive lever (feed) drive ON; increase speed until impact.
Use the preselector to set the maximum speed.

A When the machine is stopped, the parking brake is au-

tomatically engaged.

A When the drive lever is moved, the parking brake is au-

tomatically released.

A 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_01_GB.fm 5-24

10 Warning signal Switch on for safety on roads.

Travelling direc-
11 tion indicator (Di- Use it when changing direction along public road.
rection indicator)

D 1.3 5
 A

8 14

10 11

12

13

7
5

9 9a
D_1.3_01_GB.fm 6-24

Element2_konv_Rad_634.bmp

D 1.3 6
 Item Designation Brief description

Key inserted: Ignition on

Key pulled out: Ignition, engine off.
Key positions:
0 Lights switched off
Ignition switch and 1 Parking lights / rear lights, instrument panel light,
12 working floodlight as applicable
lighting switch
2 Driving lights
3 Headlights

A Override the interlocking between 1 and 2 by depress-

ing them.

If one of the control lights indicates the fault in the traction en-
gine, then a code can be queried from the machine, which
means a specific fault.
Query of fault / fail- Keep pressing the button, until a three digit error code is dis-
13
ure played.

A See Chapter Operating Failures for querying the error

code.

In case of danger (persons are exposed to risk, danger of col-

lision etc.), press it!
- Pressing the emergency stop button switches off the en-
gine, the drives and the steering system.
Steering away, lifting the screeds and other maneouvers
Emergency stop
14 are not possible in such cases! Risk of accident!
button
- The emergency stop button does not shut off the gas heat-
ing system.
Manually close the main shutoff valve and both cylinder
valves!
- To restart the engine, the button must be pulled out again.

15 has no function
D_1.3_01_GB.fm 7-24

D 1.3 7
 B

29

16

17

28
18

19
23

24 20
21
22
25

26

27
D_1.3_01_GB.fm 8-24

Element1_konv_Kette_635.bmp

D 1.3 8
 Item Designation Brief description

The transport direction of the conveyor, applicable separately

to both sides of the conveyor, 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
16 Reverse selection be avoided during transport. The conveyor travels about 1 m
(o) Feeder in the direction of the hopper.

A If necessary, press the button as many times as neces-

sary, so that the feeder operates in the opposite direc-
tion over a longer section.

Conveyor modes A - auto: drive lever turned on and continuously regulat-

of operation on the ed in the tunnel using the material limit switch
right/left sides B - stop: turned off
17 B C - manual: continuously turned on (full delivery capacity,
C (without material mix regulation)
A
- If the conveyor is to be remote controlled (o), then both
switches shall be set to auto position.

A - auto: drive lever turned on, in normal position turned

Tamper (depends off
on the screed) B - stop: completely turned off
B C - manual: continuously turned on
A C Use auto mode for laying in the basic case.
18
m 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.

A Speed regulation (see Operation manual of screed)

Vibration
(depends on the
screed)
B Operation and application similarly to the (tamper) switch.
19 A C
A Speed regulation (see Operation manual of the
screed).
D_1.3_01_GB.fm 9-24

D 1.3 9
 B

29

16

17

28
18

19
23

24 20
21
22
25

26

27
D_1.3_01_GB.fm 10-24

Element1_konv_Kette_635.bmp

D 1.3 10
 Item Designation Brief description

Screed position A Lift the screed.

B Lock the screed (the position appropriate for inserting the
A transportation safeguard of the screed)
20 C: Lower the screed and set it to Floating position
B
m During paving, the screed must always be in the float-
ing position. The same applies to temporary stops and
C
the case of changing trucks.

With this function the hydraulic unit of the screed can be con-
trolled to prevent the lowering of the screed, when the paver is
stopped (temporary stopping).
Screed control
A automatic- if the drivearm (9) is in central position, in case
in case of stopped
of stopping the paver, the screed is controlled by about 20
paver finisher
bar preliminary pressure.
- Position C can be used for setting the paver, position A
21 A can be used for paving.
C: switched off- if the drivearm (9) is in central position, in
case of stopping the paver, the screed is only maintained
C in floating position / controlled.
f In case of transportation or maintenance operations al-
ways insert the mechanical transportation safeguard of
the screed.

The screed can be thus loaded or offloaded to change the

creed loading / traction force or compacting.
unloading A: Relieving (screed lighter)
B: Function Off
A C: Charging (screed heavier)
22
- With the help of pressure regulating valve (93) the height of
loading and offloading must be adjusted.
- For the function Stop screed with prestressing select posi-
tion 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.
Starter switch
Temporary pres- A This function prevents the floating of the screed, e.g. in
23 case of temporary stopping or changing trucks.
sure load when
laying is started
After the expiry of the preset delay time of the pressure load,
the machine automatically switches to floating position.
D_1.3_01_GB.fm 11-24

D 1.3 11
 B

29

16

17

28
18

19
23

24 20
21
22
25

26

27
D_1.3_01_GB.fm 12-24

Element1_konv_Kette_635.bmp

D 1.3 12
 Item Designation Brief description

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

Preselecting regu- The delay time must be set depending on the working
lator Pressure A
24 speed.
load delay time to
start paving - High working speed - short delay time
- Low working speed - longer delay time

A auto: with the drive lever turned on and using the ma-
terial limit switch at the auger for continuous
regulation
Auger modes of B stop: turned off
operation on the C manual: turned on, transport direction inward/outward.
right/left sides (The direction set by switch (26))
25 B
A In position (C), when the switch (26) is turned on, the
A C half-augers work continuously (full transport capacity,
without automatic material regulation).

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

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
Adjustment of au-
the auger beam support.
26 ger beams on the
Basic rule: Laying thickness + 5 cm (2 inches) = auger
LH/RH sides (o)
beam height.
m Operate both switches at the same time, or else the
auger beams will go slant.

Conveying direc- For setting / switching over the transport direction of the two
27
tion of the auger auger halves in manual mode.

With this the extendable parts of the Vario screeds can be

Screed extension hydraulically extended or retracted.
28
retraction (o) In the EU countries this is permitted with the remote
A
control switch only.

top: Opening of hopper

middle: has no function
bottom: Opening of hopper
Opening/closing of
D_1.3_01_GB.fm 13-24

29
the feeding hopper
Separate actuation (o):
Necessary when laying in a tight place on one side or when
filling from the truck is hindered.

D 1.3 13
 C

53 54 47 30 31

52 51 50 49 36 34

37 38 39 40 41

42 43 44 45 46
D_1.3_01_GB.fm 14-24

l m nt3 konv ad 634 bmp uchtmodul tt 635 bmp

D 1.3 14
 Item Designation Brief description

With this the levelling cylinders can be controlled manually, if

Levelling cylinder
the levelling automatic system is switched off.
30 on the right/left
For this, the switch on the remote control shall be in manual
sides
position.

Continuously variable adjustment of speed (in case of moving

the drive lever).
Min. position: idling speed
Max. position: rated speed
Engine speed During laying in a normal case the rated speed is se-
31
adjustment (o) A
lected, while in case of travel the RPM shall be re-
duced.

A The automatic RPM control keeps the set RPM con-

stant even under a load.

32 has no function

33 has no function

In the upper position the supplementary front-wheel drive is

engaged.

Front wheel drive A Front wheel drive can be engaged only with the switch
34 in working speed position.
On/Off (o)

A See the valve and the pressure gauge for the adjust-
ment of the drive pressure.

35 has no function
D_1.3_01_GB.fm 15-24

D 1.3 15
 C

53 54 47 30 31

52 51 50 49 36 34

37 38 39 40 41

42 43 44 45 46
D_1.3_01_GB.fm 16-24

Element3_konv_Rad_634.bmp/Leuchtmodul_KONV_Kette_635.bmp

D 1.3 16
 Item Designation Brief description

Normal display up to 85 C = 185 F.

36
Hydraulic oil ther-
mometer
m 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.

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

Alarm light (red)

m In order to avoid the damage of the traction engine
drain the separated water immediately according to the
37 operation manual.
Water in the fuel

A The fault is indicated together with the Error message

light.

It indicates that a fault has occurred in the traction engine. De-

pending 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.
Fault message All the faults shall be eliminated as soon as possible!
38
(yellow)
A The error code can be queried using button (13).

A After the ignition is turned on, the light is on for a few

seconds for check-up.

High beam head- It is on, when the high beam headlight is switched on (at the
39 light control lamp ignition switch).
(blue) f Avoid blinding the oncoming traffic!

Front wheel drive

40 It is on, when the front wheel drive is engaged.
(o)

It is on if the engine cannot be started (e.g. the emergency

Stopping the en- stop button was depressed).
41
gine
A In such a case see Chapter Operating failures.

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

m The output of the engine drops automatically. (Further
travel remains possible). Stop the paver, (set drive le-
ver to neutral position), and let the engine cool at idling
Indicator light of speed. Find the cause and if necessary eliminate it
42 engine tempera- (see Chapter Operating Faults). Upon cooling down
ture (red) to normal temperature, the engine will work again at full
D_1.3_01_GB.fm 17-24

capacity.

A The fault is indicated together with the Error message

light.

D 1.3 17
 C

53 54 47 30 31

52 51 50 49 36 34

37 38 39 40 41

42 43 44 45 46
D_1.3_01_GB.fm 18-24

Element3_konv_Rad_634.bmp/Leuchtmodul_KONV_Kette_635.bmp

D 1.3 18
 Item Designation Brief description
It must go out soon after start-up. Consider the time of warm-
ing up. The hydraulic oil may be too cold and rigid.
Oil pressure indica-
43 tor for the hydraulic m If the light does not go dark, do not turn on the trac-
tion drive.
traction drive (red)

A The lamp goes out at a pressure of 2.8 bar = 40 psi.

m It is on, when the oil pressure is too low.

Stop the engine immediately!
Oil pressure indica- For additional faults, see operating instructions for the
44 tor for the Diesel en- engine.
gine (red)
A The fault is indicated together with the Error mes-
sage light.
It is on, when the differential lock is engaged.
Control light
45 In working speed the differential lock is automatically
differential lock A
engaged.
Battery indicator light It must go out after start-up at a higher speed.
46
(red). - Stop the engine.
It is on when parking brake is active.

A When the machine is stopped, the parking brake is

Parking brake light automatically engaged.
47
(red)

A When the drive lever is moved, the parking brake is

automatically released.
48 has no function
The service hours are counted by the machine with running
49 Service hour meter engine.
Daily maintenance of the paver finisher (see chapter F)
Continuously observe the fuel gauge.
50 Fuel gauge m The gas oil tank may never go empty! Otherwise, the
entire fuel system must be bled (vented).
51 has no function
The speed is displayed in revolutions per minute (rev/min).
52 RPM meter (o)
A The RPM can be modified with the speed regulator.
53 Fuse box I. A For assignment of fuse strips, refer to chapter F.
D_1.3_01_GB.fm 19-24

54 Fuse box II. A For assignment of fuse strips, refer to chapter F.

D 1.3 19
 C

53 54 47 30 31

52 51 50 49 36 34

37 38 39 40 41

42 43 44 45 46
D_1.3_01_GB.fm 20-24

Element3_konv_Rad_634.bmp/Leuchtmodul_KONV_Kette_635.bmp

D 1.3 20
 3 Remote control

55 56

61
62 57

58

59

60

Remote_konv_neu1.bmp

A With the help of the two remote controls - on the RH and LH sides of the screed - the
functions available on the specific side of the paver can be controlled.
D_1.3_01_GB.fm 21-24

D 1.3 21
 Front side

Item Designation Brief description

Its function and use are similar to those of the emergency

Emergency stop stop button on the operating panel (14).
55
button (o) It is important in such dangerous situations, which cannot be
observed by the driver.

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

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

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

Its function and use are similar to the function of the switch
59 Auger (25) on the control panel.
- The switch must be set to auto.

Screed extension/ With this the extendable parts of the Vario screeds can be
60
retraction hydraulically extended or retracted.

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

Levelling automatic switch (30) on the operating platform)
61
system auto: automatic height adjustment with grade signal
transmitter

To control the levelling cylinder on the other side of the ma-

chine.
Levelling cross-
62 The other side at any time must be set to manual.
connection (o) A

A It overrides the manual switch position.

D_1.3_01_GB.fm 22-24

D 1.3 22
 Reverse side

66 68 67
Remote_konv_neu1.bmp

Item Designation Brief description

Connection to the
66 levelling automatic Connect the cable for the grade control unit here.
system

Connection to the
67 end position switch of Connect the cable for the material limit switch here.
the auger

Cable for the remote Connect to the socket on the screed

68
control (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 lo-

cated under the left maintenance flap.

A For the specifications, refer to chapter B,

Technical Data.
For servicing, see chapter F.

m Heed the instructions when starting the

paver finisher externally. (see section
Starting the paver finisher, External
starting (starting aid).
71

Tankhood_LH.eps

Battery main switch (72)

The main switch interrupting the circuit

between the battery and the main fuse is
located under the left maintenance flap.

A For the assignment of all fuses, see

chapter F.

- For switching off, turn the key (72) to

the left and pull it out.

A Do not lose the key as in this case the 72

paver finisher can no longer be moved!

Tankhood_LH.eps

72
D_3.0_01_GB.fm 1-16

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 safe- a
guards for the hopper must be inserted.

Item:

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

or

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

f Do not enter the hopper while the engine

is running! Danger of being caught by
the conveyor! (o)
Without transport safeguards inserted, b
the hopper halves will slowly open; dan-
ger during transportation!

Hopperlock2.tif/Hopperlock_SK.eps

D_3.0_01_GB.fm 2-16

D 3.0 2
 Mechanical screed transport safe-
guard (to the left and the right be- 74
neath the drivers seat) (74)

Used to protect the lifted screed from in-

advertent lowering. The screed transport
safeguard must be inserted before trans-
portation and when work is finished.

f Transportation with an unsecured

screed bears the danger of accidents!
F0083_A1.TIF
- Lift the screed.
- Actuate the levers.
- Check that the latches (to the left and to the right) engage in the crossbeams.

m ATTENTION!
Insert screed lock only at crown adjustment zero! Screed lock only for transportation
Use the interlocking of the main girder for transportation only!
Do not enter or work under screed only secured with screed lock for transportation!
Danger of accident!

Seat lock (behind the drivers seat)

(75)

Telescoping seats (o) can be extended

beyond the basic width of the paver fin- 75
isher. They must be locked.

f The seats must not protrude from the ve-

hicle during transportation. Push the
seats back to the basic width of the pav- F0169_A1.EPS

er finisher!

- Pull out the locking button and move the seat; let the locking button engage again.

f The drivers seat can move when the locking button is not engaged properly. Danger
of accidents during transportation!
D_3.0_01_GB.fm 3-16

D 3.0 3
 Service brake (foot brake) (76)

There is a brake pedal before each driv-

er's seat on the LH and RH sides.
The service brake acts within the ma- 76
chine drive.

A Upon operating the brake, the machine

drive is regulated to stop automatically
(regardless of the position of the drive le-
ver).

A If the machine was stopped with the

service brake, it cannot be started if the
drive lever was not set to neutral before-
hand! Footbrake.eps

D_3.0_01_GB.fm 4-16

D 3.0 4
 Separator fluid spraying system (80)
(o) (o)

Used to spray the parts coming into con-

tact with asphalt with a separator emul-
sion.

- The indicator lamp (A) lights up when

the emulsion pump is running
- On/off switch (B) for the emulsion
pump
- Quick-release coupling (C) for hose
connection
A B C
m Only switch on the spraying system
when the diesel engine is running; other- Emu2.tif
wise, the battery will be discharged.
Switch off after use.

A A permanent installed hose guide (D) for

the fluid spraying system is available as (o)
an option.

Pull hose out of the guide till there is an

audible creak. The hose will engage in D
this position after discharging.The hose
will be retracted automatically into the
guide after pulling and discharging
again.

f Dont spray into open flame or on hot

surface! Danger of explosion!

Emul1.Tif

A The spraying system is feeded by a can

(E) under the side flap on R.H. side. (o)

f Refill the can only while standstill of the

paver finisher!
E
D_3.0_01_GB.fm 5-16

Emu3.tiff

D 3.0 5
A Further switch options for optional
equipment features may be located on (o)
the central panel:
85
on / off switch for additional headlight
in the roof (85):

Actuate switch (a) to activate.

a

On / off switch for fuel tank filler

pump (85a)
85a
If the pump is actuated with the switch
(a), the indicator lamp (b) lights up.

f When fuelling, ensure that no fuel pene-

trates the earth. Switch off the engine b a
and do not smoke. Do not fuel in en-
closed spaces. Danger to health! Have a
fire extinguisher ready.
85b

On / off switch special lighting (85b)

If the machine is equipped with addition-

b a
al headlights, these are actuated by
means of the switch (a). When switched
to the ON position, the indicator lamp
(b) lights up.
85c

m Switch the additional headlights and

special lighting off when the engine is
not running, as the battery is otherwise
discharged! b a

On / Off switch Exhaust of asphalt va-

pours (85c)
85d
In case of the availability of optional as-
phalt vapour exhaust system, this can
be turned on by switch (a).
In the switch position ON the control b a
light (b) is on.
D_3.0_01_GB.fm 6-16

85e

b a

D 3.0 6
 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.

A If optionally available 230 V systems are

installed, an additional switch cabinet is (o)
mounted on the paver finisher:

230 V On / Off switch Connection 85f

sockets (85f)

In case of being equipped with 230 V ac-

cessories, the connection sockets can
b a
be powered through switches. In the
switch position I the control light (b) is Schalt_230V.wmf

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):
A
- Loose the twistlock (A)
- Pull the roof frame forward holding the
clevis or the frame
- Arrest the twistlock in the second lock-
ing hole.

Dachkons.bmp
D_3.0_01_GB.fm 7-16

D 3.0 7
 Hydraulic folding roof (87) (o)

The hydraulically folding roof is secured

by means of a latch (A) at the rear sus-
pension on the left and right sides of the
machine. This must be released prior to A
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.

A The roof can be raised and lowered with- D

out having to start the drive motor.
C
- In order to lower the roof, turn the key-
operated switch (B) to the right until
the roof has been lowered to its mini-
mum level.
E
f 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 proce-
dure.

- In order to raise the roof again, turn B

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.

- Actuate the pump lever (C) until the roof can be secured with the latch bolt (A) in 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

D 3.0 8
 Electric setting of the transportation
volume of the conveyor (o) (88) (o)

With this the transport volume of the

conveyor can be adjusted when me-
chanical limit switch or ultrasonic sensor 88a
is used.

- The 0 position of the scale corre-

sponds to the smallest adjustable vol-
ume. 85d
- RH-side conveyor: (88a)
- LH-side conveyor: (88b) 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.

A This requires that the auger height has

been adjusted correctly (see chapter E). 89

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)

A The limit switches control the material

flow at the respective auger half.

The ultrasonic sensor is mounted by 90

means of an appropriate leverage to the
side plate. Loose clamping lever for ad-
justment and modify angle / height of the
sensor.
The cables must be connected to the re-
mote control units located at the sides of
the screed (socket (62)).
Ultra_Auger.bmp

A We recommend to adjust 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.

A As an option, one socket can be used to

provide power for an electrically heated 92
seat.
F0124_A1.TIF

D_3.0_01_GB.fm 10-16

D 3.0 10
 Pressure control valve for screed
charging/relieving (93)

Used to adjust the pressure for addition- 93b 93

al charging/relieving of the screed.
93a

- See screed charging/relieving de-

vice.
(Chapters Operating Panel, Opera-
tion).
- Pressure display: see pressure gauge
(93b).

Pressure control valve for screed

stop with pretensioning (93a)
93 93a
This valve is located beneath the right-
hand bottom flap of the operators plat-
form.

It is used to adjust the pressure for

screed stop with pretensioning.

- Activation: see screed charging/re-

lieving device.
- Pressure display: see pressure
gauge (93b).

93b
Pressure gauge for screed charging/
relieving and screed stop with preten-
sioning (93b)

Displays the pressure for

- Screed stop with pretensioning screed F0184_A1.TIF/Screed_Valve.eps/F0105_A1.TIF

stop with pretensioning when the drive
lever is set to the neutral position (pressure to be adjusted using valve (93a));

Screed charging/relieving device when the drive lever is in the third position (pressure
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) 94

The drive pressure of the supplementary

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).

A 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)

Experimental value: about 110 - 140 bar
Maximum value: about 200 bar)

A 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.

D_3.0_01_GB.fm 12-16

D 3.0 12
 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

a
m It is prohibited to change the factory-set
durations of pumping and break without
consulting the technical customer serv-
ice!

A Changing the duration of lubrication and

breaks may be necessary when placing
mineral or cement bound material mix.

Manual start of lubrication (pumping b

time):
Lincoln3.jpg/Lincoln9.jpg
- Remove the cover lid (a).
- Keep the starting button (b) depressed for at least 2 sec.
- Replace the cover lid (a).

A Observe the instructions of chapter Maintenance!

D_3.0_01_GB.fm 13-16

D 3.0 13
 Particle filter - control light (102) (o)

A The control light of the particle filter is

found under the control track of the oper-
ating panel. a

When observing the control light (a) it is

essential:
Partikellight.tif

Indicator
Operating condition Cause / action
colour
No counterpressure Check the
yellow No counterpressure
tightness of the system.
green Within the measuring range There is no fault
Treshold range - Increase of engine speed to raise
flashing
Counterpressure in the the temperature of the exhaust
green
warning range fume.
Increase of engine speed to raise
Set value achieved / the temperature of the exhaust
red
exceeded fume. If necessary, clean / replace
the particle filter.
The temperature or pressure Check and replace, as required,
flashing red
sensor failed the temperature / pressure sensor

A With the brief increase of the engine speed to the max. range, the filter is cleaned au-
tomatically 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.

D_3.0_01_GB.fm 14-16

D 3.0 14
 Front and side window (o) (103)
(o)
The front window can be folded up for
the maintenance works performed at the
tank.
D

- Fold the front window by its handle (A)

and lock it on the RH and LH sides
with the two locks (B) in the upper po- C
sition.

Additional functions: A
B
- If necessary, turn on the windscreen
wipers on the RH and LH sides (C).
- Fold up the side window (D) at its cle- Wetterhaus.eps

vis (window frame) and the push the

driver's seat out.
D_3.0_01_GB.fm 15-16

D 3.0 15
 Adjustment of screed eccentric (o)
(104) (o)
C
To pave thicker layers of material, if the
piston rods in the levelling cylinder are
operating close to their limit position and
if the desired paving thickness cannot be III II

reached, it is possible to alter the ap- I

proach angle of the screen by adjusting

the eccentric.

- Pos I: Paving thickness of up

to approx. 7cm B
- Pos II: Paving thickness of approx.
A
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.

A If the levelling unit is connected to a height controller, this has the function of balanc-
ing out any rapid rise in the screed position: The levelling cylinders are extended until
the correct height is reached.

A The change in approach angle can only take place slowly and uniformly on both sides
at once during paving operation, and involves the use of the eccentric adjustment.
Failing this, any rapid response in the screed could easily cause waves to appear on
the road surface.
The setting process should therefore take place before work starts!

D_3.0_01_GB.fm 16-16

D 3.0 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 de-
vices and aids are present:

- Wheel loader for transporting heavy extendable parts

- Diesel fuel
- Engine oil and hydraulic oil, lubricants
- Separating agents (emulsion) and manual injector
- Two filled propane gas bottles
- 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 inspection walk around the paver finisher and check for leaks and damag-
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 be-
low".
D_4.5_01_GB.fm 1-34

D 4.5 1
 Checklist for the machine operator

Check! How?
Emergency stop button Push in the button.
- on the operating panel The diesel engine and all running drives
- on both remote control units o must stop immediately.
The paver finisher must immediately fol-
Steering low every steering wheel movement in a
precise manner. Check straight running.
Horn
Briefly press the horn button.
- on the operating panel
The horn must sound.
- on both remote control units o
Switch on with the ignition key, walk
Lights around the paver finisher to check and
switch off again.
With the ignition switched on, press the
Hazard warning lights of the screed switches for extending/retracting the
(with vario screeds) screed parts.
The rear lights must flash.
Gas heater system (o): Check:
- Bottle holders - Secure seat
- Bottle valves - Cleanliness and tightness
- Pressure reducer - Working pressure 1.5 bar
- Hose break safety devices - Function
- Shut-off valves - Function
- Main shut-off valve - Function
- Connections - Tightness
- Indicator lamps of the switch box - All lamps must light up when the
system is switched on

D_4.5_01_GB.fm 2-34

D 4.5 2
 Check! How?
For larger working widths, the walkway
Auger covers plates must be extended and the auger
tunnels must be covered.
For larger working widths, the walkway
plates must be extended.
Hinged walkway plates must be swung
Screed covers and walkways down.
Check that the side shields, the side
plates and the covers are securely seat-
ed.
When the screed is lifted, it must be
possible to push the locking rods side-
Screed transport safeguard
ways into the recesses in the cross-
beams using the lever beneath the seat.
When the hopper is closed, it must be
possible to fold the catches over the
Hopper transport safeguard
lock studs on the two halves of the hop-
per.
Both locking bolts must be in the
Protective roof
provided bore hole.
Miscellaneous:
Check that the hoods and flaps are
- Engine hood
securely seated.
- Lateral flaps
Accessories:
- Wedges The accessories must be in the
- Warning triangle provided holders.
- First-aid kit
D_4.5_01_GB.fm 3-34

D 4.5 3
1.1 Starting the paver finisher

Before starting the paver finisher

4 2
Before starting the diesel engine and be-
ginning operation, the following steps
must be performed:

- Daily maintenance of the paver finish-

er (see chapter F)

m Check the operating hour counter to de-

termine whether or not additional main-
tenance work (such as monthly or yearly 6
maintenance) must be performed.

- Check the safety devices and protec-

tive devices.

Normal starting

Set the drive lever (1) to the center posi-

tion and the speed adjuster (2) to mini-
mum.
5
- Insert the ignition key (3) in position
0. The lights should be switched off
during starting to reduce the current
3
drain on the battery.

A Starting is not possible if the drive lever

is not in the central position or if the mo- 1
tor stop control light (4) is On (the emer-
gency stop button (5) or the one on the 7
remote control (o) is depressed, the au-
ger and the conveyor switches are
turned). Element2_konv_Rad_634.bmp/Element3a_konv_Rad_634.bmp

- Press the starter button (7) to start the engine. Do not let the starter run permanent-
ly for more than 20 seconds; allow for a break of 1 minute after every attempt
D_4.5_01_GB.fm 4-34

D 4.5 4
 External starting (starting aid)

A The engine can be started with the help of an external power source if the batteries
are empty and the starter no longer turns.

Suitable power sources are:

- Other vehicles with a 24 V system

- Additional 24 V battery
- Start device that is suitable for external starting (24 V/90 A).

m Standard chargers or quick chargers cannot be used for external starting.

To externally start the engine:

- Set the drive lever (1) to mid-position 2
and the speed regulator (2) to mini-
mum.
- Insert ignition switch (3) to position 0
to turn on the ignition.
- Connect the power source with the ap-
propriate cables.

m Check the proper polarity! Always con-

nect the minus cable last and remove it
first!

- Press the starter button (4) to start the

engine. Do not let the starter run per- 3
manently for more than 20 seconds;
allow for a break of 1 minute after eve-
ry attempt.
1
4

Element2_konv_Rad_634.bmp/Element3a_konv_Rad_634.bmp
D_4.5_01_GB.fm 5-34

D 4.5 5
 After starting

To increase the engine speed:

1
- Set the RPM regulator (1) to medium
speed.
- Switch the drive lever (2) to position 1
(slightly moving it from the central po-
sition).

m Let the paver finisher warm up for ca. 5

minutes if the engine is cold.

Indicator lamps 2

The following indicator lamps must be

observed under all circumstances:
Element2_konv_Rad_634.bmp/Element3a_konv_Rad_634.bmp
For further possible faults, refer to the
operating instructions for the engine.

Battery charge indicator (1)

Must go out after starting when the en-

gine revs up.

m Briefly rev up the engine when the lamp

does not go out or lights up during oper- Leuchtmodul_KONV_Kette_635.bmp
1
ation.
Switch off the engine and determine the cause for the malfunction if the lamp does
not go out.

For further possible malfunctions, refer to the section Malfunctions.

Oil pressure indicator lamp for the

traction drive (2)

- Must go out after starting.

D_4.5_01_GB.fm 6-34

m If the lamp does not go out: Do not

switch on the traction drive! Otherwise, 2
Leuchtmodul_KONV_Kette_635.bmp
the entire hydraulic system could be
damaged.

D 4.5 6
 When the hydraulic oil is cold:

- Set the switch (3) of the conveyor to

manual and the switch (4) of the au-
ger to manual (arrow) position.
- Set the speed regulator (5) to medium
RPM and move the drive lever (6), un-
5
til the conveyor belt and the auger
start operating.
- Let the hydraulics warm up until the in-
dicator lamp goes out.

A The lamp goes out when the pressure

drops below 2.8 bar = 40 psi.

For further possible malfunctions, refer

to section 4.

Element2_konv_Rad_634.bmp/Element3a_konv_Rad_634.bmp/
Element1_konv_Kette_635.bmp
D_4.5_01_GB.fm 7-34

D 4.5 7
1.2 Preparations for paving

Separating agent

Spray the parts coming into contact with

asphalt (hopper, screed, auger, push
roller) with a separator emulsion.

m Do not use diesel fuel as it dissolves the

bitumen (prohibited in Germany!).

F0147_A1.TIF
Screed heater

Switch on the screed heater ca. 1530 minutes (depending on the ambient tempera-
ture) before paving begins. Warming up prevents the material from sticking to the
screed plates.

Direction marks

To ensure straight paving, a direction

mark must be present or established
(road edge, chalk lines or similar).

- Slide the operating panel to the de-

sired side and secure it.
- Pull the direction indicator out of the
bumper (arrow) and adjust it accord- Stossstange.bmp
ingly.

D_4.5_01_GB.fm 8-34

D 4.5 8
 Loading/distributing material

- Open the hopper with switch (1).

Provide guidance for the truck driver
when tipping the material mix.
- Set the switch (2) of the auger and the
switch (3) of the feeder to auto posi-
tion. 4
- Set the appropriate auger switch on
the remote control and conveyor
switch (if applicable) to "auto" position.
- Set the engine speed regulator (4) to
division 10 and push the drive lever (5)
to the second position (about half en-
gine speed).

1
3

Element2_konv_Kette_635.bmp/Element3a_konv_Rad_634.bmp/
Element1_konv_Rad_656.bmp
D_4.5_01_GB.fm 9-34

D 4.5 9
 - Switch the conveyors on.
The limit switches for the conveyors
(89) or (89ao) must switch off when
the material has reached the area be-
neath the auger crossbeam.
- Check that the material is conveyed
properly.
Manually switch on or off the conveyor
if the material is not conveyed properly
until a sufficient amount of material
lies in front of the screed.
89

89a

F0114_A1.EPS/Ultra3.EPS

D_4.5_01_GB.fm 10-34

D 4.5 10
 1.3 Starting for paving

1 2

7
4

8 5

14

12
A

13
D_4.5_01_GB.fm 11-34

Element2_konv_Kette_635.bmp/Element1_konv_Kette_635.bmp/Tamprev.cdr/Vibrev.cdr/Remote_konv_neu1.bmp

D 4.5 11
 Set the switches, levers and controls listed below to the specified positions when the
screed has reached its operating temperature and a sufficient amount of material lies
in front of the screed:

Item Switch Position

1 Machine movement fast/slow slow (tortoise)
2 Preselector regulator On / Off On (at the bottom)
3 Engine RPM (o) Maximum
4 Screed stop Auto
5 Screed position to floating position.
6 Vibrator (o) Auto
7 Tamper (o) Auto
8 Left/right auger Auto
9 Left/right feeder Auto
10 Speed regulator, tamper about 40-60 divisions
11 Vibration speed regulation about 40-60 divisions
12 Feeder Auto
13 Auger Auto

- Push the drive lever (14) all the way to the front and start driving.Screed floating
position is activated now.
- Observe the distribution of the material and adjust the limit switches if necessary.
- Set the compacting elements (tamper and/or vibration) according to the required
compaction ratio.
- Let the paving master check the layer thickness after 56 meters and correct if nec-
essary.

Carry out the check in the area of the drive chains or wheels as the screed tends to
level an uneven ground. The reference points for the layer thickness are the drive
chains or wheels.

The basic setting of the screed must be corrected when the actual layer thickness de-
viates significantly from the values indicated by the scales (see the operating instruc-
tions for the screed).

A The basic setting is for asphalt material.

D_4.5_01_GB.fm 12-34

D 4.5 12
 1.4 Checks during paving

The following points must be constantly observed during paving:

Paver function

- Screed heater
- Tamper and vibration
- Engine oil and hydraulic oil temperature
- The screed parts must be retracted and extended in time when obstacles are in the
way
- Uniform material transport and distribution or supply to the screed; may require cor-
rections to settings of the material switches for conveyor and auger.

A See the section Malfunctions when paver finisher functions fail.

Quality of the layer

- Layer thickness
- Slope
- Evenness in the driving direction and at right angles to it (check with 4 m levelling
rod)
- Surface structure/texture behind the screed.

A See section 4 Malfunctions, Problems during Paving if the paving quality is poor.
D_4.5_01_GB.fm 13-34

D 4.5 13
1.5 Paving with functions "screed control, stopping of paver finisher" and "screed
loading / unloading"

General

The screed hydraulics can be influenced in two ways to attain optimum paving re-
sults:

- Screed stop with and without pretensioning with the paver finisher halted,
- Screed charging or relieving with the paver finisher driving.

A Relieving reduces the screed weight and increases the traction force.
Charging increases the screed weight, reduces the traction force, but increases the
compaction ratio. (To be used with light-weight screeds in exceptional cases.)

D_4.5_01_GB.fm 14-34

D 4.5 14
 Screed charging/relieving

This function charges or relieves the

screed regardless of its own dead A
weight.
B
Switch (1) has the following positions:
C

A: Relieving (screed lighter)

B: Function Off 1
C: Charging (screed heavier) Screedswitch_all.bmp

Switch positions Screed charging/relieving are only effective when the paver finish-
er moves. When the paver finisher stops, screed stop is automatically selected.

Screed control with the paver finisher standing still

(Floating position with and without prestressing)

When "stopping the screed" the relieving pressure and the countepressure of the ma-
terial will provide retention so that the sinking of the screed is avoided when a tempo-
rary stop occurs.

Using the switch (2) the following posi-

tions can be selected: A

A: automatic floating position with pre- B

stressing, if the drive lever is in cen-
C
tral position

C: only floating position, if the drive le- 2

ver is in central position. Screedswitch_all.bmp

A Position (C) is to be used for adjusting the paver finisher and for lifting/lowering of the
screed, and position (A) needs to be used for laying.

m In case of transportation or maintenance operations always insert the mechanical

transportation safeguard of the screed.
D_4.5_01_GB.fm 15-34

D 4.5 15
 Screed control with the paver finisher at standstill - with floating position pre-
stressing

Similarly to the screed charging and relieving function, a pressure between 2 and 50
bars can be generated with the lifting cylinders of the screed. This pressure acts
against the mass of the screed to prevent its sinking into the freshly laid mixture.

The pressure to be applied depends on the load-bearing capacity of the material. If

necessary, the pressure must be readjusted or changed as required during the first
stops until the lower edge of the screed no longer leaves any marks when the paver
finisher moves on again.

A pressure greater than 10-15 bar neutralizes the screed weight, thus preventing the
screed from sinking into the material.

A The pressure is set in the factory to about 20 bars.

Especially in those cases where the screed relieving function is only briefly used as
a start-up aid, there is a danger of uncontrolled floating when starting up again.

Adjusting the pressure

Pressure adjustments can only be made

while the diesel engine is running.
Therefore:
1
- Start the Diesel engine, turn the feed
regulator (1) down to zero.

Element2_konv_Kette_635.bmp

- Set switch (2) to the "floating position".

A

2
D_4.5_01_GB.fm 16-34

Screedswitch_all.bmp

D 4.5 16
 Adjustment of pressure for the loading/offloading of the screed

- Move the drive lever from central posi-

tion to the third position. A A A
- Set the switch (3) to position A (of-
B B
floading) or C (loading).
- Set thepressure with the regulating C C C
valve (93b) and read it on the pres-
sure gauge (93c).
3 4 2
Screedswitch_all.bmp

93c

A If the screed charging/relieving function

is necessary while working with auto-
matic levelling (grade and/or slope
transducer), the compacting perform-
ance will be modified (layer thickness).

A Pressure can be adjusted and corrected

during paving.
(max. 50 bar)
93b

Screed control pressure with the pav- 93a

er finisher at standstill - set the float-
ing position with prestressing (o)

- Set the drive lever to mid-position.

- Set the switch (4) to position C and
switch (2) to position C.
- Set the pressure (93a) with regulator
valve (under the bottom plate of the
operator position), and check the F0103_A1.EPS/Screedvalve.eps

reading of pressure gauge (93c) .

(Basic setting: 20 bar)
D_4.5_01_GB.fm 17-34

D 4.5 17
1.6 Interrupting/terminating operation

During breaks (e.g. the material supply

truck is late) 2

- Determine the approximate duration.

- When cooling down of the material be-
low the minimum paving temperature
must be expected, run the paver fin-
isher finisher empty and create an
edge like the end of a layer.
- Set the drive lever (1) to the center po-
sition.

During extended interruptions (e.g.

lunch break)
1
- Drive lever (1) into centre position,
RPM speed adjustment (2) to mini-
mum position.
- Switch off ignition.
- Switch off screed heater (system).
Element2_konv_Rad_634.bmp/Element3a_konv_Rad_634.bmp/
- When screed is operated with the op-
tional gas heating system, close the valves of the bottles.

A The screed must be heated up to the correct paving temperature before paving may
be restarted.

D_4.5_01_GB.fm 18-34

D 4.5 18
 When work is finished

- Run the paver finisher empty and stop

it.
- Lift the screed. Set the switch (1) to
mid-position, switch (2) to the upper
position and switch (3) to lifting.
- Retract the screed parts to the basic
screed width and lift the auger. Where
applicable, completely extend the lev-
elling cylinders.

2
3

Element1_konv_Kette_635.bmp

- Insert the mechanic screed transport

safeguard (74) on both screed lifting
74
cylinders.
- While operating the tampers at a low
speed, let any material residues drop
out.

F0083_A1.TIF

- Set the drive lever (5) to the center po-

sition and the speed adjuster (6) to
minimum
6
- Switch off the ignition.
- Switch off screed heater (system).
- When screed is operated with the op-
tional gas heating system, close the
main shut-off valves and the valves of
5
the bottles.
- Remove the levelling units and stow
them away in the boxes, close all flaps
D_4.5_01_GB.fm 19-34

- Remove all parts that extend beyond

the paver finisher contour or secure
them if the paver finisher is to be trans-
ported over public roads on a low-bed Element2_konv_Rad_634.bmp
trailer.

D 4.5 19
m Do not turn off main switch until 15 sec-
onds after the ignition has been turned
off!

A The engine electronics need this length

of time to back up data.

F0077/0078_A1.EPS

- Read and check the operating hour

meter (8) to determine whether main-
tenance work must be performed (see
chapter F).
- Cover and lock the operating panel.
- Remove material residues from the Element3_konv_Rad_656.bmp
8
screed and the paver finisher and
spray all parts with separator fluid.

D_4.5_01_GB.fm 20-34

D 4.5 20
 2 Malfunctions

2.1 Querying the error messages of the traction engine

Should the fault detected in the traction engine be indicated by the control light (1)
(flashing or is on continuously), then the error message can be queried from the ma-
chine using the diagnostic button (2), which represents a specific fault. The flashing
code is also displayed by the control light (1).

Display of the number code

D_4.5_01_GB.fm 21-34

- Set the diagnostic switch (2) to display position for 1-3 sec until the control light
displays the three-digit code. While the switch is kept depressed, the control light
(1) goes out, which indicated the fault by flashing or by continuous lighting.

D 4.5 21
A The flashing code is displayed by flashing of the control light over a different length
of time. There is a difference between the "long" and "short" signals. There is a longer
break between the short and long blocks of signals.

Duration of the short flashing signal: 400ms

Duration of the long flashing signal: 800ms
Duration of the break: 2000ms

If the error query switch is again in position 0, the warning light, which indicated the
fault, will come on again (will flash or will be lit up continuously). This will be as long
as the fault or problem is eliminated.

A In order to check if no several faults have occurred at the same time, the diagnostic
switch has to be turned on again.
If the same flashing code can be seen again as before, then there is no additional
fault.
Repeat this process until the first error message appears again.
Record all the faults displayed.

m Report the displayed fault code to the customer service of the paver finisher and they
will discuss with you the steps to be taken.

D_4.5_01_GB.fm 22-34

D 4.5 22
 Example:

t = 400ms t = 400ms t = 400ms

2x

BREAK
t = 2000ms

t = 800ms t = 800ms t = 800ms

2x

BREAK
t = 2000ms

t = 400ms t = 400ms t = 400ms t = 400ms t = 400ms

3x
D_4.5_01_GB.fm 23-34

Sequence of flashing: 2-2-3.

Diagnostics according to the error message list: Charging air pressure -> Faulty sen-
sor input (e.g. short circuit or broken cable)

D 4.5 23
2.2 Error messages

D_4.5_01_GB.fm 24-34

D 4.5 24
 D_4.5_01_GB.fm 25-34

D 4.5 25
D 4.5 26
D_4.5_01_GB.fm 26-34
 D_4.5_01_GB.fm 27-34

D 4.5 27
D 4.5 28
D_4.5_01_GB.fm 28-34
 2.3 FMI-codes
D_4.5_01_GB.fm 29-34

D 4.5 29
2.4 Problems during paving

Problem Cause:
- change in the material temperature, demixing
- wrong material composition
- incorrect operation of the roller
- incorrectly prepared foundation
- long standstill times between loads
- grade control reference line is not suitable
- grade control jumps to the reference line
- grade control toggles between up and down
Wavy surface
(inertia setting is too high)
(short waves)
- bottom plates of the screed are loose
- bottom plates of the screed are warped or not uniformly
worn
- screed does not work in the floating position
- too much play in the mechanical screed link/suspension
- paver finisher speed is too high
- augers are overloaded
- changing material pressure against the screed
- change in the material temperature
- demixing
- roller has stopped on the hot material
- roller has turned or roller speed has been changed too fast
- incorrect operation of the roller
- incorrectly prepared foundation
- truck brake is applied too tight
- long standstill times between loads
Wavy surface
- grade control reference line is not suitable
(long waves)
- incorrect installation of the grade control
- limit switch is not correctly set
- screed is empty
- screed has not been switched to the floating position
- too much play in the mechanical screed link
- auger is set too deep
- auger is overloaded
- changing material pressure against the screed
- material temperature is too low
- change in the material temperature
- moisture on the foundation
Cracks in the layer - demixing
(over the entire - wrong material composition
width) - wrong layer height for the maximum grain size
- cold screed
- bottom plates of the screed are worn or warped
- paver finisher speed is too high
- temperature of the material
D_4.5_01_GB.fm 30-34

Cracks in the layer - cold screed

(center strip) - bottom plates are worn or warped
- wrong crowning

D 4.5 30
 Problem Cause:
- temperature of the material
- screed extendable parts are incorrectly installed
Cracks in the layer - limit switch is not correctly set
(outer strip) - cold screed
- bottom plates are worn or warped
- paver finisher speed is too high
- temperature of the material
- change in the material temperature
- moisture on the foundation
- demixing
- wrong material composition
- incorrectly prepared foundation
- wrong layer height for the maximum grain size
Layer composition is - long standstill times between loads
not uniform - vibration is too slow
- screed extendable parts are incorrectly installed
- cold screed
- bottom plates are worn or warped
- screed does not work in the floating position
- paver finisher speed is too high
- auger is overloaded
- changing material pressure against the screed
- truck hits too much against the paver finisher while aligning
to the paver finisher
Marks in the surface - too much play in the mechanical screed link/suspension
- truck brake is applied
- vibration is too high while standing on a spot
- temperature of the material
- change in the material temperature
Screed does not re- - wrong layer height for maximum grain size
act to corrective - incorrect installation of the grade control
measures as expect- - vibration is too slow
ed - screed does not work in the floating position
- too much play in the mechanical screed link
- paver finisher speed is too high
D_4.5_01_GB.fm 31-34

D 4.5 31
2.5 Malfunctions on the paver finisher or screed

Malfunction Cause: Remedy

See operating instructions for
At the diesel engine Diverse
the engine
See External starting
Diesel engine does Batteries empty
(start assistance)
not start
Diverse see Towing
Tamper is obstructed by
Properly heat the screed
cold bitumen
Hydraulic oil level in the
Top up the oil
tank is too low
Pressure limiting valve is Replace the valve; if necessary,
Tamper or vibration defective repair and adjust the valve
does not operate
Seal or replace the connections
Leak in the suction line of
Tighten or replace the hose
the pump
clamps
Clean the filter; if necessary,
Oil filter is soiled
replace the filter
Hydraulic oil level in the
Top up the oil
tank is too low.
Check fuses and cables; replace
Power supply is interrupted
if necessary
Switch is defective Replace the switch
One of the pressure limiting
Repair or exchange the valves
Conveyor or augers valves is defective
run too slowly Pump shaft broken Replace the pump
Limit switch does not switch Check the switch; replace and
or regulate correctly adjust the switch if necessary
Check the high pressure filter for
Pump is defective dirt particles; replace if
necessary
Oil filter is soiled Replace the filter
Engine speed is too low Increase the speed
Hydraulic oil level is too low Top up the oil
Leak in the suction line Tighten the connections
Flow rate regulator
Replace
Hopper cannot be defective
swung open Leaking seals of the
Replace
hydraulic cylinder
Control valve is defective Replace
Check fuse and cables; replace
Power supply interrupted
if necessary
D_4.5_01_GB.fm 32-34

D 4.5 32
 Malfunction Cause: Remedy
Control valve is defective Replace
Hoppers lowers
Leaking seals of the
inadvertently Replace
hydraulic cylinder
Oil pressure too low Increase the oil pressure
Leaking seal Replace
Screed cannot be Screed relieving or Switch must be in the center
lifted charging is switched on position
Check fuse and cables; replace
Power supply is interrupted
if necessary
Switch on the remote
Set the switch to manual
control is set to auto
Check fuse and cables; replace
Power supply is interrupted
if necessary
Switch on the operating
Crossbeams cannot panel defective Replace
be lifted or lowered
Excess pressure valve
Replace
defective
Flow rate regulator
Replace
defective
Seals defective Replace
Control valves defective Replace
Crossbeams lower Pilot-controlled non-return
Replace
inadvertently valves defective
Seals defective Replace
D_4.5_01_GB.fm 33-34

D 4.5 33
 Malfunction Cause: Remedy
Replace
Traction drive fuse
(Fuse holder on the operating
defective
panel)
Check potentiometer, cables,
Power supply is interrupted
connectors; replace if necessary
Traction drive monitoring
Replace
(type-specific) defective
Traction does not
Electro-hydraulic servo unit
work Replace the servo unit
of the pump defective
Check and adjust if necessary
Insufficient supply pressure Check the suction filter; replace
the supply pump and the filter if
necessary
Drive shaft of hydraulic
Replace pump or engine
pumps or engines broken
Check the fuel level; refill fuel if
Fuel level too low
necessary
Irregular engine Replace
Fuse engine speed
speed, engine stop (fuse strip on the operating
control defective
function does not panel)
work Defective power supply
Check potentiometer, cables,
cables (cables broken or
connectors; replace if necessary
short-circuited)

D_4.5_01_GB.fm 34-34

D 4.5 34
 E 01 Set-up and modification
1 Special notes on safety

f Danger to personnel by inadvertent starting of the engine, the traction drive, the con-
veyor, the auger, the screed or the lifting units. Unless specified otherwise, work may
only be performed when the engine is at a standstill!

- To protect the paver finisher against inadvertent starting:

Set the drive lever to the center position and set the preselector to zero; if applica-
ble, remove the drive traction fuse from the operating panel; pull out the ignition key
and the battery main switch.
- Secure lifted machine parts (e.g. screed or hopper) against lowering by means of
mechanical supports.
- Replace parts or have them replaced as stipulated.

f When connecting or disconnecting hydraulic hoses and when working on the hydrau-
lic system, hot hydraulic fluid can spurt out at a high pressure.
Switch off the engine and de-pressurize the hydraulic system! Protect your eyes!

- Mount all protective devices before re-commissioning the paver finisher.

- The walking platform must always reach over the entire width of the screed. The
hinged walkway (option for all variable screeds) may only be swung up under the
following circumstances:
- When paving next to a wall or a similar obstacle.
- During transportation on a low-bed trailer.
E_01_GB.fm. 1-18

E 01 1
2 Auger

2.1 Height adjustment

1
Depending on the mix of materials,
when working with layer thicknesses of
up to 15 cm, the height of the distribution
auger (1) measured from its bottom
edge should be around 5 cm
(2 inches) above the material layer thick-
ness (depending on its mix of materials).

Example: Layer height 10 cm

Adjustment: 15 cm from the F0130_A1.TIF
ground

An incorrect height adjustment can result in the following problems:

- Auger too high:

Too much material in front of the screed; material overflow. When operating with
larger widths, demixing and traction problems may occur.
- Auger too low:
Not enough material that can be precompacted by the auger. Irregularities resulting
from this cannot be completely compensated for by the screed (wavy surface).
In addition, an increased wear on the auger segments occurs.

2.2 Auger crossbeam installed in a fixed

position

- Lower the screed onto a suitable sup-

port (e.g. squared timbers).
- Completely extend both levelling cylin-
ders. 2
- Hook lifting chains (2) for lifting the au-
ger crossbeam into the hooks of the
crossbeams. F0131_A1.TIF

- Loosen the fixing screws (3) of the auger crossbeam.

- Retract the levelling cylinders until the
auger crossbeam has reached the de-
sired height.
- Tighten the fixing screws (3) of the au-
ger crossbeam.
3

F129_A1.TIF
E_01_GB.fm. 2-18

E 01 2
 2.3 Mechanical adjustment with ratchet
(optional)

- Set the ratchet direction lever to clock-

wise or anticlockwise direction. Turn-
ing anticlockwise lowers the auger,
turning clockwise lifts the auger.
- Set the desired height by alternatingly
adjusting the right-hand and the left-
hand side. 1
- The actual height can be read on scale
(1) in cm or inch (LH side column:
inch, RH side column: inch).

F0116_A1.EPS
2.4 In case of hydraulic adjustment (op-
tion)

- Determine the currently set height of

the auger crossbeam (left and right)
by means of the scale (1).

F0117_A1.EPS
E_01_GB.fm. 3-18

E 01 3
m Equally press both switches/buttons (2)
so that the auger beam does not get into
inclined position.

- Check whether the heights on the left

and on the right are identical.
2

Screedlift_konv.bmp/Screedlift_SPS.bmp

A The height indicating scales (3) may be

optionally also along the climbing rungs
on the LH/RH sides!

Schnskal.wmf

E_01_GB.fm. 4-18

E 01 4
 2.5 Auger extension, auger type I

Auger_Dyn.bmp

Depending on the type of screed, the most diversified working widths can be reached.

A Auger and screed extension must match. See the operating instructions of the appro-
priate screed, chapter Set-up and modification, especially:
Screed extension chart,
Auger extension chart.

To attain the desired working width, the respective screed extensions, side plates, au-
gers, tunnel plates or cut-off shoes must be mounted.

For widths of more than 3.00 m, the auger should be fitted with extension parts on
both sides to improve material distribution and to reduce the wear.

f The diesel engine must be switched off whenever work is performed on the auger.
Danger of injuries!
E_01_GB.fm. 5-18

E 01 5
2.6 Mounting extension parts
5
- Loosen the clamping screws (6) on
the support tube. Then turn in the
center expanding screw (5) to expand
the clamping joint.

6
F132_A1.TIF

- Pull the telescopic tube out of the sup-

port tube (7). 7
- Mount the required extension parts.

m Observe the guide groove of the spline!

Make sure that the shaft end is clean!

- Slide in the telescopic tube. When do-

ing so, make sure that the drive of the
auger gear is slid all the way over the
shaft end of the auger extension part
and that the threads of the augers F0133_A1.TIF
match.
- Remove the expansion screw (5). Then tighten the clamping screws (6). Finally
tighten the expansion screw by hand.

m Before the clamping screws (6) can be tightened again, the expansion screw (5) must
be sufficiently turned back!
Otherwise, the telescopic tube cannot be safely clamped and the splined shaft ends
break.

f When clamped insufficiently, the telescopic tube can slide out of the support tube.
Danger of accidents during transportation! E_01_GB.fm. 6-18

E 01 6
 2.7 Mounting support tube extensions

If the working width exceeds 7.25 m, an

auger crossbeam extension must be
mounted.

The support tube extension of the auger

crossbeam consists of two halves (8)
and is attached to the existing support
tube by using a total of 5 screws. After 8
the two halves have been screwed to the
support tube, they also must be linked to F0134_A1.TIF
each other by means of screwed con-
nections.

Clamping of the telescopic tube occurs

by tightening the screwed connections
(9) linking the support tube extension.

9
F0136_A1.TIF

If the working width exceeds 7.50 m the

hydraulic hoses (10) for the auger mo-
tors must be replaced with longer ones. 10
These long hoses are included in the
scope of delivery for this working width.

f When connecting or disconnecting hy-

draulic hoses, hydraulic fluid can spurt
out at a high pressure.
Switch off the paver finisher and de-
pressurize the hydraulic circuit! Protect
your eyes!

m When installing the hoses, make sure F0135_A1.TIF

that the area around the connections is
clean.
Any dirt that enters the hydraulic system can cause malfunctions.
E_01_GB.fm. 7-18

E 01 7
2.8 Installing tunnel plates

To ensure an optimum material flow

especially in the case of large paving
widths so-called tunnel plates (11)
must be installed.
They are located directly in front of the
auger distributor and in conjunction
with the auger are an ideal system for
conveying the material.
11 12
When operating with widths of more 13
than 3.90 m, two or more combined tun- F0140_A1.TIF

nel plates (13) must be used.

In this case, additional stabilizing sup-
ports (12) must be attached to the tele-
scopic tube.

The tunnel plates must be directly

screwed to the receptacles provided for
this purpose (14); they are located on
the auger frame sides and can thus be
adjusted in height.

Refer to the auger extension chart to de-

termine which parts of the conveyor sys-
tem are required for the desired paving
width.

A The auger extension chart is contained

14
in the operating instructions for the re-
spective screed.

F0139_A1.TIF

E_01_GB.fm. 8-18

E 01 8
 2.9 Installing additional braces

When operating with width of more than

7.25 m the augers must be provided with
an additional support.

F0141_A1.TIF

To do so, attach two braces on both the

left-hand and the right-hand side, be-
tween the tunnel plate support and the
bracket provided on the paver finisher.

The braces are included in the scope of

delivery for this working width.

F0142_A1.TIF
E_01_GB.fm. 9-18

E 01 9
2.10 Auger mounting chart for 310 mm auger

* from working width of 6.75 m the machine can be operated only with appropriate
braces (screed, auger, material pipeline).
E_01_GB.fm. 10-18

E 01 10
 2.11 Auger mounting chart for 380 mm auger

* from working width of 6.75 m the machine can be operated only with appropriate
braces (screed, auger, material pipeline).
E_01_GB.fm. 11-18

E 01 11
3 Auger extension, auger type II

Auger_DEM.bmp

E_01_GB.fm. 12-18

E 01 12
 3.1 Mounting extension parts

16

Sch_ver1.tif

9 10
8

12

11

14 15
E_01_GB.fm. 13-18

12
Sch_ver2.tif

E 01 13
 - Lock the material shaft (5) with bolts (6), washers (7) and nuts (8) to the basic de-
vice.
- The material shaft can be adjusted in order to match the existing shaft.
- Loosen the nuts (9) for this and turn the sleeve (10) of bolt (6).
- Mount the extension of the auger shaft (11) on the auger shaft of the basic device.
- Fasten the auger segments (12) using bolts (13), washers (14) and nuts (15) for the
extension of the auger and simultaneously bolt the auger shafts firmly together.

A If the application conditions on the job-site allow or demand auger extension, by all
means dismount the external bearing of the auger (16), if the auger extension is long-
er than 600 mm.
When extending the auger on the basic device with external auger bearing, the short-
er auger segment shall be mounted on the bearing. In the opposite case, both the au-
ger segment and the bearing may get damaged, when paving with 30 mm aggregate.

E_01_GB.fm. 14-18

E 01 14
 3.2 Auger modification plan.

Marking Meaning

Basic auger

Auger section to be mounted +

material shaft 320mm

Auger section to be mounted +

material shaft 640mm

Auger section to be mounted +

material shaft 960mm

Auger - outer bearing

E_01_GB.fm. 15-18

E 01 15
 Paving
Mountable parts / bearing Mountable parts / bearing
width
2.5 m
- 3.7 m

3.2 m
- 4.4 m

4.1 m
- 5.0 m

4.1 m
- 5.0 m

4.8 m
- 5.7 m

4.8 m
- 5.7 m

5.4 m
- 6.3 m

5.4 m
- 6.3 m

6.0 m
- 6.9 m

6.0 m
- 6.9 m

6.7 m
- 7.6 m

6.7 m
- 7.6 m

7.3 m
- 8.2 m

7.3m
- 8.2 m

8.0 m
- 8.9 m

8.6 m
- 9.6 m
E_01_GB.fm. 16-18

E 01 16
 4 Screed

The operating instructions for the screed cover all work required for mounting, setting
up and extending the screed.

5 Electrical connections

Establish the following connections when the mechanical components have been
mounted and set up:

5.1 Remote controls

to socket (15) (on the screed).

17
15

Socket.bmp

5.2 Grade control

to socket (16) (on the remote control

unit)
17

5.3 Auger limit switches

to socket (17) (on the remote control

unit)

16
F0119_A1.TIF

5.4 Working lights

to sockets (18) (on the paver finisher).

E_01_GB.fm. 17-18

18

F0124_A1.TIF

E 01 17
 F 1.0 Maintenance
1 Notes regarding safety

f Maintenance work: Maintenance work may only be carried out when the engine is
at a standstill.

Secure the paver finisher and the attachments against inadvertent starting before be-
ginning any maintenance work:

- Set the drive lever to the center position and the speed preselector to zero.
- Remove the ignition key and the battery main switch.

f Lifting and jacking up: Secure lifted machine parts (e.g. screed or hopper) against
lowering by means of mechanical supports.

m Spare parts: Use only approved parts and install them according to the specifica-
tions! If in doubt, contact the manufacturer!

f Re-commissioning: Mount all protective devices before re-commissioning the paver

finisher.

f Cleaning: Cleaning must not be carried out while the engine is running.
Do not use any inflammable substances (such as petrol).
Avoid directly cleaning electrical parts and insulation material with a steam jet; cover
them up beforehand.

f Working in closed environments: Exhaust fumes must be led into the open. Pro-
pane gas bottles must not be stored in closed rooms.

m In addition to these Maintenance Instructions, the Maintenance Instructions of the en-

gine manufacturer must always also be observed. All other maintenance work and in-
tervals noted in these instructions are also binding.

A The instructions for the maintenance of the optional equipment are included in the
sub-chapters of this chapter.
F_1.0_01_GB.fm 1-2

F 1.0 1
 F 2.2 Maintenance review
1 Maintenance review

6 8 9 10

3 5.1

4.2
7.4
F_2.2_01_GB.fm 1-2

F 2.2 1
 Maintenance required after the
following service hours

2000 / 2 years

as required
1000 / year
Sub-units Chapter

20000
5000
100
250
500
10
50
Feeder F3 q q q q
Auger F4.2 q q q q q
Drive engine F5.1 q q q q q q
Hydraulics F6.0 q q q q q q
Travel drive, steering F7.4 q q q q
Electronics F8 q q q q q q q
Lubrication points F9 q q q q
Checking/stopping F10 q q q

Maintenance required q

A This review also includes the maintenance intervals of the optional equipment of the
machine!

F_2.2_01_GB.fm 2-2

F 2.2 2
 F 3.0 Maintenance - Conveyor
1 Maintenance - Conveyor
F_3.0_01_GB.fm 1-4

F 3.0 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Checking the tightness of the

q
conveyor chain
1
- Adjustment of the tightness of the
q
conveyor chain
- Checking the oil level of the
q
conveyor drive
- Topping up the oil level of the
2 q
conveyor drive:
- Changing the oil of the
q
conveyor drive

Maintenance q
Maintenance during run-in period g

F_3.0_01_GB.fm 2-4

F 3.0 2
 1.2 Points of maintenance

Chain tightness of the conveyor (1)

Checking the chain tightness:

For daily inspection look straight through

under the bumper. The chain must not
hang below the bottom edge of the bumper.
Should readjustment be necessary, measure the slack unladen from the bottom edge
of the floor plate until the lower edge of the chain (see the figure).

m The chains should not be too tight or too

slack. Material between the chains and
the sprocket wheel can lead to stoppage
280 280
or breakage, in case of too tight chains.
If the chain is too slack, it may get stuck F0159_A1.TIF
in the protruding objects and be dam-
aged.

Adjustment of chain tightness:

x
A The chain tightness can be adjusted with
grease press. The filling ports (A) are lo-
cated behind the bumper on the RH and
LH sides.

Conveyor_set.eps
F_3.0_01_GB.fm 3-4

F 3.0 3
 The drive of conveyor (to the left/to
the right) (2)

The drive unit of the conveyor is under

the floorboard of the operating position.
Checking the oil level Only before the
work starts. The oil level must reach the upper notch of the dipstick (A).
Filling in the oil: After removing cover lid (B) through fill-in stub (C).

A On the dipstick about 10 cm corre-

sponds to about 0,25 l oil to be added.
The drive of the conveyor is filled in the
factory with Optimol Optigear 220 oil.
Owing to the excellent quality of the oil
filled in, there is no need for regular oil
change.
It is sufficient to regularly check the oil A
level in the drive (see chapter of mainte-
nance intervals).

m The above applies only if Optimol Op-

tigear 220 or oil of a similar quality from
another manufacturer is used.
B

F0151_A1.TIF/F0152_A1.TIF
F_3.0_01_GB.fm 4-4

F 3.0 4
 F 4.2 Maintenance - Auger
1 Maintenance - Auger sub-unit I
F_4.2_01_GB.fm 1-6

F 4.2 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Auger - outer bearing

1 q
Lubrication
- Auger central bearing
2 q
Lubrication
- Auger drive neck bearing
3 q
Lubrication
- Auger bevel gear
q
oil level check
- Auger bevel gear
4 q
topping up the oil
- Auger bevel gear
q
oil change

Maintenance q
Maintenance during run-in period g

F_4.2_01_GB.fm 2-6

F 4.2 2
 1.2 Points of maintenance

Auger - outer bearing (1)

The grease nipples (A) are located on

each side on the top of outer bearing.
These nipples must be lubricated each
time when work is finished.

A The outer bearings of the auger shall be

lubricated when hot, so that the eventual
bitumen residues are expelled. A

Schneckaula_Dyn.tif

Auger middle bearing (2)

Lubrication of central bearing (A) is per-

formed on the LH-side of the auger.
To do so, the bevel gear unit must be
pulled off.

A The central bearing shall be lubricated

when hot, so that the eventual bitumen
residues are expelled.

A
F_4.2_01_GB.fm 3-6

F0015_A1.TIF

F 4.2 3
 Auger - drive gear neck bearing (3)

Remove the hexagonal screw plug (A) in

the neck of the drive. Replace the screw
under it with a grease nipple 10x1. Using
a grease gun press in about 10 strokes
of grease.

A Thereafter, unscrew the grease nipple

and drive in both screws. The neck of the
drive is sealed downwards and is lubri-
cated with grease only.

F0139_A1.TIF

F_4.2_01_GB.fm 4-6

F 4.2 4
 Auger bevel gear (on the RH and LH
sides) (4)

- For checking the oil level unscrew

the inspection / filling plug (A).

A In case of proper oil level, the oil is at the

lower edge of the inspection port or a lit-
tle oil flows from the hole.

For filling in the oil:

- Remove the inspection / filling plug

(A).
- Fill oil of the correct specification
through the filling hole (A) until the oil
level reaches the lower edge of the in-
spection hole (A).
- Replace the inspection / filling plug
(A).

For changing the oil:

A Change the oil when the engine is at op-

A
erating temperature.

- Remove the inspection / filling plug (A)

and the drain plug (B). B
F0139_A1.TIF
- Drain the oil.
- Drive in the oil drain plug (C) again.
- Fill oil of the correct specification through the filling hole (A) until the oil level reach-
es the lower edge of the inspection hole (A).
- Replace the inspection / filling plug (A).

m Take care of cleanliness!

F_4.2_01_GB.fm 5-6

F 4.2 5
 F 5.1 Maintenance - Engine
1 Maintenance - engine sub-unit
F_5.1_01_GB.fm 1-12

m In addition to these Maintenance Instructions, the Maintenance Instructions of the en-

gine manufacturer must always also be observed. All other maintenance work and in-
tervals noted in these instructions are also binding.

F 5.1 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Fuel tank
q
Check the filling level
- Fuel tank
1 q
Refill with fuel
- Fuel tank
q
Clean the tank and device
- Engine lube-oil system
q
oil level check
- Engine lube-oil system
q
topping up the oil
2
- Engine lube-oil system
q
oil change
- Engine lube-oil system
q
oil filter change
- Engine fuel system
q Fuel filter (drain the water separa-
tor)
- Engine fuel system
q
3 replacement of the fuel pre-filter
- Engine fuel system
q
replacement of the fuel filter
- Engine fuel system
q
bleeding of fuel system

Maintenance q
Maintenance during run-in period g
F_5.1_01_GB.fm 2-12

F 5.1 2
 Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Engine air filter

q
checking of air filter
- Engine air filter
q
4 dust collecting bin emptying
- Engine air filter
q q Clean / Replace the filter car-
tridge
- Cooling system of the engine
q
Inspection of radiator fins
- Cooling system of the engine
q
Cleaning of the radiator fins
- Cooling system of the engine
q
Check the level of the coolant.
5 - Cooling system of the engine
q
topping up the coolant
- Cooling system of the engine
q
changing the coolant
- Cooling system of the engine
q Inspection of coolant
(additive concentration)
- Engine drive belt
q q
checking of drive belt
6
- Engine drive belt
q
tightening of drive belt
- Engine exhaust system
q (o)
checking of particle filter
7
- Engine exhaust system
g q q (o)
cleaning of particle filter
F_5.1_01_GB.fm 3-12

Maintenance q
Maintenance during run-in period g

F 5.1 3
1.2 Points of maintenance

Engine fuel tank (1)

- Check the filling level on the gauge

on the operating panel.

A Fill the fuel tank before each start of

work so that the fuel system cannot run
dry and this way the time consuming
venting (bleeding) can be avoided.

For filling in the fuel:

- Unscrew cap (A) (under the tank cov-

er).
A
- Fill in fuel through the filling port until
the required filling is achieved.
- Replace the cap (A).

Cleaning of tank and device:

- Unscrew the plug (B) at the bottom of

the tank and drain into a collection pan
about 1 lit fuel.
- After drainage screw back the plug
with a new seal ring.

Dieseltank.eps/HDieseltank_bot.bmp
F_5.1_01_GB.fm 4-12

F 5.1 4
 Engine lube-oil system (2)

Checking the oil level

A In case of correct oil level, the oil is be-

tween the two notches of the dipstick
(A).

A Check the oil level with a paver finisher

standing on a flat area!

m If there is too much oil in the engine, the

gaskets and seals may get damaged,
while too little oil can lead to the over-
heating of the oil and the damage of the
engine.

For filling in the oil:

- Remove cap (B).

- Fill in oil until the correct level is A
achieved.
- Return cap (B).
- Check the oil level once again using
the dipstick. D

Oil change:
B
A Change the oil when the engine is at op-
erating temperature.

- Remove the cover cap of the oil drain

port (C) and screw on the hose provid- C
ed as an accessory.
- Place the end of the hose in a dish to
catch the oil.
- Open the shutoff valve with a spanner
and let the oil fully drain.
- Shut off the valve, remove the hose
and return the cover cap.
- Fill in the oil of specified quality
through the filling port on the engine
F0112_A1.bmp
until the oil level rises to the correct
mark of the dipstick (A).
F_5.1_01_GB.fm 5-12

F 5.1 5
 Changing the oil filter:

A As part of the oil change mount the new filter after the used oil was drained.

- Untighten the filter (D) and clean its resting surface.

- Apply thin coat of oil to the seal of the new filter and fill the filter with oil before
mounting.
- Tighten the filter by hand.

A After mounting the oil filter check the oil pressure gauge and the proper tightness dur-
ing the trial operation. Check the oil level once again.

F_5.1_01_GB.fm 6-12

F 5.1 6
 Engine fuel system (3)

A The fuel filter system consists of three fil-

ters:

- Pre-filter (A) with water separator

- Two main filters (B)

A Depending on the machine, the pre-filter

is in the engine compartment or under
the tank lid!

Pre-filter - draining of water

A Empty the collection bin by the specified

intervals or when the engine electronic
indicates a fault.

- Drain the separated water at the tap (C), collect it, and close the tap again.

Change of pre-filter:

- Drain the separated water at the tap A A

(C), collect it, and close the tap again.
E
- Pull down the connection of the water
detector (D)
- Untighten the filter cartridge (A) with C
the collection sump using a pair of oil D F
filter tongs or oil filter strap and un-
screw it.
- Unscrew the collection sump (E) from
the filter cartridge and clean as re-
quired.
- Clean the sealing surface of the filter
holder.
- Apply a thin coat of oil to the gasket of
the collection sump, drive it under the
filter cartridge and tighten by hand.
- Apply a thin coat of oil to the gasket of
B B
the filter cartridges, drive them under
the holder and tighten by hand.
- Replace the connection of the water
detector (D)
F_5.1_01_GB.fm 7-12

F 5.1 7
 Replacement of the main filter:

- Untighten the filter (B) and clean its resting surface.

- Apply a thin coat of oil to the gasket of the new filter.
- Tighten the filter by hand.

A After mounting the filter check for proper tightness during the trial run.

Venting the filter:

- Release the bayonet-mount of the manual fuel pump (F) by pressing and twisting
counter-clockwise at the same time.
- The pump piston now can be displaced by a spring.
- Until strong resistance is felt and the pump moves already very slowly.
- Keep on pumping a few times. (Fill the return pipelines).
- Start the engine and run it for about 5 minutes at idling speed or under a slight load.
- Check the tightness of the pre-filter in the meantime.
- Close the bayonet-mount of the manual fuel pump (F) by pressing and twisting
clockwise at the same time.

F_5.1_01_GB.fm 8-12

F 5.1 8
 Engine air filter (4)

Emptying the dust collection bin

- Empty the dust collection valve (B) on

the air cleaner housing (A) by pressing
the discharge port in the direction of
the arrow.
- Discharge the eventually compacted
dust by pressing together the upper
part of the valve.

A Clean the discharge port from time to

time. D

Cleaning / replacement of the air filter

cartridge C B

Pollution of the filter of the combustion A

A
air depends on the dust content of the air
and the mesh size of the filter selected.

A The maintenance of the filter becomes

necessary if:
E
- The maintenance indicator (O) red
servicing field (C) is fully visible when C
the engine is stopped.
- When the engine electronic unit indi-
cates service need

- Open the air filter lid.

- Withdraw the filter cartridge (C) and the safety cartridge (D)

A Clean the filter cartridge (C) and replace min. after one year.

- Blow out with dry pressure air (max. 5 bar) from inside out or tap it (in case of emer-
gency only).

A The cartridges should not get damaged in the process.

- Check the soundness of the filter papers of the filter cartridge (by exposing to light)
and the soundness of the seals. Replace them as required.

A Replace the safety cartridge (D) after 5 filter maintenance, but min. after 2 years (nev-
F_5.1_01_GB.fm 9-12

er clean it!).

After completing the maintenance works:

- Press the reset button (E) of the maintenance indicator (O). The maintenance indi-
cator is ready for operation once again.

F 5.1 9
 Coolant system of the engine (5)

Checking / topping up of coolant

The coolant level is checked when the

engine is cold. Make sure that the anti-
freeze and anti-corrosive liquid us suffi-
cient (-25 C).

f When hot, the system is under pressure.

When opening, there is a danger of
scalding!

- If necessary fill in sufficient amount of

coolant through the open port (A) of
the compensating tank.

Changing the coolant

A

A See operating instructions for the engine

Checking and cleaning of the radiator

fins

- If necessary, remove leaves, dust or

sand from the radiator.

Engine drive belt (6)

Checking of drive belt/replacement

A See operating instructions for the engine

F_5.1_01_GB.fm 10-12

F 5.1 10
 Engine exhaust system (7)

Cleaning of particle filter

m As considerable amount of soot is accu-

mulated in the filter, the cleaning must
be performed under appropriate exhaust
system.

m Clean the filter element removed with

oil-free and grease-free pressure air!
a
- Marking the flow of direction of the ex-
haust gas on the filter case.
- Remove the filter element by untight-
ening the two clips (a).
- First blow out the inlet side.

m The pressure of the compressed air can

be max. 5 bars and the nozzle shall not
be closer to the filter edge than 10 cm.

- Carefully blow out all the filter passag-

es.
- Turn around the filter element, and re- Partikelfilter.eps
peat the process on the other side as
well.
- Repeat the process until no more carbon residue leaves the filter.
- Replace the filter element, taking care of the proper direction of flow.

A After cleaning for a short while more soot discharge is expected during operation.

- In case of sticky, oily soot the filter must be heated to about 450C and the cleaning
shall be carried out preferably with the hot filter.

m The filter shall not be cleaned with water/steam or detergent in any case!

f The carbon particles are harmful to your health! In case of filter change or cleaning,
wear appropriate protection gear!
F_5.1_01_GB.fm 11-12

F 5.1 11
 F 6.0 Maintenance - Hydraulic system
1 Maintenance - hydraulic system
F_6.0_01_GB.fm 1-8

F 6.0 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Hydraulic oil tank

q
Check the filling level
- Hydraulic oil tank
1 q
Top up with oil
- Hydraulic oil tank
q
oil change and cleaning
- Hydraulic oil tank
q Checking of maintenance indica-
tor
2
- Hydraulic oil tank
q q Intake / return
change of hydraulic filter, venting
- High pressure filter
q Checking of maintenance indica-
3 tor
- High pressure filter
q
replacement of filter cartridge
- Pump distribution gear
q
oil level check
- Pump distribution gear
4 q
topping up the oil
- Pump distribution gear
q
oil change
- Hydraulic hoses
q
observation
5
- Hydraulic hoses
q q
Replace the hoses

Maintenance q
F_6.0_01_GB.fm 2-8

Maintenance during run-in period g

F 6.0 2
 1.2 Points of maintenance

Hydraulic oil tank (1)

- Oil level check on dipstick (A).

A In case of retracted cylinders the oil level

shall be at the upper mark.

For filling in the oil:

- Remove cap (B).

- Fill in oil through the filling port until the
required filling level is achieved on the
dipstick (A). A
- Return cap (B).

A Regularly clean the vent port of the oil

tank from dust and pollution. Clean the B
surfaces of the oil cooler.

m Use only the recommended hydraulic

oils - see section Recommended hy-
draulic oils.

For changing the oil:

- To drain the hydraulic oil unscrew the

drain plug (C) at the bottom of the
tank.
- Collect the oil in a bin using a funnel.
- After drainage screw back the plug
with a new seal ring.

A Change the oil when the engine is at op-

erating temperature. C

m When changing the hydraulic oil also

change the filter.

Hytank_dip.wmf/Hydtank_bot.bmp
F_6.0_01_GB.fm 3-8

F 6.0 3
 Suction/return flow hydraulic filter (2)

Change the filter by the intervals speci-

fied or when the maintenance indicator
(A) at a hydraulic oil temperature of 80C
comes to the red mark.

A The temperature of the hydraulic oil can

be read on the hydraulic temperature in-
dicator (O) at the operating position.

m When changing the hydraulic oil also

change the filter. B

- Remove the lid fastening screws (B)

and remove the lid.
- Disassemble the withdrawn unit into
the following parts:
- lid (C) A
- separating plate (D)
H
- filter (E)
- dirt collection cage (F)
- Clean the filter case, the lid, the sepa-
rating plate and the dirt collection
G
cage.
- Check and replace the O-rings (G)
when required.
- Wet the seal surfaces and the O-ring
with clean fuel.

F E D C

Hydtank_V2.eps/Montage2.eps/Hydtank_V2a.eps
F_6.0_01_GB.fm 4-8

F 6.0 4
 Venting the filter:

- Fill the open filter case with hydraulic oil to about 2 cm below the upper rim.
- Should the oil level drop, top up with oil.

A The slow sinking of the oil level by about 1 cm/min is normal!

- When the oil level remains steady, mount the assembled unit with the new filter car-
tridge, carefully into the housing and tighten the locking screws of the lid (B).
- Open the vent screw (H).
- Mount a transparent hose (l) on the vent screw and lead it into an appropriate con-
tainer.
- Start the traction engine at idling speed.
- Shut-off the bleeding screw (H) as soon as the oil discharged through the hose is
clean and free of bubbles of air.

A The process from the mounting of the filter lid until starting the engine shall take place
within 3 min or else the oil level drops too much in the filter case.

m Check the seal after changing the filter.

F_6.0_01_GB.fm 5-8

F 6.0 5
 High pressure filter (3)

Replace the filter cartridge when the

maintenance indicator (A) turns red.

- Unscrew filter house (B).

- Remove the filter cartridge
- Clean the filter house.

- Insert the new filter cartidge.

A
- Replace the seal ring of the filter hous-
ing.
- Turn on the filter housing by hand and
tighten it using a wrench.
- Start the trial operation and check the
tightness of the filter.
B
A Replace the seal ring whenever the filter
cartridge is replaced.

A After the replacement of the filter car-

tridge the red signal of the maintenance
indicator (A) automatically reverts to
green.
Hochdr.bmp

F_6.0_01_GB.fm 6-8

F 6.0 6
 Pump distribution gear (4)

- Oil level checking on the viewing

glass (A) (at the side of the distribution
box).

A The oil level must be up to the center of

the viewing glass.

For filling in the oil:

B
- Unscrew the filling in screw plug (B).
- Fill in oil through the filling port until the
required filling level is achieved on the
viewing glass (A).
- Return filling screw plug (B).

m Take care of cleanliness!

Oil change:

Change the oil when the engine is at op-

erating temperature.

- Remove the cover cap of the oil drain

port (C) and screw on the hose provid-
ed as an accessory.
- Place the end of the hose in a dish to
catch the oil.
A
- Open the shutoff valve with a spanner
and let the oil fully drain.
- Shut off the valve, remove the hose
and return the cover cap.
- Fill in the oil of specified quality
through the filling port on the distribu-
C
tion box (B) until the oil level rises to
the center of the viewing glass (A).

PVG2.wmf/PVG_Glas.wmf/F0112_A1.bmp
F_6.0_01_GB.fm 7-8

F 6.0 7
 Hydraulic hoses (5)

- Check the condition of the hydraulic

hoses specifically.
- Immediately replace the injured hos-
es.

f The aged hoses may become porous

and burst! Risk of accident!

A The numbers stamped in the joints of the

hoses state the date of manufacture (A)
and the maximum pressure (B) allowed
for that hose.

m Do not fit hoses, which were in storage

for a long time and check the permitted
pressure rating.

A B

PVG2.wmf
DHH 09/00 225BAR

F_6.0_01_GB.fm 8-8

F 6.0 8
 F 7.4 Maintenance - travel drive, steering
1 Maintenance - travel drive, steering
F_7.4_01_GB.fm 1-6

F 7.4 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Checking the oil level of

q
the planetary gear
- Checking the oil level of
1 q
the planetary gear (drive)
- Planetary gear (drive) -
q
Change the oil
- Air pressure (drive wheels) -
q
check
2
- Air pressure (drive wheels) -
q
adjust
- Lubrication points -
q
lubrication of axle stubs
- Lubrication points -
q
lubrication of steering
3
- Lubrication points -
q
lubrication of swing axle
- Lubrication points -
q
lubrication of swing axle

Maintenance q
Maintenance during run-in period g
F_7.4_01_GB.fm 2-6

F 7.4 2
 1.2 Points of maintenance

Planetary gear (1)

- For checking the oil level unscrew

the inspection plug (A).

A In case of proper oil level, the oil is at the

lower edge of the inspection port (A) or a
little oil flows from the hole.

For filling in the oil:

- Remove the inspection plug (A) and

filling plug (B).
- Fill oil of the correct specification
through the filling hole (B) until the oil
level reaches the lower edge of the in-
spection hole (A). B
- Replace the inspection plug (A) and C
filling plug (B).

Oil change:

A Change the oil when the engine is at op- A

erating temperature.

m Make sure that no pollution or foreign

matter gets into the drive. Pgear634.bmp

- Stop the machine so that the TOP is at the topmost position and the drain plug
(C) is at the bottom.
- Unscrew the drain plug (C) and the filling plug (B) and drain the oil.
- Check and replace the seals of both screw plugs.
- Return drain plug (C).
- Remove the inspection plug (A).
- Fill oil of the correct specification through the filling hole (B) until the oil level reach-
es the lower edge of the inspection hole (A).
- Replace the inspection plug (A) and filling plug (B).
F_7.4_01_GB.fm 3-6

F 7.4 3
 Air pressure (driving wheels) (2)

Check/adjust the belt tightness

A The required tyre pressure is stamped in

each wheel rim and marked by colour
(A).

Check the air pressure in valve (B) and

adjust as required.
B

Pgear634.bmp

F_7.4_01_GB.fm 4-6

F 7.4 4
 Places of lubrication (3)

Axle stubs
5x
A A grease nipple (A) is fitted in each of the
four axle stubs. A

Steering

A The grease nipple (B) is located on the

right side wall and the steering linkage
is supplied with grease through a lubri-
cation line. B C D
F0149_A1.TIF

Swing axle

A Grease nipple (C) is located on the RH and LH sides on the central bearing of the
swing axle.

Wheel bearing

A The grease nipples (D) are found on the wheel hub at each wheel.
There is no grease nipple in the driven wheel in case of front-wheel drive.
F_7.4_01_GB.fm 5-6

F 7.4 5
 F 8.0 Maintenance - Electronic System
1 Maintenance - Electronic System
F_8.0_01_GB.fm 1-20

F 8.0 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

q Check the level of battery electrolyte

1 q Top up with ion exchanged water

q Coat the battery poles with grease

Maintenance q
Maintenance during run-in period g

F_8.0_01_GB.fm 2-20

F 8.0 2
 Interval

as required
No.
Points of maintenance Remark

20000
1000
5000
100
250
10
50

Also see
- Generator
the opera-
Operational checking of the insu-
q tion manu-
lation supervision of electrical
al of the
equipment
screed

- Generator
Visual checking for pollution or
damage
q (o)
- Check the cooling air openings for
pollution or clogging, clean as re-
quired.
- Generator
Check the ball bearings by listen-
q (o)
2 ing and replace them as re-
quired.
- Generator
q q (o)
Replacement of ball bearings
- Generator
q Check the drive belts (o) for inju- (o)
ry and replace them as required.

(o)
- Generator
Only on
q Drive belts (o) - check tightness
version with
and adjust as required.
V-belt!

- Generator
q (o)
Replacement of drive belts (o)

Maintenance q
Maintenance during run-in period g
F_8.0_01_GB.fm 3-20

F 8.0 3
 Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

3 q Electric fuses

Maintenance q
Maintenance during run-in period g

F_8.0_01_GB.fm 4-20

F 8.0 4
 1.2 Points of maintenance

Batteries (1)

Maintenance of storage batteries

The batteries are filled with the appropri-

ate volume of electrolyte in the factory.
The electrolyte level shall be up to the
top mark. Top up with ion exchanged
water only, when required!

The shoes shall be free of oxyde and

coated with special battery protection
grease.

m When removing the batteries always

separate the minus pole first and avoid
short circuit between the battery poles.

Tankhood_LH.eps
F_8.0_01_GB.fm 5-20

F 8.0 5
 Generator (2)

Checking of operation of the insulation monitoring

A Check insulation daily with operating

machine and switched on connection
sockets.

- Turn on the electrical equipment with

switch (1), control light (2) comes on.
- Press testing button (3) and the in-
scription Isolationsfehler - Insulation
Fault shall come on. 2 1
- Depress the button clear (4) and the
insulation fault inscription will go dark. 3 4

f If the test is completed successfully,

work can proceed with the electrical sys-
tem and external consumers can be
used.
If the Insulation Fault control light indi-
cates a fault already before pressing the
control button, then work cannot pro-
ceed with the electrical system and the
external consumers. In case of insula-
tion fault the connection sockets are au- Schalt_230V.wmf/230V.wmf
tomatically turned off.
Work with the electric system cannot proceed if the simulation does not indicate a fail-
ure.

f In case of failures, the electric equipment needs to be tested and repaired by an elec-
trician. With these devices and the equipment work can be resumed only after such
test and repair.

Danger from electric voltage

Failure to comply with the safety precautions and safety regulations can result
in electrical shock injuries from the electrical system.
Danger to life!
All maintenance and repair work on the electrical system must always be car-
ried out by an electrician!
F_8.0_01_GB.fm 6-20

F 8.0 6
 Checking of ball bearings / Replace-
ment of ball bearings

A Report the displayed fault code to the

customer service of the paver finisher
and they will discuss with you the steps
to be taken.
F_8.0_01_GB.fm 7-20

F 8.0 7
 Drive belts (V-belt)

Checking belt tension

The tightness of each belt shall be in-

spected with a tightness checking instru-
ment.

Specified tension:

- in case of first assembly: 550 N

- after the run-in period /
maintenance interval: 400N Riemensp.tif

A Instructions for checking of tightness in

the description of the tightness measuring instrument.

A The tightness measuring instrument can be ordered according to the Article No.
532.000.45!

Adjustment of belt tightness

- Untighten locking screw (A) so that the

bracket (B) of the tightening roller
comes to position zero (scale (C) =
0).
- For the adjustment of the locking de-
vice loosen or turn the appropriate nut
(D) or counter-nut (E), until the tight-
ening roller contacts the loosened up-
per belt.
- Turn the bracket of the tightening roll A
(B) to adjust the correct tightness, to-
wards the upper belt (scale (C) = 15).
- Retighten locking bolt (A).
C
- Retighten the previously loosened nut
(D) or (E).

Replacement of belt B E

- Reduce the belt tightness on the ad-

justing device so that the belt can be D
removed from the pulley.
- Mount the new belt and adjust tight-
ness again.
F_8.0_01_GB.fm 8-20

A Always replace the belts in sets. Generator_belt.wmf/Generator_spann.wmf

F 8.0 8
 Drive belt (toothed belt)

Replacement of belt
A A
- Unfasten both lock nuts (A) from the
clamping lock.
- Rotate and open clamping lock (B) un-
til belt (C) can be replaced.

A Pre-tension newly fitted belt using B

clamping lock (B). A

- Checking / adjusting belt tension

Riemenspann.jpg
B
F_8.0_01_GB.fm 9-20

F 8.0 9
 Checking / adjusting belt tension:

A The tension of the V-belt must be

checked and set after the belt has been
replaced.

- The tension of the belt can only be ad-

justed using a pre-tensioning test de-
vice.
Deflection
Specified belt tension levels: (read from
bottom to top)
- Generator 17KVA:
- Deflection force, min: 101.4N
- Deflection force, max: 110.6N Rubber rings
Deflection
- Belt deflection approx. 9.9mm

- Generator 20KVA: Redirection

- Deflection force, min: 72.4N (read from

- Deflection force, max: 79.0N bottom to top)

- Belt deflection approx. 5.4mm Belt deflection

Read off directly below the ring. Before you use the
- Generator 28KVA: voltage tester again, slide the ring back down again.

- Deflection force, min: 92.2N Riemenspann.jpg

- Deflection force, max: 100.5N

- Belt deflection approx. 5.4mm

If necessary, adjust the belt tension:

A A
- Set belt to correct tension using
clamping lock (B).
- Retighten both lock nuts (A).

A Further instructions for checking of ten-

sion - see description of the belt pre-ten- B
sioning test device. A

A A belt pre-tensioning test device can be

ordered from Dynapac as a spare part!
Item number on request.
F_8.0_01_GB.fm 10-20

Riemenspann.jpg
B

F 8.0 10
 Electric fuses (3)

Type of machine: Conventional electronics

Terminal box

B C
A

Fuses_635_konv.eps

A Main fuses

B Fuses in terminal box

C Relays in terminal box

Main fuses (A)

F. A

3.1 Main fuse 50

3.2 Reserve / auxiliary lighting 50

F_8.0_01_GB.fm 11-20

F 8.0 11
 Fuses in terminal box (B)

F5.5

!
F. A
5.1 Travel drive 7,5
5.2 Differential lock, ASC 5
5.3 Temperature control, electric heating 10
5.4 Power supply to screed gas heater 10
5.5 Integrated receptacles 10
5.6 Integrated receptacles 10
5.7 Integrated receptacles 10
5.8 Integrated receptacles 10
5.9 Engine start 10
41 Power supply for engine control 25
51 Diesel spray pump 3
52 Emulsion spraying system 3
53 Diesel tank filler pump 5
54 Rotary beacon 3
55 Lighting on glassfibre-reinforced roof 10
59 Working lights (o) 15
84 Seat heating 10
F_8.0_01_GB.fm 12-20

85 Windscreen wiper 7,5

86 Reserve 10
89 Travel drive (brake light) 2

F 8.0 12
 Relays in terminal box (C)

!
K

15 Engine start

18.1 Screed hazard warning flasher, left

18.2 Screed hazard warning flasher, right

42 Power supply for travel drive

44 Compactor lift

52 Engine changeover, travel drive

53 Engine changeover, travel drive

83 Speed raising for screed heater

88 Auxiliary emergency stop

94 Engine feedback control

148 Speed raising for screed heater

145 Engine feedback control

F_8.0_01_GB.fm 13-20

F 8.0 13
 Fuses on operating panel

A B

A
1 2 3 4 5 6 7 8

B
1 2 3 4 5 6 7 8

Bedienpult_konv_Kette_635_Fuse1/Fuse1.tif/Fuse.bmp

Fuse carrier (A)

No. F. A
1. 1.1 Engine start, start interlock, idle speed, reverse buzzer 5
2. 1.2 Locking relay, relay batt. 15+, monitoring equipment 3
3. 1.3 Levelling unit, screed stop 5
4. 1.4 Conveyor, auger, right 5
5. 1.5 Conveyor, auger, left 5
6. 1.6 Tamper, vibration, ASC ON/OFF 3
Hoppers, lifting/lowering screed, extending/retracting
7. 1.7 screed, power supply screed, compactor lift (o), mov- 10
ing cab (o), lifting/lowering auger (o)
8. 1.8 Emergency stop 7.5

Fuse carrier (B)

No. F. A
1. 2.1 Hazard warning flashers, flasher, right 5
2. 2.2 Hazard warning flasher, flasher, left, horn 3
3. 2.3 Brake light 7,5
4. 2.4 High-beam headlights, left/right 7,5
5. 2.5 Low-beam headlights, right 3
6. 2.6 Low-beam headlights, left 3
F_8.0_01_GB.fm 14-20

7. 2.7 Parking lights, right 3

Parking lights, left, instrument panel lighting,
8. 2.8 3
instrument panel lighting

F 8.0 14
 Relays in operating panel

!
Bedienpult_konv_Rad_656_Fuse3.wmf

Relays

11 Engine idling speed

12 Conveyor/auger, left

13 Conveyor/auger, right

17 Screed function

32 Flasher sensor (lighting)

33 Engine stop

39 Start interlock

80 Timer relay, revers. conveyor, right

81 Timer relay, revers. conveyor, right

149.1 Priority circuit for extending/retracting screed, left

149.2 Priority circuit for extending/retracting screed, right

133 Function interlock (Italy)

F_8.0_01_GB.fm 15-20

F 8.0 15
 Type of machine: PLC electronics

Terminal box

B C
A

Fuses_635_konv.eps

A Main fuses

B Fuses in terminal box

C Relays in terminal box

Main fuses (A)

F. A

3.1 Lighting, engine 50

3.2 Lighting, engine 50

F_8.0_01_GB.fm 16-20

F 8.0 16
 Fuses in terminal box

F5.5

!
F. A

5.1 Travel drive 7,5

5.2 Differential lock, ASC 5

5.3 10

5.4 Screed power supply 10

5.5 Integrated receptacles 10

5.6 Integrated receptacles 10

5.7 Integrated receptacles 10

5.8 Integrated receptacles 10

5.9 Engine start 10

7.1 Slave A51 5

7.2 Slave A52 5

7.3 Slave A53 5

7.4 Slave A54 5

F_8.0_01_GB.fm 17-20

7.5 Slave A55 5

7.6 Slave A56 5

41 Engine feedback control 25

F 8.0 17
 F. A

51 Spraying system 3

52 Emulsion spraying system 3

53 Diesel tank filler pump 5

54 Rotary beacon 3

55 Lighting on glassfibre-reinforced roof 10

59 Working lights (o) 15

80 Power supply, Master A1 5

82 Particulate filter (o) 3

83 Asphalt fume control system (o) 3

84 Seat heating 10

85 Windscreen wiper 7,5

86 Reserve 10

88 Power supply, Master A1 7,5

F_8.0_01_GB.fm 18-20

F 8.0 18
 Relays in terminal box (C)

!
K

15 Engine start

30 Horn

42 Travel drive

47 Start interlock

49 Reverse buzzer

52 Engine changeover, travel drive

53 Engine changeover, travel drive

94 Engine

145 Engine feedback control

F_8.0_01_GB.fm 19-20

F 8.0 19
 Fuses on operating panel

A B

A
1 2 3 4 5 6 7 8

B
1 2 3 4 5 6 7 8

Bedienpult_konv_Rad_635_Fuse1/Fuse1.tif/Fuse.bmp

Fuse carrier (A)

No. F A
1. 1.1 Emergency stop 7.5
Monitoring equipment, relay batt. 15+,, engine
2. 1.2 3
sensors
3. 1.3 Display power supply 3
4. 1.4 Keyboard power supply 3
5. 1.5 Free
6. 1.6 Free
7. 1.7 Screed power supply (o), moving cab 5
8. 1.8 Free

Fuse carrier (B)

No. F. A
1. 2.1 Hazard warning flashers, flasher, left 5
Hazard warning flashers, flasher, right, horn, reverse
2. 2.2 3
buzzer
3. 2.3 Brake 3
4. 2.4 High-beam headlights, left/right 7,5
5. 2.5 Low-beam headlights, right 3
6. 2.6 Low-beam headlights, left 3
F_8.0_01_GB.fm 20-20

7. 2.7 Parking lights, right 3

Parking lights, left, instrument panel lighting
8. 2.8 3
Instrument panel lighting

F 8.0 20
 F 9.0 Maintenance - Points of lubrication
1 Maintenance- Points of lubrication

A The information related to the lubrication points of the various sub-units are included
F_9.0_01_GB.fm 1-8

in the specific maintenance descriptions and additional reading is recommended as

follows.

A In case of applying a central lubrication unit (o) the number of the lubrication points
may differ from the data provided in the description.

F 9.0 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

- Check the filling level of the lubri-

q (o)
cant tank

q - Fill up the lubricant tank (o)

1 q - Vent the central lubrication unit (o)

q - Check the pressure limiting valve (o)

- Check the leakage of the lubri-

q (o)
cant at the consumer unit

2 q - Bearings

Maintenance q
Maintenance during run-in period g

F_9.0_01_GB.fm 2-8

F 9.0 2
 1.2 Points of maintenance

Central lubrication (1)

Danger of injuries!

f Do not reach into the tank when the

pump is running.

f Operate the central lubrication system

with a mounted safety valve only!

f During operation do not perform mainte-

nance operations on the safety valve!
Handverl.jpg/Gefahr.jpg

f The lubricant ejected may cause injuries as the equipment operates under high pres-
sure!

f Make sure that the starting of the diesel engine should be prohibited while work is per-
formed on the equipment!

f Observe the rules applicable to the operation of the hydraulic equipment!

m Take care of perfect cleanliness when work is performed on the central lubrication
system.

The lubrication points of the following

units can be provided with grease
through the central lubrication system:

- Feeder
- Auger
- Steering, axles (wheel type paver fin-
isher)

Lincoln3.jpg
F_9.0_01_GB.fm 3-8

F 9.0 3
 Central lubrication unit
Check the filling level

A The lubrication tank shall always be

filled so that the system could not run
dry and the proper lubrication of the
points of lubrication is ensured and there a
is no need for a time consuming venting
operation.

- Always keep the filling level above the

MIN mark of the tank (a).

Lincoln3.jpg/Lincoln4.jpg

Fill up the lubricant tank

Lincoln3.jpg/Grease2.wmf/Greasegun.wmf
b

- A grease nipple (b) is mounted for filling on the lubricant tank (a).
- Connect the grease gun (c) supplied with the machine to the filling head (b) and fill
the lubricant tank (a) until the MAX mark.

A In case of an empty lubricant tank the pump may work for even 10 minutes before is
reaches its full delivery performance after filling.
F_9.0_01_GB.fm 4-8

F 9.0 4
 Vent the central lubrication unit

The venting of the lubrication system be- c

comes necessary if the central lubrica-
tion unit was operated with an empty
lubrication tank. a

- Untighten the main line (a) of the lu-

brication pump at the flow divider (b). d
- Start the operation of the central lu-
brication unit with the refilled lubri-
cant tank (c).
- Leave the pump running until grease d
is squeezed from previously untight-
ened main line (a).
b
- Retighten the main line (a) at the Lincoln3.jpg/Lincoln4.jpg
flow divider.
- Remove all the manifold lines (d) at the flow divider.
- Reconnect again the manifold lines once lubricant is discharged through them.
- Check the tightness of all the connections and lines.

Check the pressure limiting valve

m If lubricant is discharged at the pressure

limiting valve (a), this refers to failure in
the system.
The consumers receive not enough lu-
bricant.

- Disconnect the manifold lines (b),

which run from the flow divider (c) to
the consumers, one after the other.
- If lubricant is ejected from one of the
disconnected distribution pipes (b)
under pressure, then the clogging, a
which led to the tripping of the pres-
sure limit valve, must be searched
for in this lubrication circuit. b
- After correcting the fault and the re-
peated connection of all the lines,
check once again for lubricant dis- b
charge from the pressure limit valve
(a).
- Check the tightness of all the con- c
nections and lines. Lincoln3.jpg/Lincoln4.jpg/Lincoln5.jpg
F_9.0_01_GB.fm 5-8

F 9.0 5
 Check the leakage of the lubricant at
the consumer unit
a
Check the continuity of all the lubrication
canals at the consumers.

- Disconnect the lubrication pipe (a)

and fit a standard grease nipple (b).
- Connect the grease gun (c) supplied
with the machine to the grease nip-
ple (b).
- Keep on operating the grease gun
until lubricant is visibly discharged. b
c
- If necessary, eliminate the faults of
the lubricant flow.
- Refit the lubricant pipelines.
- Check the tightness of all the con- Lincoln6.jpg/Lincoln8.jpg/Greasegun.wmf
nections and lines.

F_9.0_01_GB.fm 6-8

F 9.0 6
 Bearings (2)
2x
There are grease nipples on the bearing
points of the hydraulic cylinder (one
each, at the top and bottom) (a).

Zylinder.bmp
F_9.0_01_GB.fm 7-8

F 9.0 7
 F 10.0 Checks, decommissioning
1 Tests, check-up, cleaning, stopping
F_10.0_01_GB.fm. 1-6

F 10.0 1
1.1 Maintenance intervals

Interval

2000 / 2 years
as required
1000 / year
No.
Points of maintenance Remark

100
250
500
10
50

1 q - General observation

2 q q - Checks by a specialist

3 q - Cleaning

4 q - Conservation of paver finisher

Maintenance q
Maintenance during run-in period g

F_10.0_01_GB.fm. 2-6

F 10.0 2
 2 General observation

The daily practice includes the walk around the machine with checking the following
items:

- Are there injuries on the parts or control elements?

- Are there leaks on the engine, the hydraulics, the gear box, etc.?
- Are all the locking points secure (conveyor, auger, screed)?

m Repair the detected faults immediately in order to avoid risks of accidents and envi-
ronmental pollution!

3 Checks by a specialist

A Subject the paver finisher, the screed and the optional gas or electric operated equip-
ment to checks by a specialist

- as required (according to the circumstances of application and operating condi-

tions),
- however, minimum once a year, so that the machine retains its reliable operating
condition.
F_10.0_01_GB.fm. 3-6

F 10.0 3
4 Cleaning

- Clean all parts which come into contact with the material to be laid.
- Spray the polluted parts with the separating agent spray equipment (o).

m Before cleaning with high pressure jet, lubricate all the bearings with grease as spec-
ified.

- Clean the machine with water after laying mineral mixes, lean concrete etc.

m Do not spray water on the bearings,

electric or electronic parts.

- Remove the residue of the material

laid.

m After cleaning with high pressure jet, lubricate all the bearings with grease as speci-
fied.

f Risk of slipping! Take care of the clean-

liness of the walkways and steps, make
sure that they are free of grease and oil.

F_10.0_01_GB.fm. 4-6

F 10.0 4
 5 Conservation of paver finisher

5.1 Downtime up to 6 months

- Stop the machine in a place protected from intensive sunshine, wind, moisture and
frost.
- Lubricate all the lubrication points with grease as specified, use the optional central
lubrication unit as appropriate.
- Change the oil in the Diesel engine
- Tightly seal the muffler of the exhaust pipe.
- Remove the batteries, charge and store them at room temperature in well ventilat-
ed premises.

m Recharge the dismounted batteries every 2nd month.

- Protect all shiny metal surfaces, e.g. piston rods of the hydraulic cylinder against
corrosion using an appropriate agent.
- If the machine cannot be halted in a closed hall or under a shed, it must be covered
with an appropriate canvas. In each case all the air inlets and outlets shall be tightly
sealed using plastic film and adhesive tape.

5.2 Downtime between 6 months and 1 year.

- Perform all operations described for Downtime up to 6 months.

- After draining the engine oil, fill the engine with conservation oil permitted by the
manufacturer of the engine.

5.3 Re-commissioning:

- Perform the operations opposite to what were described in the section Downtime.
F_10.0_01_GB.fm. 5-6

F 10.0 5
 F 11.3 Lubricants and operating
substances
1 Lubricants and operating substances

m Use only the lubricants listed below or comparable qualities of well-known brands.

Use only clean containers (inside and outside) for pouring oil or fuel in.

A Pay attention to the correct filling volumes (see the section Filling volumes).

m Incorrect oil or lubricant levels promote rapid wear and cause the paver finisher to fail.

m Never mix synthetic oils with mineral oils!

Total Fina
BP Esso Mobil Renault Shell Wisura
(Total)

SHELL
BP Multi-pur- ESSO Multi-
Total Mobilux 2 Alvania
Grease pose grease Multi-pur- purpose Retinax A
Multis EP 2 Mobiplex 47 Grease EP
L2 pose grease grease
(LF) 2

See operating instructions for the engine

Engine oil
Shell Remula Super-FE 10 W 40 has been filled at the factory.

See (see section 1.1)

Hydraulic oils
Shell Tellus Oil 46 has been factory-filled.
SHELL
BP Multi ESSO MOBIL Tranself
Gear oil 90 Total EP 90 Spirax G
EP SAE 90 GP 90 GX 90 EP 90
80 W - 90

MOBIL
Chevron
BP ESSO Mobilgear Optimol
Total Carter NL Gear SHELL
Energol Spartan 630 Optigear
Gear oil 220 EP 220 Compound Omala 220
GR-XP 220 EP 220 Mobil-gear 220
220
SHC 220

Optimol Optigear 220 has been factory-filled.

Shell
Optimol
Transaxle
Planetary gear Optigear
SAE
Travel drive 220 **
75W-90 *

Optimol Optigear 220 has been factory-filled.

Dist. water

Diesel fuel

BP
Brake oil, ATE disk
Blue original Total HB F 4 ELF
brake fluid brake fluid
Brake fluid

Cooling liquid (anti-freeze and corrosion protection)

Cooling liquid
AGIP Antifreeze Spezial 956.99.58.15
F_11.3_01_GB.fm 1-8

* Synthetic oil
** Mineral oil

F 11.3 1
1.1 Hydraulic oils

Preferred hydraulic oils:

a) Synthetic hydraulic liquids based on ester, HEES

Manufacturer ISO viscosity class VG 46

Shell Naturelle HF-E46

Panolin HLP SYNTH 46

Esso HE 46

Total Fina Elf Total Biohydran SE 46

b) Mineral oil pressure fluids

Manufacturer ISO viscosity class VG 46

Shell Tellus Oil 46

Total Fina Elf Total Azolla ZS 46

m When switching from mineral oil pressure fluids to biodegradable pressure fluids,
please contact our factory advisors!

A Use only clean containers (inside and outside) for pouring oil or fuel in.

F_11.3_01_GB.fm 2-8

F 11.3 2
 1.2 Filling volumes

Operating substance Volume

Fuel tank Diesel fuel 280 litres

Hydraulic oil reservoir Hydraulic oils 175 litres

Pump distribution gear Gear oil 90 4.5 litres

see the section

Planetary gear
"Lubricants and operat- 2.8 litres
Travel drive **
ing substances"

Drive axle (differential)*** Gear oil 90 18.0 litres

Conveyor gear transmission

Gear oil 220 1.5 litres
(each side)

Central lubrication system

Grease
(option)

Batteries Distilled water

** Only on planer-finishers with wheel drive (direct drive)

*** Only on planer-finishers with wheel drive (manual gearbox)
F_11.3_01_GB.fm 3-8

F 11.3 3
 Engine type Deutz TCD 2013 L06 2V

Deutz_2013L06

Operating substance Volume

Diesel engine
Engine oil 10W40 20,0 litres
(with oil filter change)

Cooling system of the engine Coolant 20,0 litres

Engine type Deutz TCD 2013 L04 2V

Deutz_2013L06

Operating substance Volume

Diesel engine
Engine oil 10W40 15,0 litres
(with oil filter change)
F_11.3_01_GB.fm 4-8

Cooling system Coolant 20,0 litres

F 11.3 4
 Engine type Deutz TCD 2012 L06 2V

Deutz_2013L06

Operating substance Volume

Diesel engine
Engine oil 10W40 21,5 liters
(with oil filter change)

Cooling system of the engine Coolant 20,0 liters

Engine type Cummins QSB 6.7 C190, C205, C220

Cummins_QSB6.7.tif

Operating substance Volume

Diesel engine
Engine oil 10W40 16,5 liters
(with oil filter change)
F_11.3_01_GB.fm 5-8

Cooling system Coolant 20,0 liters

F 11.3 5
 Auger type I

Auger_Dyn.bmp

Operating substance Volume

Auger bevel gear (each side) Gear oil 90 0.6 litres

Auger type II

Auger_DEM.bmp

Operating substance Volume

Planetary gear
Gear oil 90 0.5 litres
Augers (each side)

Auger box Gear oil 460 2.5 litres

F_11.3_01_GB.fm 6-8

Outer auger bearing

Hot bearing grease 115 grammes
(per bearing)**

** for new installation

F 11.3 6
 2 Notes on changing over from mineral oil to synthetic oil / synthetic oil to min-
eral oil

2.1 Track planetary gear

m Never mix synthetic oils with mineral oils!

- Always drain used oil completely.

A The oil should be changed when at oper-

ating temperature.

- Flush out assembly with the new

grade of oil to be used.
- Operate track for 10 minutes for
flushing purposes.
- Top up correct grade of oil in accord-
ance with the relevant maintenance
instructions.
F_11.3_01_GB.fm 7-8

F 11.3 7
TRAINING/EDU-
CATION
We offer our Customers various
training programmes on DYNAPAC
equipment in our specialised training
centre in our factory. We hold train-
ing sessions also for special arrange-
ments in addition to courses and
programs held on fixed dates

SERVICE
In case of operational failures and questions
related to parts, please, contact one of our au-
thorised service representations. Our skilled
specialists will arrange for the fast and pro-
fessional repair.

OPERATING ADVICE
Anytime when our dealers cannot help you,
please, feel free to contact us directly. The
team of our "Technical Advisors" is at your
disposal.
Dont hesitate to contact
your local dealer for:
service
spare parts
documentation
accessories
and
information
about the complete
Dynapac
paving and planing
range