DYNAPAC Paver finisher F 121 C, F 141 C Type 635. Operation & Maintenance (Order number: 4812026925)

Table of contents

Preface

General safety instructions

1.1

Acts, directives, accident prevention regulations

1.2

Warning instructions

1.3

Prohibitive signs

1.4

Protective gear

1.5

Environmental protection

1.6

Fire prevention

1.7

Further instructions

Correct use and application

Vehicle description

Application

Description of assemblies and functions

2.1

Vehicle

Construction

Danger zones

Safety devices

4.1

Emergency stop button

4.2

Steering system

4.3

Horn

4.4

Ignition key / lights

4.5

Main switch (17)

4.6

Hopper transport safeguards (18)

4.7

Screed transport safeguard (19)

4.8

Latch for protective roof (20)

Technical data, standard configuration

5.1

Dimensions (all dimensions in mm)

5.2

Allowed angle of rise and slope

5.3

Allowed angle of driving up

5.4

Weights F 121 C (all weights in t)

5.5

Weights F 141 C (all weights in t)

5.6

Performance data F 121 C

5.7

Performance data F 141 C

5.8

Traction drive/chassis

5.9

Engine F 121 C

5.10

Engine F 141 C

5.11

Hydraulic system

5.12

Material compartment (hopper)

5.13

Material conveying

5.14

Material distribution

5.15

Screed lifting device

5.16

Electrical system

Location of instruction labels and identification plates

6.1

Identification label for the paver finisher (6)

EN standards

7.1

Continuous sound level F121C, Deutz TCD 2012L06

7.2

Operating conditions during measurement

7.3

Measuring point configuration

7.4

Continuous sound level F141C, Deutz TCD 2013L06

7.5

Operating conditions during measurement

7.6

Measuring point configuration

7.7

Vibration acting on the entire body

7.8

Vibrations acting on hands and arms

7.9

Electromagnetic compatibility (EMC)

C1.1

Transportation

Safety regulations for transportation

Transportation on low-bed trailers

2.1

Preparations

2.2

Driving onto the low-bed trailer

2.3

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

2.4

After transportation

Transportation

3.1

Preparations

3.2

Traction drive:

Loading by crane

Towing

Safely parking the vehicle

D1.1

Operation

Safety regulations

Operating elements

2.1

Operating panel

Remote control

D2.0

Operation

Operation of the input and display terminal

Allocation of the keyboard of the display

1.1

Working in the menu

Menu structure of the setting and display options

Main menu 00

Display and function menu

Menu 01 - Engine speed

Submenu 101 - Setting the engine speed

Menu 02 - Measuring value of drive engine

Submenu 103 - Display of measuring value Drive engine

Menu 03 - Trip meter and fuel gauge

Submenu 301 - Road section, fuel consumption display/reset

Menu 04 - Emergency function / stopping the screed and turning

on the tamper

Submenu 401 - Emergency functions adjustment

Menu 05 - Layer thickness

Submenu 501 - Preselection of layer thickness

Submenu 502 - Setting the speed of auger

Submenu 503 - Adjustment of the speed of conveyor

Menu 06 - Screed charging

Submenu 102 - Starting load setting

Menu 07 - Screed type

Submenu 701 - Setting the screed type

Menu 08 - Service hour meter

Menu 09 - Service

Submenu 201 - Password prompt

Menu 10 - Error memory

Error message display:

Error display

Menu 11 - Error memory Computer of machine operation

Error message display:

Error display

Menu 12 - Program version

Menu 13 - Terminal settings

Submenu 104 - Terminal settings

1.2

Further messages on the display

Terminal error messages

2.1

Instructions related to error messages

2.2

Fault codes of the traction engine

2.3

Error messages

2.4

FMI-codes

2.5

Special functions

Emergency operation program for the case of keyboard failure

Reversible conveyor

D3.1

Operation

Operating elements on the paver finisher

Batteries (71)

Battery main switch (72)

Transport safeguards for the hopper (73)

Mechanical screed transport safeguard

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

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

Separator fluid spraying system (80) (o)

On / off switch for additional headlight in the roof (85):

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

On / off switch special lighting (85b)

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

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

On/Off switch of flasher (85e):

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

Locking of the collapsible roof (LH and RH on the roofs console) (86): .6

Hydraulic folding roof (87) (o)

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

Conveyor limit switches (89)

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

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

Pressure control valve for screed charging/relieving (93)

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

Pressure gauge for screed charging/relieving and screed stop

with pretensioning (93b)

Central lubrication unit (o) (100)

Track cleaner (o) (101)

Particle filter - control light (102) (o)

Front and side window (o) (103)

Adjustment of screed eccentric (o) (104)

D4.1

Operation

Preparation of operation

Required devices and aids

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

Checklist for the machine operator

1.1

Starting the paver finisher

Before starting the paver finisher

„Normal” starting

External starting (starting aid)

After starting

Indicator lamps

Oil pressure indicator lamp for the traction drive (46)

Battery charge indicator (49)

1.2

Operation in case of transportation

Lifting and securing the screed

Driving and stopping the paver finisher

Switching off and securing the paver finisher

1.3

Preparations for paving

Separating agent

Screed heater

Direction marks

Loading/distributing material

1.4

Starting for paving

1.5

Checks during paving

paver finisher function

Quality of the layer

1.6

Paving with screed stop and screed charging/relieving

General

Screed charging/relieving

Screed stop with prestressing

Adjusting the pressure (o)

Screed stop (with prestressing):

For screed charging/relieving:

1.7

Interrupting/terminating operation

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

During extended interruptions (e.g. lunch break)

When work is finished

Malfunctions

2.1

Problems during paving

2.2

Malfunctions on the paver finisher or screed

Emergency device/steering, drive system

E01

Set-up and modification

Special notes on safety

Auger

2.1

Height adjustment

2.2

Auger crossbeam installed in a fixed position

2.3

Mechanical adjustment with ratchet (optional)

2.4

In case of hydraulic adjustment (option)

2.5

Auger extension, auger type I

2.6

Mounting extension parts

2.7

Mounting support tube extensions

2.8

Installing tunnel plates

2.9

Installing additional braces

2.10

Auger mounting chart for ø 310 mm auger

2.11

Auger mounting chart for ø 380 mm auger

Auger extension, auger type II

3.1

Mounting extension parts

3.2

Auger modification plan

Screed

Electrical connections

5.1

Remote controls

5.2

Grade control

5.3

Auger limit switches

5.4

Working lights

F1.0

Maintenance

Notes regarding safety

F2.4

Maintenance overview

Maintenance review

F3.0

Maintenance - Conveyor

1.1

Maintenance intervals

1.2

Points of maintenance

Chain tightness of the conveyor (1)

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

F4.2

Maintenance - Auger

Maintenance - Auger sub-unit I

1.1

Maintenance intervals

1.2

Points of maintenance

Auger - outer bearing (1)

Auger middle bearing (2)

Auger - drive gear neck bearing (3)

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

F5.1

Maintenance - Engine

Maintenance - engine sub-unit

1.1

Maintenance intervals

1.2

Points of maintenance

Engine fuel tank (1)

Engine lube-oil system (2)

Engine fuel system (3)

Engine air filter (4)

Coolant system of the engine (5)

Engine drive belt (6)

Engine exhaust system (7)

F6.0

Maintenance - Hydraulic system

Maintenance - hydraulic system

1.1

Maintenance intervals

1.2

Points of maintenance

Hydraulic oil tank (1)

Suction/return flow hydraulic filter (2)

Venting the filter:

High pressure filter (3)

Pump distribution gear (4)

Hydraulic hoses (5)

F7.1

Maintenance - running gear

1.1

Maintenance intervals

1.2

Points of maintenance

Track tightness (1)

Planetary gear (2)

F8.1

Maintenance - Electronic System

1.1

Maintenance intervals

1.2

Points of maintenance

Batteries (1)

Generator (2)

Adjustment of belt tightness

Replacement of belt

Checking / adjusting belt tension:

If necessary, adjust the belt tension:

Electric fuses (3)

Type of machine: Conventional electronics

Switch box

Fuses in the switching cabinet (B)

Relays in the switching cabinet (C)

Fuses on the operating panel

Relays on the operating panel

Type of machine: PLC- electronics

Switch box

Fuses in the switching cabinet

Relays in the switching cabinet (C)

Fuses on the operating panel

F9.0

Maintenance - Points of lubrication

Maintenance- Points of lubrication

1.1

Maintenance intervals

1.2

Points of maintenance

Central lubrication (1)

Bearings (2)

F10.0

Checks, decommissioning

Tests, check-up, cleaning, stopping

1.1

Maintenance intervals

General observation

Checks by a specialist

Cleaning

Conservation of paver finisher

5.1

Downtime up to 6 months

5.2

Downtime between 6 months and 1 year

5.3

Re-commissioning:

F11.0

Lubricants and Fuels

Lubricants and fuels

1.1

Hydraulic oil

1.2

Instructions referring to the oil types applied

1.3

Filling volumes

Instructions to change from mineral oil to synthetic oil /

from synthetic oil to mineral oil

2.1

Caterpillar drive - planetary gear

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

Ammerländer Strasse 93

D-26203 Wardenburg / Germany

Telephone: +49 / (0)4407 / 972-0

Fax:

+49 / (0)4407 / 972-228

www.dynapac.com

V 1

General safety instructions

1.1

Acts, directives, accident prevention regulations

The locally applicable acts, directives and accident prevention regulations shall be

observed, even if the attention is not specifically directed to these.

The operator himself shall be responsible for the observation and performance of the

related regulations and actions!

The following alerts, prohibitions and instructions refer to the risks to which people,

machinery and environment are exposed.

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

Furthermore, the Dynapac publication "Directives for the correct and specified 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 2

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 6

Correct use and application

The “Guidelines for the Correct Use and Application of Paver finishers” compiled by

Dynapac are included in the scope of delivery for the present machine. The 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 1

Description of assemblies and functions

635_ISO_DYN.bmp

Item

Designation

Material compartment (hopper)

Truck push rollers

Tube for sensor rod (direction indicator) and holder for levelling shoe

Caterpillar drive

Levelling cylinder for paving thickness

Traction roller

Traction arm rail

Paving thickness indicator

Arm

Traction drive of the caterpillar drive

Auger

Screed

Operator’s platform

Operating panel (can be moved to either side)

Protective roof

Working lights

Track cleaner

Hydraulic front hopper lid

Exhaust of asphalt vapours

t = Standard equipment

o = Optional equipment

B 2

2.1

Vehicle

Construction

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

mounted.

The caterpillar drives compensate uneven areas on the ground; the suspension of the

attached screed additionally helps to attain a high paving precision.

The continuously adjustable hydrostatic traction drive allows the speed of the paver

finisher to be matched to all work conditions.

Operation of the paver finisher is faciliated by the automatic material handling system,

the separate traction drives and the clearly structured operating and control elements.

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 finisher and/or the screed

o Protective roof

o Further equipment and upgrade options on request

Engine: The paver is driven by a water cooled Diesel engine. For further details see

the technical data and the engine's instruction manual.

The 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.

Caterpillar drive: Both caterpillar drives are directly driven by separate drives with-

out any drive chains that would require maintenance and servicing.

The tension of the caterpillar chains can be readjusted using tensioners.

Folding track cleaners are mounted before each crawler track (o), which ensure the

flat road section while paving. The minor obstacles found in the track lane are pushed

to the side by the machine.

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.

B 3

Traction drive: The continuously adjustable traction drive pumps are connected to

the traction motors by means of high pressure hydraulic hoses.

These oil motors drive the caterpillar chains via planetary gears that are mounted di-

rectly inside the drive wheels of the caterpillar chains.

Steering system/operator’s platform: The independent hydrostatic traction drives

allow the finisher to be turned on the spot.

The electronic synchronisation, controlled from the operating panel, ensures that the

finisher runs straight ahead.

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.

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.

B 4

Levelling system/slope control system: The slope control system (option) allows

the traction point to be regulated at the left-hand or the right-hand side with a defined

difference to the opposite side.

To determine the actual value, the two 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

is stopped (changing trucks), 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.

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.

B 5

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

Steering system

F0069_A1.EPS

4.3

Horn

- on the operating panel

- on the two remote control units

Horn.Tif

(option)

4.4

Ignition key / lights

F0064_A1.EPS

B 7

5.4

Weights F 121 C (all weights in t)

Paver finisher without screed

about 16,3

Paver finisher with screed:

- VB510 T/TV

about 18,2

With extensions for max. working

about 1,4

width additionally max.

With filled hopper

about 13,0

additionally max.

For the weights of the screed and the screed attachments, see the operating instruc-

tions for the screed.

5.5

Weights F 141 C (all weights in t)

Paver finisher without screed

about 16,6

Paver finisher with screed:

- VB510 T/TV

about 18,5

Including mounted accessories

for max. paving width

about 1,4

additionally max.

With filled hopper

about 13,0

additionally max.

For the weights of the screed and the screed attachments, see the operating instruc-

tions for the screed.

B 12

5.8

Traction drive/chassis

Hydrostatic drive,

Drive

continuously controllable

Two separately driven caterpillar drives with rub-

Caterpillar drive

ber grouser chains.

Turning capacity

Turning on the spot

Speed

See above

5.9

Engine F 121 C

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)

5.10

Engine F 141 C

Make/type

Deutz TCD 2013 L06 2V

Model

6-cylinder diesel engine (water-cooled)

Performance

140 KW / 190 HP (at 1800 rpm)

Volume of fuel tank

(see chapter F)

5.11

Hydraulic system

Hydraulic pumps via distribution gear

Pressure generation

(directly flanged to the engine)

Hydraulic circuits for:

- Traction drive

- Material conveying and distribution

- Screed lifting drives for tamper / vibration

Pressure distribution

(option)

- Cylinder actuators for steering, hopper,

levelling, screed lifting, extending/retracting

screed parts, auger lift (option)

Hydraulic oil reservoir - volume

(see chapter F)

B 15

5.12

Material compartment (hopper)

Volume

about 6.0 m³ = about 13.0 t

Minimum inlet height, center

520 mm

Minimum inlet height, outside

595 mm

5.13

Material conveying

Conveyors

Left and right auger separately controllable

Drive

Hydrostatic, continuously controllable

Conveying volume controller

Fully automatic via configurable switching points

5.14

Material distribution

Augers

Left and right auger separately controllable

Hydrostatic external drive, continuously controlla-

ble

Drive

independent from the conveyor

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 16

Item

Designation

Label ”Filler neck for diesel fuel” *

Label ”Filler neck for engine oil” *

Label „Heed the operating instructions!“

Warning label ”Danger of squeezing!” **

Punched vehicle identification number

Label ”Securing or fixing points for crane transportation” **

Paver finisher identification label

„CE + noise level“ plate (O)

„Fan danger!“ warning plate

„Spraying with water prohibited“ plate

Label „Heed the operating instructions!“ ***

Label ”High voltage!”

Label ”Operating instructions for the engine”

„Crossbeam lock“ plate

„All switches to STOP“ plate ***

Label „Wear Ear Mufflers“

Label „Risk of hand injury“

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 19

DYNAPAC Paver finisher F 121 C, F 141 C Type 635. Operation & Maintenance (Order number: 4812026925) - page 1