Operating instructions

01-1203900 98 07 28

F 150 CPaver finisher

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Preface

Safe operation of the machine requires specific knowledge that is imparted by thepresent operating instructions. The information is provided in a concise, clearly struc-tured form. The individual chapters are arranged in alphabetical order Every chapterstarts on page 1. The designation of pages consists of a letter denoting the chapterand a numeral denoting the page number in that chapter.Example: Page B 2 is the second page of chapter B.

These operating instructions cover various machine options. Make sure that duringoperation and maintenance work the description appropriate to the machine option isused.

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 makechanges to the machine (which will not, however, change the essential features of thetype of machine described) without updating the present operating instructions at thesame time.

Dynapac GmbHWardenburg

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

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Table of contents

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

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

1 Application ................................................................................................. 12 Description of assemblies and functions of the paver finisher ................... 22.1 Vehicle ....................................................................................................... 2

Construction ........................................................................................... 32.2 Description of assemblies and functions of the

emulsion spraying system .......................................................................... 6Construction ........................................................................................... 7

3 Safety ......................................................................................................... 83.1 Emergency stop button on paver finisher .................................................. 83.2 Emergency stop button on emulsion spraying system ............................... 83.3 Steering system ......................................................................................... 83.4 Horn ........................................................................................................... 83.5 Ignition key / lights ..................................................................................... 83.6 Safety switch, remote power supply .......................................................... 83.7 Residual dangers caused by the spraying system ..................................... 93.8 Main switch (36) ....................................................................................... 103.9 Hopper transport safeguards (37) ............................................................ 103.10 Screed transport safeguard ..................................................................... 103.11 Locking for protective roof (38) ................................................................ 104 Technical vehicle data ............................................................................. 124.1 Performance data .................................................................................... 124.2 Traction drive/chassis .............................................................................. 124.3 Engine ...................................................................................................... 124.4 Hydraulic system ...................................................................................... 134.5 Material compartment (hopper) ................................................................ 134.6 Weights (all weights in t) .......................................................................... 134.7 Material conveying ................................................................................... 144.8 Material distribution .................................................................................. 144.9 Screed lifting device ................................................................................. 144.10 Electrical system ...................................................................................... 145 Technical data for emulsion spraying system .......................................... 155.1 Dimensions .............................................................................................. 155.2 Electric system ........................................................................................ 155.3 Additional hydraulics ................................................................................ 155.4 Emulsion ................................................................................................. 165.5 Spraying nozzles ...................................................................................... 165.6 Dimensions (all dimensions in mm) ........................................................ 176 Location of instruction labels and identification labels ............................. 186.1 Identification label for the paver finisher (54) .......................................... 206.2 Identification label for spraying system (60) ............................................. 21

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7 EN standards ........................................................................................... 227.1 Continuous sound level ............................................................................ 227.2 Operating conditions during measurement .............................................. 227.3 Measuring point configuration .................................................................. 227.4 Vibration acting on the entire body .......................................................... 237.5 Vibrations acting on hands and arms ....................................................... 237.6 Electromagnetic compatibility (EMC) ....................................................... 23

C Transportation ......................................................................... 1

1 Safety regulations for transportation .......................................................... 12 Transportation on low-bed trailers ............................................................. 22.1 Preparations ............................................................................................... 22.2 Driving onto the low-bed trailer .................................................................. 32.3 After transportation .................................................................................... 33 Transportation on public roads .................................................................. 43.1 Preparations ............................................................................................... 43.2 Driving on public roads .............................................................................. 54 Loading by crane ....................................................................................... 65 Loading the dismounted emulsion spraying system .................................. 65.1 Loading by crane ....................................................................................... 75.2 Loading by fork-lift truck ............................................................................. 76 Towing ....................................................................................................... 86.1 Safely parking the vehicle ........................................................................ 10

D Operation .................................................................................1

1 Safety regulations ...................................................................................... 12 Controls ...................................................................................................... 22.1 Operating panel ...................................................................................... 22.2 Operating the input and display terminal ................................................. 24

Display keyboard ................................................................................. 24Working in the menu ............................................................................ 25

2.3 Diagnosing and detecting malfunction ..................................................... 352.4 Engine error messages ............................................................................ 43

Error message, "Coolant level too low" ............................................... 442.5 Remote control ......................................................................................... 45

Emergency program for TDM-failure ................................................... 482.6 Special functions ...................................................................................... 50

Reversible conveyor ............................................................................ 502.7 Controls on the paver finisher .................................................................. 51

Batteries (71) ....................................................................................... 51Battery main switch (72) ...................................................................... 51Transport safeguards for the hopper (73) ............................................ 52Mechanical screed transport safeguard (to the left and the right beneath the driver’s seat) (74) ........................................................................... 52Seat lock (behind the driver’s seat) (75) .............................................. 53Separator fluid spraying system (80) o ................................................ 54Pressure control valve for screed charging/relieving (84) (o) .............. 55Pressure control valve for screed stop with pretensioning (84a) ......... 55Pressure gauge for screed charging/relieving and screed stop with pre-tensioning (84b) ................................................................................... 55On / off switch for additional

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3headlight in the roof (85): ..................................................................... 56On/off switch for 230V sockets (85a) ................................................... 56On / off switch for fuel tankfiller pump (85b) ................................................................................... 56On / off switch special lighting (85c) .................................................... 56Folding roof locking brackets (on left and right sides of roof console ) (86): .............................................................................................................. 57Hydraulic folding roof (87) (o) .............................................................. 58Conveyor limit switches ....................................................................... 59Ultrasonic auger limit switches (90) (left and right) .............................. 59Sockets for the remote control (left and right) (91) .............................. 60Sockets for working lights(left and right) (92) ............................................................................... 60

2.8 Switch cabinet for the spraying system .................................................... 612.9 Operating panel, paver finisher ................................................................ 652.10 Remote control of emulsion spraying system, right side ..................... 662.11 Remote control of emulsion spraying system, left side ....................... 672.12 Compressed air indicator .................................................................... 682.13 Switch cabinet for emulsion heating ................................................... 692.14 Switch cabinet for remote power supply ................................................ 712.15 Left-hand tank side ................................................................................ 722.16 Manual spraying device, rear ................................................................. 732.17 Manual spraying device, front ................................................................ 743 230 Volt electrical system ........................................................................ 753.1 230 Volt sockets on left and right sides ................................................... 75

On/off switch for 230V sockets ............................................................ 763.2 Insulation test ........................................................................................... 764 Operation ................................................................................................. 774.1 Preparing for operation ............................................................................ 77

Required devices and aids .................................................................. 77Before starting work(in the morning or when starting paving) ............................................. 77Checklist for the machine operator ...................................................... 78

4.2 Starting the paver finisher ........................................................................ 80Before starting the paver finisher ......................................................... 80"Normal" starting .................................................................................. 80External starting (starting aid) .............................................................. 81After starting ........................................................................................ 82Observe indicator lamps ...................................................................... 83Coolant check (43) ............................................................................... 83Oil pressure indicator lamp for the diesel engine (45) ......................... 83Oil pressure indicator lamp for the traction drive (44) .......................... 83Battery charge indicator (47) ............................................................... 84

5 Starting the spraying system .................................................................... 855.1 Compressed air system .......................................................................... 855.2 Loading the emulsion tank ....................................................................... 866 Heating system ........................................................................................ 886.1 Working temperatures .............................................................................. 886.2 Heating before the spray process ............................................................ 886.3 Heating during spraying ........................................................................... 896.4 During work interruptions (remote power supply) .................................... 897 Emulsion circuit ........................................................................................ 907.1 Tank circuit ............................................................................................... 91

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7.2 Spraying ramp circuit ............................................................................... 917.3 Preparations for paving ............................................................................ 92

Separating agent ................................................................................. 92Screed heating system ........................................................................ 92Direction marks .................................................................................... 92Loading/distributing material ............................................................... 93

7.4 Starting for paving .................................................................................... 947.5 Checks during paving .............................................................................. 96

Paver function ...................................................................................... 96Quality of the layer ............................................................................... 96

7.6 Paving with screed stop and screed charging/relieving device: ............... 97General ................................................................................................ 97Screed charging/relieving .................................................................... 97Screed stop .......................................................................................... 98Screed stop with pretensioning ............................................................ 98Adjusting the pressure (o) .................................................................... 99For screed stop with pretensioning: ..................................................... 99For screed charging/relieving .............................................................. 99

7.7 Spraying ................................................................................................. 1007.8 Emptying the spraying ramp (end of paving) ......................................... 1017.9 Cleaning the spraying nozzles ............................................................... 1027.10 Cleaning the emulsion filter .................................................................... 1027.11 Notes on handling the spraying equipment ............................................ 103

General .............................................................................................. 1037.12 Finishing work with the spraying equipment ......................................... 1037.13 Finishing work with the spraying equipment ......................................... 1047.14 Interrupting/terminating operation .......................................................... 105

During paving breaks (e.g. a delay in supply of material by trucks) .. 105During extended interruptions (e.g. lunch break) ............................... 105When work is finished ........................................................................ 106

8 Malfunctions ........................................................................................... 1078.1 Engine error codes ................................................................................. 1078.2 Problems during paving ......................................................................... 1128.3 Malfunctions on the paver finisher or screed ......................................... 1148.4 Malfunctions on the emulsion spraying equipment ................................ 1179 Emergency device/steering, drive system ............................................. 120

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3E Set-up and modification .........................................................1

1 Special notes on safety .............................................................................. 12 Auger ......................................................................................................... 22.1 Height adjustment ...................................................................................... 22.2 Auger crossbeam installed in a fixed position ............................................ 22.3 With mechanical adjustment with ratchet (option) ..................................... 32.4 With hydraulic adjustment

(option) 32.5 Auger extension ......................................................................................... 42.6 Mounting extension parts ........................................................................... 52.7 Mounting support tube extensions ............................................................. 62.8 Installing tunnel plates ............................................................................... 72.9 Installing additional braces ......................................................................... 8

Pendulum drive system ......................................................................... 93 Screed ...................................................................................................... 104 Electrical connections .............................................................................. 104.1 Remote controls ....................................................................................... 104.2 Grade control ........................................................................................... 104.3 Auger limit switches ................................................................................. 104.4 Working lights .......................................................................................... 105 Operating principle for the spraying system ............................................. 115.1 Selecting the nozzles and the method ..................................................... 135.2 Explanations ............................................................................................ 146 Programming the computer ..................................................................... 156.1 Setting parameters for automatic operation ............................................. 20

Calculating the base value ................................................................... 20Calculating the parameters .................................................................. 21

6.2 Calculation sheet for the automatic mode ............................................. 226.3 Settings for semi-automatic operation ..................................................... 23

Completing the calculation sheet ......................................................... 236.4 Calculation sheet for the semi-automatic mode (FORWARD + BACK-

WARD) 256.5 Calculation sheet for the semi-automatic mode (FORWARD only) ...... 267 Performing a set-up before work starts .................................................... 277.1 Calculation sheet for spraying nozzles behind the drives ...................... 287.2 Explanations for the calculation sheet for the spraying nozzles behind the

drives 29

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F Maintenance ............................................................................1

1 Notes regarding safety ............................................................................... 12 Maintenance intervals for the paver finisher .............................................. 22.1 Daily (or every 10 operating hours) ............................................................ 32.2 Weekly (or every 50 operating hours) ........................................................ 52.3 Every 100 operating hours ......................................................................... 52.4 Every 250 operating hours ......................................................................... 52.5 Every 500 operating hours ......................................................................... 72.6 Yearly (or every 1000 operating hours) ..................................................... 72.7 Every 2 years (or every 2000 operating hours) .......................................... 93 Maintenance intervals for the emulsion spraying equipment ................... 103.1 Daily (or every 10 operating hours) .......................................................... 113.2 Weekly (every 50 operating hours) .......................................................... 113.3 250 operating hours ................................................................................. 133.4 Every 500 operating hours ....................................................................... 133.5 Yearly (or every 1000 operating hours) ................................................... 133.6 Every 2 years (or every 2000 operating hours) ........................................ 154 Checking, lubricating, oil drain points on the paver finisher ..................... 164.1 Check points ............................................................................................ 17

Pump distributor gear (11) ................................................................... 17Caterpillar drive - planetary gear (10) .................................................. 17Conveyor gear (left/right) (4) ................................................................ 18Auger bevel gear (left/right) (8) ............................................................ 18Engine lube oil (12) .............................................................................. 19Oil level check ...................................................................................... 19Oil change ............................................................................................ 19Engine oil filter (12a) ............................................................................ 20Cooling system for engine and hydraulics (13) .................................... 21Water cooler (radiator) ......................................................................... 21Hydraulic cooler ................................................................................... 21Fuel tank (18) ....................................................................................... 22V-belts and ribbed V-belts (1) .............................................................. 22Air filter (2) ........................................................................................... 23High pressure hydraulic filter (3) .......................................................... 24Suction/return flow hydraulic filter (19) ................................................ 24Hydraulic oil reservoir (20) ................................................................... 25Chain tension, conveyor (23) ............................................................... 25Grease tensioner on conveyor (O) ...................................................... 25Engine - fuel filter (17) ......................................................................... 26Upstream filter - draining off water: ...................................................... 26Upstream filter - replacing the filter cartridge ....................................... 26Main filter - replacing filter cartridge ..................................................... 27Bleeding the fuel system ...................................................................... 27Batteries (16) ....................................................................................... 28Chain tension - caterpillar drive (14) .................................................... 28General visual checks .......................................................................... 29Checks by a specialist ......................................................................... 29

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34.2 Lube points on paver ............................................................................... 30

Push rollers (22) .................................................................................. 30Steel hopper flaps (option) (21) ........................................................... 30Conveyor deflection rollers (15) ........................................................... 30Centre auger bearing (7) ..................................................................... 31Auger external bearing (6) ................................................................... 31Auger, gear neck bearing (9) ............................................................... 31Centre conveyor bearing (5) ................................................................ 32

4.3 Oil drain points on the paver finisher ....................................................... 32Pump distributor gear (11) ................................................................... 32Diesel engine (12) ................................................................................ 32Caterpillar-drive planetary gear (10) .................................................... 32Auger bevel gear (8) ............................................................................ 33Hydraulic oil reservoir (20) ................................................................... 33Engine mounting (33) .......................................................................... 33Hoses and hose connections (34) ....................................................... 34Filter mats (35) ..................................................................................... 35Insulation test (36) ............................................................................... 36

5 Checking, lubricating, oil drain points on the emulsion spraying equipment 37

5.1 Emulsion pump (24) ................................................................................ 385.2 Emulsion filter (25) ................................................................................... 385.3 Emulsion pump gear (26) ....................................................................... 39

Oil level check ...................................................................................... 39Oil change ............................................................................................ 39

5.4 Rotary joints of the flexible emulsion hoses (27) ..................................... 405.5 Spraying ramp (28) .................................................................................. 405.6 Compressed air vessels (29) ................................................................... 405.7 Compressor air filter (30) ......................................................................... 415.8 Compressor oil cooler (31) ....................................................................... 415.9 Compressor (32) ..................................................................................... 42

Oil level check ...................................................................................... 42Oil change ............................................................................................ 43Oil filter change .................................................................................... 44

6 Lubricating agents and operating substances ......................................... 456.1 Filling volumens for paver finisher ........................................................... 467 Electric fuses ............................................................................................ 477.1 Main fuses (1) (beside the batteries) ................................................. 477.2 Fuses in the terminal box (beside the fuel tank) ...................................... 477.3 Fuses on the operating panel .................................................................. 498 Lubricant and operating fluids on emulsion spraying equipment ............. 518.1 Grease ..................................................................................................... 518.2 Transmission oil ....................................................................................... 518.3 Compressor oil ......................................................................................... 528.4 Filling volumes ......................................................................................... 529 Electrical fuses / relays on emulsion spraying equipment ....................... 539.1 Fuses/relays in the spraying system switch cabinet ................................ 53

Fuses ................................................................................................. 53Relays ................................................................................................ 53

9.2 Fuses in the switch cabinet of the three-phase system (380 V) .............. 54

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A Correct use and application

A The "Guidelines for the Correct Use and Application of Paver Finishers" compiled byDynapac are included in the scope of delivery for this machine. The guidelines arepart of the present operating instructions and must always be heeded. National reg-ulations are fully applicable.

The road construction machine described in these operating instructions is a paverfinisher that is suited for laying mixed materials, roll-down concrete or lean-mixedconcrete, track-laying ballast and unbound mineral aggregates for foundations forpavingThe emulsion spraying system is provided to apply an emulsion layer immedi-ately prior to installing the material.The paver finisher and the emulsion spraying system must be installed, operated andmaintained in accordance with the instructions in these operating instructions. No oth-er form of usage is permitted and could cause injury to people or damage to the paverfinisher and the emulsion spraying system, or to other material assets.

Any usage other than the intended application described here constitutes a violationof these operating instructions and is therefore expressly prohibited! Especially inthose cases where the paver finisher is to be operated on inclines or where it is to beused for special purposes (construction of dumps, dams), it is absolutely necessaryto contact the manufacturer.

Duties of the user: A "user" within the meaning of the present operating instructionsis 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 isconsidered the person who, in accordance with existing contractual agreements be-tween the owner and the user of the paver finisher, is charged with the observanceof the operating duties.The user must ensure that the paver finisher is only used in the stipulated manner andthat all danger to life and limb of the operator, or third parties, is avoided. In additionto this, it must be ensured that the relevant accident prevention regulations and othersafety-related provisions as well as the operating, servicing and maintenance guide-lines are observed. The user must also ensure that all persons operating the paverfinisher have read and understood the present operating instructions.

Mounting of attachments: The paver finisher must only be operated in conjunctionwith screeds that have been approved by the manufacturer. Mounting or installationof any attachments that will interfere with or supplement the functions of the paverfinisher 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 approvalby the manufacturer unnecessary.

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B Vehicle description

1 Application

The DYNAPAC F 150 C is a caterpillar paver finisher that is used for laying bitumi-nous mixed material, roll-down or lean-mixed concrete, track-laying ballast and un-bound mineral aggregates for foundations for paving.

The DYNAPAC emulsion spraying system is used in conjunction with the F 150 Cpaver finisher.

The hydraulically extendable emulsion spraying system has been designed for pav-ing at variable working widths.

A For the technical specifications of the emulsion spraying system, see the section "Tech-nical data".

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2 Description of assemblies and functions of the paver finisher

2.1 Vehicle

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 Caterpillar drive

5 t Levelling cylinder for paving thickness

6 t Traction roller

7 t Arm traction rail

8 t Paving thickness indicator

9 t Arm

10 t Traction drive of the caterpillar drive

11 t Auger

12 t Screed

13 t Operator’s platform

14 o Protective roof

t = Standard equipment o = Optional equipment

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Construction

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

The caterpillar drives (4) compensate uneven areas on the ground; the suspensionof the attached screed (12) additionally helps to attain a high paving precision. The continuously adjustable hydrostatic traction drive (10) allows the speed of thepaver finisher to be matched to all work conditions.

Operation of the paver finisher is faciliated by the automatic material handling system(1), the separate traction drives (10) and the clearly structured operating and controlelements (14).

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 (15)

o Further equipment and upgrade options on request

Engine: The paver finisher is powered by a water-cooled 6-cylinder Deutz diesel en-gine. For further information please refer to the operating instructions for the engine.

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.

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

Traction drive: The continuously adjustable traction drive pumps are connected tothe 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.

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Steering system/operator’s platform: The independent hydrostatic traction drivesallow the finisher to be turned on the spot.The electronic synchronisation, controlled from the operating panel, ensures that thefinisher runs straight ahead.The operating panel can be secured in a position at the left-hand or the right-handside 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 crossbar that is pivoted at its centre. 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 incurves 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 approx. 12.5 tons. To facilitate emptying and to improve material transport, each of the lateral covers ofthe hopper can be hydraulically moved (option).

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 orspeed is regulated fully automatically.

Augers: The augers are driven and actuated independently from the conveyors. Theleft-hand and the right hand half of the auger can be controlled separately. The drivesystem is fully hydraulic. The conveyor unit can be used to direct material inwards or outwards with a choiceof settings. This ensures that there is always a sufficient supply with material even ifan excessive amount of material is required at one side. The auger speed is control-led across an infinitely variable range by the flow of material using a set of sensors.

Height adjustment and extension of augers: Height adjustment and extension ofaugers 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 theside arms and by actuating the hydraulic screed lifting device. When adjusting by means of ratchets (option), the height of the locking clamp spin-dles is set using the guide journals in the back wall. 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 differentpaving widths.

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Levelling system/slope control system: The slope control system (option) allowsthe traction point to be regulated at the left-hand or the right-hand side with a defineddifference to the opposite side. To determine the actual value, the two traction arms are linked with a slope controlrod.

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 heightof the material or the paving height of the screed can be controlled. Actuation occurs electro-hydraulically on both sides and can be controlled manuallyby means of toggle switches or automatically by means of an electronic grade controlsystem.

Screed lifting device: The screed lifting device is used to lift the screed during trans-portation. Lifting occurs electro-hydraulically on both sides by actuating the hydrauliccylinders on the arms and is controlled by means of toggle switches on the operatingpanel.

Automatic screed stop and screed charging/relieving device: The automaticscreed stop prevents the formation screed marks caused by a stopped screed. Whenthe paver finisher stops (during a truck change), the control valves set to the floatingposition are shut and locked, thus preventing the screed from sinking during the stop.

The screed relieving device puts a higher load on the chassis, thus increasing thetraction. Activating the screed charging device can improve the compacting result under cer-tain conditions.

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2.2 Description of assemblies and functions of the emulsion spraying system

Item Designation

17 t Remote control for the spraying ramp

18 t Switch cabinet for remote power supply, 380V

19 t Switch cabinet for the spraying system, 24V

20 t Switch cabinet for three-phase current, 380V

21 t Compressor

22 t Emulsion tank gauge (on the paver finisher side)

23 t EMERGENCY STOP switch for loading and spraying pump (on the paver finisher side)

24 t Filler neck for loading and unloading the emulsion tank (left-hand side)

25 t Drain cock on emulsion tank

26 t Spraying ramp

27 t Emulsion tank

28 t Filler neck for loading and unloading the emulsion tank (right-hand side)

29 t Spraying nozzles behind the drives

t = Standard equipment o = Optional equipment

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Construction

Remote control for the spraying ramp The remote controls are located at the right-hand and the left-hand side. They control the spraying nozzles in the spraying ramp,in the extendable parts and behind the drives as well as the hydraulic extension part.

Switch cabinet for remote 380 V power supply: The remote 380 V power supplysupplies the heating system with power when the paver finisher is switched off, e.g.to keep the emulsion at its minimum temperature at night.

Switch cabinet for the spraying system: The switch cabinet accommodates theoperating and control elements for the spraying system.

Switch cabinet for the heating system: The switch cabinet accommodates the fus-es for heating circuits I and II and for the remote power supply.

Compressor: The hydrostatically driven compressor supplies the nozzle, the valveand the pump controller (emulsion pump).

Emulsion tank gauge: The gauge indicates the amount of emulsion in the tank. Thesafety switch automatically switches off the heating system if the tank contains lessthan 500 l of emulsion.

EMERGENCY STOP switch for the loading and spraying pump (emulsionpump): Pressing this switch cuts out the loading and spraying pump in the case ofmalfunctions or emergencies during operation or filling.

Drain cock on emulsion tank The filler necks are used to empty the emulsion tank.Drain the rest of the emulsion here to completely empty the emulsion tank, for exam-ple, to clean it or to remove dirt particles, etc.

Spraying ramp: The spraying ramp can be extended from 2.50 m to 6.00 m. Theamount and the area sprayed depend on the movement of the spraying ramp.The spraying ramp speed is proportional to the working speed. There is a nozzle lo-cated behind each of the drives which extends across the width of the drive, coveringthe area not sprayed by the main ramp.

Emulsion tank: All the equipment required for the spraying process, e.g. loading andspraying pump, compressor, filter and heating, is fitted on the emulsion tank whichhas a capacity of approx. 2800 litres.The tank is filled through filler necks located on the left and right sides. This processinvolves switching over the spraying pump function, which now acts as a loadingpump.The hydrostatically powered compressor supplies the pneumatic nozzle and pumpcontrol system.Electrical power to the tank heating system is provided by two 10 kVA generators.

Filler necks: Filling of the emulsion tank occurs via the loading and spraying pump.The tank can be filled via the left-hand or the right-hand filler neck.

Spraying nozzles behind the drives: Behind each drive there is a nozzle that cov-ers the areas not sprayed by the spraying ramp.

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3 Safety

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

A The function of this items of equipment must be checked at regular intervals.

3.1 Emergency stop button on paver fin-isher

- on the operating panel- on the two remote control units (op-

tion)

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 manoeuvres,lifting the screed, etc.) are not possible in this case! Danger of accidents!

3.2 Emergency stop button on emulsionspraying system

- on the left-hand side of the tank

m Pressing the EMERGENCY STOP but-ton switches the emulsion pump off.

3.3 Steering system

3.4 Horn

- on the operating panel- on the two remote control units (op-

tion)

3.5 Ignition key / lights

3.6 Safety switch, remote power supply

The remote power supply safety switch switches the paver finisher engine off whenthe switch cabinet door is opened.

A It is not possible to start up the paver finisher while the switch cabinet door is open!

F0005_A1.EPS

F0005_A1.EPS

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Horn_K.cdr/Horn_sps.cdr

Light_K.cdr

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3.7 Residual dangers caused by the spraying system

f Risk of crushing! All moving parts of the spraying system constitute the danger of being squeezed,pinched or torn. Keep away from these parts!

Danger of being pulled in! All rotating or moving parts of the screed constitute the danger of being caught,wound up or pulled in. Keep away from these parts!

Danger of falling! Never jump on or off while the machine moves! Use only the walking platforms andsteps provided!

Danger of burns! Heating the spraying system creates a potential hazard caused by hot surfaces, es-pecially on the emulsion tank and the spraying ramp. Keep away from these parts! If this cannot be avoided, were protective gloves!

- Always were all of your protective clothing! Incomplete or negligently worn protective clothing can constitute a danger tohealth.

- 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! - Always make sure during operation that no-one is endangered by the machine!

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3.8 Main switch (36)

3.9 Hopper transport safeguards (37)

3.10 Screed transport safeguard

3.11 Locking for protective roof (38)

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Accessories:

- Wedges - Warning triangle- First-aid kit

Item Designation

39 Engine hood

40 Lateral flaps

41 Walkway

42 Screed coverings

43 Auger covers

44 Hazard warning lights of the screed

Techn.TIF

39

40

41

42

43

44

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4 Technical vehicle data

4.1 Performance data

4.2 Traction drive/chassis

4.3 Engine

Scr

eed

used

Bas

ic w

idth

(with

out c

ut-o

ff sh

oes)

Min

imum

pav

ing

wid

th(w

ith c

ut-o

ff sh

oe)

Con

tinuo

usly

hyd

raul

ical

lyad

just

able

up

to

Max

imum

wor

king

wid

th(w

ith e

xten

sion

par

ts)

VB 850 T/TV 2.50 2.00 4.75 8.50 m

VB 805 T/TV 2.50 2.00 5.00 8.00 m

VB 1105 T/TV 3.00 2.50 6.00 9.00 m

VB 805 TV Plus 2.50 2.00 5.00 8.00 m

VB 1105 TV Plus 3.00 2.50 6.00 9.00 m

VB 1005 V 3.00 2.50 4.75 8.10 m

Transport speed 0 - 3.8 km/h

Working speed 0 - 20 m/min

Layer thickness 0 - 300 mm

Max. grain size 40 mm

Theoretical paving performance 800 t/h

Drive Hydrostatic drive, continuously controllable

Caterpillar drive Two separately driven caterpillar drives with rubber grouser chains.

Turning capacity Turning on the spot

Speed See above

Make/type Deutz BF6M 2012

Model 6-cylinder diesel engine (water-cooled)

Capacity 131 KW / 178 PS (at 2300 rpm)

Volume of fuel tank (see chapter F)

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4.4 Hydraulic system

4.5 Material compartment (hopper)

4.6 Weights (all weights in t)

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

Pressure generationHydraulic pumps via distribution gear(directly flanged to the engine)

Pressure distribution

Hydraulic circuits for:- Traction drive- Material conveying and distribution- Screed lifting drives for tamper / vibration (option)- Cylinder actuators for steering, hopper, levelling,

screed lifting, extending/retracting screed parts, auger lift (option)

Hydraulic oil reservoir - volume (see chapter F)

Volume approx. 5.7 m3 = approx. 12.5 t

Minimum inlet height, centre 480 mm

Minimum inlet height, outer 600 mm

Paver finisher without screed approx. 16.70

Paver finisher with screed(incl. side plates)- VB 850 T/TV- VB 805 T/TV- VB 1105 T/TV- VB 805 TV Plus- VB 1105 TV Plus- VB 1005 V

approx. 19.70approx. 19.77approx. 20.02approx. 19.79approx. 19.99approx.19.92

With extension parts for max. work-ing widthplus max.

approx. 1.40

With filled hopperadditionally max.

approx. 12.50

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4.7 Material conveying

4.8 Material distribution

4.9 Screed lifting device

4.10 Electrical system

Conveyors Left and right auger separately controllable

Drive Hydrostatic, continuously controllable

Conveying volume controller Fully automatic via configurable switching points

Augers Left and right auger separately controllable

Drive

Hydrostatic external drive, infinitely variable controlindependent of conveyorauger halves capable of contra-rotation

Conveying volume controller Fully automatic via configurable switching points

Auger height adjustment- mechanically via chain- mechanical (option)- hydraulic (option)

Auger extension With extension parts (see auger extension chart)

Special functions

At standstill:- Screed stop- Screed stop with pretensioning (max. pressure 50

bar)During paving:- Screed charging- Screed relieving (max. pressure 50 bar)

Levelling systemMechanical grade control,optional systems with and without slope control

On-board voltage 24 V

- Batteries 2 x 12 V, 88 Ah

- Fuses see chapter D, section 3

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5 Technical data for emulsion spraying system

5.1 Dimensions

5.2 Electric system

5.3 Additional hydraulics

Spraying ramp:- basic ramp- hydraulically extendable up to- with extension parts:

0.4 m0.6 m1.0 m

2.504.00

3.30 - 4.803.70 - 5.204.50 - 6.00

mm

mmm

Operating voltage 24 F

Generator 2 x10 KW

Remote power supply 380 F

PumpsCompressor

Spraying ramp adjustmentEmulsion pump

Compressor- Capacity- Tank pressure

455.5

m3/hbar

F151C.wmf

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5.4 Emulsion

5.5 Spraying nozzles

Emulsion tank2800

o 4000l

Emulsion meteringContinuous200 - 1000 g/m3

Model 727- Low coverage

(spraying in one direction)- High coverage

(spraying in both directions)

450 - 600

600 and more

g/m3

g/m3

Model 647- Low coverage

(spraying in one direction)- High coverage

(spraying in both directions)

250 - 450

450 and more

g/m3

g/m3

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5.6 Dimensions (all dimensions in mm)

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

Designation

AMin. transportation height without roof and exhaust tail pipe

2825

B Operator’s platform height 1720

C Transportation height with roof swung down 3200

D Overall height with roof 3750

E Hopper length 1900

F Caterpillar drive length 3370

G

- Length without screed walkway- VB 850 T/TV- VB 805 TV- VB 1105 TV- VB 805 TV Plus- VB 1105 TV Plus- VB 1005

72107450745074507450

H

- Max. length (depending on the screed)- VB 850 T/TV- VB 805 TV- VB 1105 TV- VB 805 TV Plus- VB 1105 TV Plus- VB 1005

74807620762076207620

I Chain width 300

J External track width 2200

K Overall/transportation width 2500

L Max. width with open hopper 3400

Techn.pic

J

K

L

G

H

A

E

B

F

C D

I

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6 Location of instruction labels and identification labels

45 46

50

51

51

54

48

55 56

58

59

47

52

57

53

49

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

Item Designation

45 Label "Summary of operating fluids, engine" *

46 Label "Filler neck for diesel fuel" *

47 Label "Filler neck for engine oil" *

48 Label "Heed the operating instructions!"

49 Warning label "Danger of squeezing!" **

50 Punched vehicle identification number

51 Label "Securing or fixing points for crane transportation"**

52 Label "High voltage!"

53 Warning plate, "Nip risk!"

54 Paver finisher identification label

55 Label "Maximum permitted speed 20 km/h^" in self-propelled operation

56 Label "Engine operating instructions"

57 Label "Heed the operating instructions!" ***

58 Identification label, liquid gas system

59 Label "Close bottle valves immediately"

60 Identification label, spraying system

60

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6.1 Identification label for the paver finisher (54)

A The punched vehicle identification number on the paver finisher must match the prod-uct identification number (68).

Item Designation

61 Paver finisher type (e.g. F 8-4 W)

62 Year of construction

63 Serial number of the paver finisher series

64 Max. permissible operating weight, incl. all extension parts, in kg

65 Max. permissible load on the front axle, in kg

66 Max. permissible load on the rear axle, in kg

67 Rated performance in kW

68 Product identification number (PIN)

61

62

63

64

65

66

67

68Fertiger2.tif

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6.2 Identification label for spraying system (60)

Item Designation

75 Manufacturer

76 Machine type

77 Machine No.

78 Year of construction

79 Serial No.

TYP_Sch.TIF

75

77 78

79

76

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7 EN standards

7.1 Continuous sound level

m The operator always must use ear protection. The emission value at the ear of thedriver 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 finisher has been measured under free-field conditionsaccording to prEN 500-6, dated March, 1997, and ISO 4872 at a normal engine speedof 2100 rpm.

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

Sound capacity level: LWA = dB(A)

Sound pressure level at the machine

7.2 Operating conditions during measurement

The diesel engine was running at maximum speed. The screed was arrested in thetransportation position. Conveyors, augers, tampers and vibration were running atleast at 50% of the maximum speed.

7.3 Measuring point configuration

Semispherical measuring surface with a radius of 16 m. The machine was at the cen-tre. The measuring points had been assigned the following co-ordinates

Measuring point 2 4 6 8 10 12

Sound pressure level LAFeq (dB(A))

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

Co-ordinates X Y Z X Y Z

±11.2 ±11.2 1.5-4.32+4.32

+10.4-10.4

11.3611.36

SCHALL.TIF

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7.4 Vibration acting on the entire body

When the machine is used properly, the weighted effective acceleration values at thedriver’s seat of aw = 0.5 m/s2 according to prEN 1032-1995 are not exceeded.

7.5 Vibrations acting on hands and arms

When the machine is used properly, the weighted effective acceleration values at thedriver’s seat of ahw = 2.5 m/s2 according to prEN 1033-1995 are not exceeded.

7.6 Electromagnetic compatibility (EMC)

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

- interference emission according to DIN EN 50081-1/03.93:< 40 dB µV/m for frequencies of 30 MHz - 230 MHz measured at a distance of 3 m< 47 db µV/m for frequencies of 20 MHz - 1 GHz measured at a distance of 3 m

- interference immunity against electrostatic discharge according to DIN EN 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 finishercontinues to work without malfunction during the test.

A Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

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C Transportation

1 Safety regulations for transportation

m There is a risk of accident unless proper preparations are made for the paver finisher,screed and spraying system, or if transport is not performed correctly!

Dismantle the paver finisher and screed right down to basic width and retract thespraying system to basic width. Remove all loose and protruding components (auto-matic level control unit, auger limit switch, limiting plates etc.). When transporting un-der a special permit, secure these parts!

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

Check that the clamping device for the auger frame is fastened and that the telescopictube cannot slide out (see chapter E, section 2.6).

Stow all components not firmly attached to the paver finisher, screed and sprayingsystem in the boxes and recess provided. Close all coverings and check that they are securely seated.

In Germany, gas bottles must not remain on board of the paver finisher during trans-port.Disconnect the gas bottles from the gas system and protect them with their caps. Usea 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!

After transport, reinstall all protective equipment properly.

When transporting the unit on public highways, the following also applies:

m Caterpillar paver finishers in Germany must never be driven independently on pub-lic highways. 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 securedin this position. The driving lights must be properly adjusted.

Only accessories and extension parts may be transported in the hopper, no materialor 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.

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2 Transportation on low-bed trailers

m Reduce the paver finisher and thescreed to their basic widths; also re-move any attached side plates. Toprevent damages to the screed, the in-clination of the ramp to be used mustnot exceed 11° (19%).

2.1 Preparations

- Prepare the paver finisher for opera-tion (see chapter D, section 3).

- Close hopper lids using buttons (1). - Engage both hopper transport safe-

guards (6).

- Raise screed with button (2). Retractthe screed parts by using switch (3) inconnection with the keys in the keyblockleft until the screed matches the basicwidth of the paver finisher. Engage thescreed transport safeguard (7).

- Extend the levelling cylinders complete-ly by using key (4) in connection withthe keys in the keyblock right.

- Press button (5)- Set the preselector (8) to "zero". Set

the drive lever (9) to the centre posi-tion.

- Remove all protruding or loose partsfrom the paver finisher and the screed(see also the Operating instructionsfor the screed). Store these parts in asafe place.

- When screed is operated with the op-tional gas heating system:

- Remove the gas bottles for the screedheating 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.

A B C D

START

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2.2 Driving onto the low-bed trailer

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

- Use the work gear and low engine speeds to drive onto the low-bed trailer. - Lower the screed onto wooden blocks on the low-bed trailer. - Switch off the paver finisher. - Attach and secure the protective hood to protect the operating panel. - If necessary, swing down the protective roof:

- Unfasten locking pins on roof console and push roof forwards using handle onframe. When it is in the lower position, secure it with the bolts.

- On models with a tarpaulin roof: remove tarpaulin weather protector prior to anyextended journeys.

- Secure the paver finisher to the low-bed trailer: - Use only appropriate, approved at-

tachment devices. - Use the provided four retaining points

(9, 10).

- After it has had time to cool down, removethe exhaust extension pipe.

2.3 After transportation

- Remove the attachment devices.- Swing up the protective roof. Pull out locking pins, raise protective roof backwards

by pressing handle then lock back into position.- 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.

F0128_A1.TIF

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3 Transportation on public roads

m Reduce the paver finisher and thescreed to their basic widths; also removeany attached side plates.

3.1 Preparations

- Prepare the paver finisher for opera-tion (see chapter D, section 3).

- Close hopper lids using buttons (1).Engage both hopper transport safe-guards (6).

- Raise screed with button (2). Retractthe screed parts by using switch (3) inconnection with the keys in the keyblockleft until the screed matches the basicwidth of the paver finisher. Engage thescreed transport safeguard (7).

- Extend the levelling cylinders complete-ly by using key (4) in connection withthe keys in the keyblock right.

- Press button (5)- Set the preselector (8) to "zero". Set

the drive lever (9) to the centre posi-tion.

- Remove all protruding or loose partsfrom the paver finisher and the screed(see also the Operating instructionsfor the screed). Store these parts in asafe place.

- When screed is operated with the op-tional gas heating system:

- Remove the gas bottles for the screedheating system:- Close the main shut-off valves and

the bottle valves.- Unscrew the valves on the bottles

and remove the gas bottles from thescreed.

- Transport the gas bottles on asecond vehicle; heed all pertaining safety regulations.

A B C D

START

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3.2 Driving on public roads

- Switch Fast/slow switch (12) to "Hare"(i.e. fast) if necessary.

- Turn the preselector (8) to maximum. - Use the drive lever (9) to regulate the

speed.

f Press the emergency stop button when adangerous situation arises!

A B C D

START

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4 Loading by crane

m Use only lifting gear that can bear the load.(For the weights and dimensions, see chapter B, sections 4)

A When loading the vehicle with crane equipment, use four load-bearing points (9, 10).

- Park the vehicle safely.- Engage the transport safeguards.- Remove any attachments and acces-

sories from the paver finisher and thescreed until the basic width has beenattained.

- Remove all protruding or loose com-ponents and the gas bottles from thescreed heating system (see ChapterD).

- Attach crane lifting tackle to the fourretaining points (9, 10).

m Make sure that the paver finisher re-mains in a horizontal position duringtransport!

5 Loading the dismounted emulsion spraying system

Protruding or loose parts must be removed.

f Heed the lifting capacity of the fork-lift truck or the crane and its lifting gear (chains,ropes, hooks, etc.)!

A For the weights and dimensions of the spraying system, see chapter B, section"Technical Data".

F0048_A1.TIF

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5.1 Loading by crane

Attach the hooks to the provided secur-ing points (13, 14).

m Oil, grease and/or emulsion may leak outif the emulsion spraying system is not at-tached exactly horizontally. Danger to theenvironment!

f Suspended load! Do not step under the suspended load!

5.2 Loading by fork-lift truck

m Always bear in mind that the centre of gravity for the spraying system or accessoriesbox might be off centre.

f During loading with a fork-lift truck, the load may topple over or parts may fall down.Keep out of the danger area!

Trans.TIF14

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6 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 finisher, even on slopes.

Use only approved tow bars!

If necessary, remove nay attachments and accessories from the paver finisher andthe screed until the basic width has been attained.

A hand pump is located behind the left lateral flap that must be actuated to be able totow 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 securedagainst accidental rolling or is already properly connected to the towing vehicle.

- Release lock nut (2), screw threadeddowel (3) into pump as far as possibleand secure with lock nut.

- Actuate lever (4) of hand pump untilsufficient pressure has been built upand traction system brakes have beenreleased.

m Always only tow the shortest distance tothe means of transport or the next park-ing possibility.

Following towing, unscrew the threadeddowel (3) a few turns again and lock withthe lock nut (2).The traction system brakes are no reac-tivated and the machine is secured againstrolling. The pump lever should be locked when the upper cylinder (5) is retracted.

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

Pumpe150.jpg

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- Remove spraying system.- Attach towbar rod to the trailer coupling

(19) on the bumper.- Carefully and slowly tow the paver fin-

isher out of the construction site or thedanger area (use the shortest possibledistance).

Schlepp.tif 19

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6.1 Safely parking the vehicle

m When the paver finisher is parked at a lo-cation accessible to the public, it must besecured in such a way that unauthorisedpersons or paving children cannot damagethe vehicle.

- Remove the ignition key and the mainswitch (1) and take them with you – donot hide them somewhere on the ma-chine.

- Fit cover over operating panel (2) andlock it down.

- Store loose parts and accessories in asafe place.

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D Operation

1 Safety regulations

f Starting the engine, the traction drive, the conveyor, the auger, the screed, the spray-ing system 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 forbidden! Unless otherwise specified, the controls may only be actuated when the engine isrunning!

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 driver’s position that is opposite to the flowing traffic! Lock

the operating panel and the driver’s seat. - Keep a sufficient safety clearance to overhanging objects, other machines and

points of danger! - Be careful when travelling on rough terrain to keep the paver finisher from slipping,

tipping or turning over.

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

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2 Controls

2.1 Operating panel

A B C D

START

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m General notes on the observation of CE regulations

All functions of self-engaging buttons which might provoke a risk during start-up of thediesel engine (conveying function of auger and conveyor) are set to STOP in case ofan emergency stop or a control restart. Changes of settings which are performedwhen the diesel engine is at a standstill ("AUTO" or "MANUAL") are reset to "STOP"when the diesel engine is started.Turning on the spot (button 19) is reset to straight-ahead travel.

Item Designation Brief description

1Steering potenti-ometer

The steering wheel movement is transferred electrohydrauli-cally.

A For precision adjustment, (position "0" = straight ahead)refer to adjustment for straight ahead travel. For turning on the spot, refer to switch (turning on thespot).

2Retaining bracket for operating panel

For securing the movable operating panel against inadvertent movement at the desired finisher height. - Turn the knurled screw at the desired location into the

designated notch and secure with the knurled nut.

f When not secured, the operating panel can move. Dan-ger of accidents during transportation!

3Latch for operatingpanel

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

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

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

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Item Designation Brief description

5Ignition lock and illumination switch

Positions:1 Ignition on2 Parking/reversing light, dashboard lighting, working lights where applicable 3 Headlights (low-beam lights)4 High-beam headlights

A Press inhibit between 2 and 3 to cancel. Turning key anticlockwise = parking lights

6 not used

7Emergency stop button

In the case of an emergency (danger to persons, possible collision etc.), press in the button! Pressing the emergency stop button switches off the engine,

the drives and the steering system. Making way, lifting the screed or other actions are then no longer possible! Danger of accidents!

The emergency stop button does not shut off the gas heating system. Close the main shut-off valve and the valves on the bottles by hand!

If electrical malfunctions occur, the engine must be shut down manually using the linkage on the fuel injection pump. To restart the engine, the button must first be pulled back out again.

8Driver's cab: deploy (O)

To deploy the driver's cab hydraulically out beyond the outer edge of the vehicle.

f Watch out for oncoming traffic and obstacles!

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9Drive lever(forward - reverse)

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 To swivel outwards, pull ring (9a) upwards. Depending on the position of the drive lever, the following functions can be activated: Position 1:Conveyor and auger on. Position 2: Screed motion (tamper/vibration) on; Engine on;

increase speed until the stop is reached. Use the preselector to set the maximum speed.

10Preselector trac-tion drive

For setting the maximum speed that can be reached when the drive lever is at its stop.

A The scale roughly matches the speed in m/min (duringpaving).

11 StarterStarting is only possible when the driver lever is in the neutral position. All emergency stop buttons (on the operating panel and the remote controls) must be pulled out.

12Straight-ahead travel synchronisa-tion

Additional function for machines without synchronisation or when sensors in the caterpillar drives are defective.Using this potentiometer, both chains can be synchronised for straight-ahead travel while driving: - Set the steering wheel to position "0"; then adjust the

potentiometer until the finisher is travelling straight ahead.

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13 Open hopperPush-button:Open left lid of hopper + open right lid of hopper

13 A Close hopperPush-button:Close left lid of hopper + close right lid of hopper

14Raise frame on spraying system

The switch controls the two drive cylinders via a hydraulic valve. These cylinders move the frame to the desired height.The optimum position is displayed by the indicator lamp (48).

14 ARaise frame on spraying system

refer to Pos. (14)

15Filling the machine for paving

Self-engaging button with LED indicationOperating requirements: button 16 "OFF"

Button 15 is used for the filling function:The diesel engine speed is increased to the preselected

nominal speed and all conveying functions (conveyor and auger) which are set to "Automatic" can be activated.

Switching off: Press button 15 again or tilt the drive lever to the paving position.

16Main function switch

Self-engaging button with LED indication

Button 16 locks all functions necessary for paving. Although the individual functions are set to "Auto", they are not acti-vated when the drive lever is moved.

The set-up is retained, allowing the machine to be re-posi-tioned and unlocked at the paving site. Paving can be contin-ued by moving the drive lever.

A Button 16 is set to "ON" when restarting.

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Item Designation Brief description

17Traction drivefast/slow

Self-engaging buttons with LED indicationHare: transport speedWhen button 16 is set to OFF (stands for paving), button 17 has to be set to "tortoise".Tortoise: operating speed for pavingOnly change the speed when the paver finisher is at a

standstill!

A When restarting, the buttons are set to working speed(tortoise).

18Straight-ahead travel

Self-engaging buttons with LED indication

A When restarting, the button is set to "Straight-aheadtravel".

Normal position for straight-ahead travel.

A If the button at the bottom has been inadvertently ac-tivated (with the steering knob (1) set to straight-aheadtravel), the finisher does not move. This is often inter-preted as a ‘malfunction’.

Button 17 is set to "tortoise".

19Turning on the spot

Self-engaging buttons with LED indicationThe finisher turns on the spot (the caterpillar chains run in opposite directions) when the steering knob (1) is set to "10". Steering knob turned to the left = finisher turns to the left Steering knob turned to the right = finisher turns to the right

f When the finisher turns, persons and objects next to thefinisher are in extreme danger. Watch the area wherethe finisher turns!

20Tamper(screed-specific)

Self-engaging button with LED indicationOperating requirements: button 16 must be set to "OFF"

Switching function ON or OFF.The function is activated when moving the drive lever.Set-up operation is actuated in conjunction with button 21.

21 Set-up operation

When the machine is at a standstill, this button is used for the commissioning of all working functions which are only acti-vated when the drive lever (travelling machine) is moving.Button 21 "ON"Button 16 "OFF"The diesel engine speed is increased to the preselected set value.

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Item Designation Brief description

22Engine speed / compressor opera-tion

Self-engaging button with LED indicationIncreases the engine speed to nominal speed without needing to deploy the driving lever.The compressor cuts in and builds up pressure.

A Makes it possible to spray emulsion directly, as soon asthe paving operation commences.

23 Vibration Operation and application: see button (20).

24 Auger left/right

Self-engaging buttons with LED indication

Toggling between two switching conditions.Stop: Operational readinessAuto

Reset to STOP in case of an emergency stop or a restart.Button 16 locks the conveying function.

25Levelling cylinderleft/right

Self-engaging button with LED indicationFor manually actuating the levelling cylinders when automatic levelling is switched off. The switch on the remote control must be set to "manual". LED "C" (left) and LED "D" (right) indicate the setting.Switched off by pressing the button again or by pressing but-ton 28 or 31.Adjustment of the levelling cylinders occurs by using the appropriate button in the pad (right) for the directions of move-ment (27).

26Engine speed adjuster o

For continuous adjustment of the engine speed (when drive lever (9) is at the stop). Pressing the button opens a menu on the display in which the set value for the diesel engine speed can be viewed or changed.Min. position: idling speedMax. position: rated speed

A For paving, select the rated speed; reduce the speed fortransportation.

A The automatic speed control keeps the set speed con-stant even under a load.

27Pad (right) for directions of move-ment

Used in conjunction with buttons 25, 28 and 31; releases a movement towards the indicated direction.

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Item Designation Brief description

28"MANUAL" auger operation and lifting/lowering the auger

Self-engaging button with LED indicationSwitched off by pressing the button again or by pressing but-ton 25 or 31.

1. Move auger in "MANUAL" modeRequirements: button 24 must be set to "AUTO"Using the buttons in the pad (left) for the directions of

movement (29), the conveying speed of the automatic function can be exceeded with full conveying performance in the direction of the corresponding arrow.

2. Lifting/lowering the augerUsing the buttons in the pad (right) for the directions of

movement (27), the auger is lifted or lowered to the direction of the arrow.

29Pad (left) for the directions of move-ment

Used in conjunction with buttons 25, 28 and 31; releases a movement towards the indicated direction.

30 HornMust be activated in the case of emergencies and to indicate that the machine starts to move!

31Extend / retract screed

Self-engaging button with LED indicationSwitched off by pressing the button again or by pressing but-ton 25 or 28.Using the buttons in the pad for the directions of movement, the screed is moved to the indicated direction of the arrow.LED "A" and LED "B" indicate the vario screeds.

32 Conveyor left/right

Self-engaging buttons with LED indicationTo change between the three switching states, press the but-ton again:STOP: Operational readinessAUTOMANUAL

Reset to STOP in case of an emergency stop or a restart.Button 16 locks the conveying function.

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Item Designation Brief description

33 Screed position

Push-button function Lift screed

Self-engaging button with LED indicationLower screed/screed in floating position

Screed floating position: Pressing the button turns the LED ON and prepares the screed for "floating position", which is acti-vated by the actuated drive lever (9). Pressing the button again or pressing the button Lift screed turns the LED off.Lower screed: Keep the button (LED ON) pressed. As long as the button is pressed, the screed is lowered. After releasing the button, the screed is blocked again and the LED indicates OFF. Button 16 is set to the OFF position

m During paving, the screed must always be in the floatingposition. This also applies to brief stops and truckchanges if the automatic screed stop function is used.

A If the floating position is not activated during paving, thehorn issues a warning signal.

34Screed charging or relieving

Self-engaging buttons with LED indicationSwitched off by pressing the button again or by toggling between the two buttons.

For charging/relieving the screed to influence traction and the compacting ratio. To pre-adjust the pressure of the hydraulic oil, set this button

and button 21 to "ON".

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Item Designation Brief description

35TDM Control, input and display termi-nal

Display keyboard Button "Enter" starts the menu operation

Buttons "Left/right"

Buttons "Scroll up/down"

Button "Escape" closes the menu

36Temperature indi-cator for hydraulic oil

Normal display up to 120 °C = 248 °F.

m Stop the paver finisher when higher temperatures areencountered (drive lever (9) to the centre position), letthe engine cool down while idling. Determine the causeand correct it if necessary.

37 Fuel gaugeAlways heed the fuel gauge.

m Do not completely empty the diesel tank! Otherwise, theentire fuel system must be ventilated.

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Item Designation Brief description

38Warning lamp for "Water in fuel" (red)

Lights up if too much water is detected in the water separator on the fuel system.

m To avoid damaging the engine, drain off the separatedwater immediately as described in the Maintenance In-structions.

A Lights up for a few seconds once the ignition has beenswitched on for checking purposes.

39Error message (yellow)

Indicates that there is an error on the engine. Depending on how serious the malfunction is, the machine can either continue to be operated for a short period or, alter-natively, the engine needs to be shut down automatically. To prevent further damage, the fault should however be rectified as soon as possible.

A Lights up for a few seconds once the ignition has beenswitched on for checking purposes.

A For error diagnosis, refer to the section on "Engine errormessages"

40High beam indica-tor (blue)

Lights up when the high beam is switched on (at the ignition key (18)).

f Avoid blinding the oncoming traffic!

41 not used

42 not used

43Coolant check (red)

Lights up whenever the coolant level is too low.

m If the lamp does not go out, switch off engine immediately.For further possible malfunctions, refer to Operating in-structions for the engine.

44

Oil pressure indi-cator for the hydraulic traction drive (red)

Must go out shortly after the engine has been started. Observe warm running. The hydraulic oil is possibly too cold and stiff.

m Do not switch on the traction drive when the lamp doesnot go out (see the section "Malfunctions").

A The lamp goes out when the pressure drops below2.8 bar = 40 psi.

45Oil pressure check in diesel engine (red)

Must go out shortly after the engine has been started.

m If the lamp does not go out, switch off engine immediately. For further malfunctions, refer to Operating instructionsfor the engine.

46 not used

47Battery charge check (red)

Must go out after starting when the engine revs up. - Switch off the engine.

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Item Designation Brief description

48Indicator lamp for frame adjustment

Indicator lamp shows the optimum position for spraying ramp relative to ground.If the lamp fails to go out (irregular features on ground), the frame needs to be raised or lowered using the height adjustment switch until the lamp lights up again.

49Engine tempera-ture check (red)

Lights up whenever the engine temperature is too high.

m Engine power is automatically governed back. (still pos-sible to drive vehicle). Stop paver finisher (drive lever incentre position), allow engine to cool down at idlespeed. Establish cause of problem and remedy wherenecessary (refer to section on "Malfunctions"). Aftercooling to normal temperature, engine can once againoperate at full power.

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

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

52Indicator lamp foremulsion level (red) (O)

Lights up as soon as the level in the emulsion tank gets too low.

A A warning lamp on the spraying ramp controller switchbox also lights up.

53Indicator lamp for compressor(green) (O)

Indicates that the compressor is running.

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2.2 Operating the input and display terminal

Display keyboard

(A) Button "Escape" closes the menu

(B)/(C) Buttons "Left/right"

(D)/(F) Buttons "Scroll up/down"

(F) Button "Enter" starts the menu operation

TDM.cdr

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3Working in the menu

Once the ignition has been switched on and after a brief charging process, the mainmenu appears on the display:

Various actual values are displayed here and operators can select from 6 sub-menus.

- Capacity of flow/paving depth (1)- Operating hour meter (2)- Heating control for electrical screed heating system (o) (3)- Emergency function / screed stop and tamper start (4)- Display showing various actual engine statuses (5)- Service program for workshop and mechanics (6)

Push button (F) to select one of the subordinates, choose one of the subordinates bypressing push button (D/E) (the arrow becomes black) and enter by pressing pushbutton (F).

The following actual values are shown on the right-hand side of the display.

- Present roadspeed / operating speed in m/min (7)- Present roadspeed / operating speed in km/h (8)- Fuel consumption in L/h (9)- Distance travelled in one operation (10)

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Transport volume/layer thickness (1)

Transport volume of conveyor

As with the two remote controls, the trans-port speed of the two conveyors can beset separately.

- Reduce speed of left-hand conveyor - button (B)- Increase speed of left-hand conveyor - button (C)- Reduce speed of right-hand conveyor - button (D)- Increase speed of right-hand conveyor - button (E)

The speed can be set to 8 different stages. The speed stage set for each conveyor isshown in displays (1) and (2).

Press this button (F) to jump into a sub-menu where the layer thickness can be set.Return to main menu by pressing button (A).

Layer thickness

It is possible to select from three presetlayer thicknesses.

- Top layer (3)- Bonding layer (2)- Substrate (1)

m (o) Select the Top layer function (3) for a "soft" tamper startup: Softly tamper start-up when function top course (3) is selected:

To adjust the desired layer thickness, press push button (F) (figure becomes blackand flashes), select by pressing push buttons (D/E). To select one of these threepress push button (F) (figure becomes black and flashes), choose one of the subor-dinates by working push button (D/E) and confirm by pressing push button (F).

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3Operating hour meter (2)

Two different operating hours values aredisplayed:

- Total operating hours (1) with enginerunning

- Real operating hours (2) during paving

m In order to observe maintenance intervals (chapter F), call up every day and note thetotal operating hours!

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Heating control for electrical screedheating system (3) (o)

In this menu sub-item, the heating tem-perature for the following screed ele-ments can be read off and can be jointlyset for all screed elements:

- Actual temperature value, main screed, on left (1)- Actual temperature value, main screed, on right (2)- Actual temperature value, extendable part, on left (3)- Actual temperature value, extendable part, on right (4)- Nominal temperature value set for all screed elements (5)

A The temperature is set in stages of 1°C in a range of between 20° and 180°C

To change the nominal value (5), press button (F) (number is highlighted with blackbackground and flashes). The nominal value can now be modified using the buttons (D/E). Confirm the value required by pressing the button (F) (number no longer flashes). The menu sub-item can be exited by pressing the button (A).

Select the "Sub-menu" symbol (6) and confirm by pressing button (F) to jump into thesub-menu for selecting the activated consumers:

Selection of activated electronic elements

This menu sub-item is used to set whichelectronic elements on the screed heat-ing system switch cabinet can be acti-vated:

- Selection 1: heating only- Selection 2: heating and lighting- Section 3: lighting only

To change the present selection (1), press button (F) (number is highlighted with blackbackground and flashes). To modify the selection, press buttons (D) or (E) until the number required can be seenon the display (1).Confirm the required selection by pressing the button (F) (number no longer flashes).

The sub-item can be exited by pressing the button (F)

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3Emergency function / screed stopand tamper start (4)

If a nominal value specification or actualvalue measurement fails (e.g. sensordefective, remote control failed), the per-formance of various functions can be set for automatic operations.

- auger (1)- conveyor (2)- tamper (3)- vibration (4)The current value can be set to between 0 and 100%.

A Settings can only be made to these functions during an instance of failure.

Three further sub-items can be selected as variable functions:

- screed stop (5)- tamper start (6)- tamper stop (7)

- The screed stop (5) is opened to restart the machine after the defined time limithas elapsed.

- The nominal value for the tamper start dynamics (6) can be set in the range ofbetween 0 and 100%. Nominal specification is 50%. (Delayed tamper start)

- The nominal value for the tamper start dynamics (7) can be set in the range ofbetween 0 and 100%. Nominal specification is 50%. (Delayed tamper stop)

Use the (B/C) or (D/E) buttons to select the function required and use the (F) buttonto enter the sub-item (number has black background and flashes). Use the (D/E) buttons to change the value and press the (F) button to confirm(number stops flashing). If necessary, use the (B/C) or (D/E) buttons to select the nextsub-item or transfer the value modified and exit the menu sub-item by pressing the(F) button twice.

Select the "Sub-menu" symbol (8) and confirm by pressing button (F), to jump to thesub-menu for setting the automatic steering unit:

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Automatic steering unit

A No functions are saved in the wheeledpaver program in this menu sub-item!

In this menu sub-item, the operator canuse the selection (1) to set whether the automatic steering unit is to be activated ordeactivated:

- Selection 0: automatic steering unit deactivated- Selection 1: automatic steering unit activated.

If the appropriate equipment (Sonic-Ski) is fitted, the finisher can independently travelalong a reference body (e.g. securing rope) when the automatic steering unit is acti-vated.

A If the operator undertakes a steering movement, for reasons associated with safety,this overrides the automatic steering unit.

The menu sub-item can be exited by pressing the button (A).

Select the "Sub-menu" symbol (2) and confirm by pressing button (F) to jump into thesub-menu for calling up saved error messages:

2

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3Error memory

A No functions are saved in the wheeledpaver program in this menu sub-item!

Errors which have arisen and are savedin the system can be called up in this menu sub-item:

The number of error messages saved is shown in display (1). Selection (2) can beused to set whether the errors are to be shown one another in the display or whetherthis is initially not to be the case.

- Selection 0: do not display error messages- Selection 1: display error messages

If error messages are not to be called up,exit the menu item by pressing the button(A). To call up the messages, use button (C)to call up the selection window (2), makeselection with button (F) and press the but-ton (E) to set the value to "1".After confirming (by pressing button Fagain), the faults in memory are displayedon screen in sequence:

Example:

There are two error messages in thememory.

- Selection 1: error display- Error information- 1st error: right drive sensor- Error information- 2nd error: left drive sensor"

A For a more precise error diagnosis, referto "Error diagnosis and error localisa-tion" section

A The errors saved can be called up againif the ignition is switched off and back onagain.

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Display showing various actual en-gine statuses (5)

Several actual engine statuses can bemonitored in this sub-item:

- Engine temperature (1)- Oil pressure (2)- Fuel consumption in L/h (3)- Battery voltage (4)

Select the "Sub-menu" symbol (6) and confirm by pressing button (F) to jump into the"Counter showing distance travelled" sub-menu:

Counter showing distance travelled

The counter showing distance travelled(on the working site in metres) which isfitted in the paver can called up in thisdisplay.

The display can be set to "zero" by pressing the button (D).

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3Service program for workshop andmechanics (6)

After choosing this subordinate a re-quest for a password input appears inthe display.

m Only instructed personal is authorised for the further proceedings!

- Return to the basic menu by pressing the (A) button

- By pressing the (F) button, the follow-ing screed is called up and the PLCversion (1) can be queried:

- Return to the basic menu by pressingthe (A) button

A Settings can only be made in this screen if the correct numerical code has been en-tered.

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Additional information and adjustments / showing up via LC-display

Adjustment of the RPM speed of theengine

Comes up when pressing push button(26) of the operating panel.

- Indicating the scheduled value as well as actual value of the RPM speed.

To adjust the scheduled value, press push button (A) (figure becomes black andflashes), reset the value by working push button (D/E). To undertake the changepress push button (F) and confirm by pressing button (A). To leave the level of sub-ordinate press push button (26) again.

Set-up operation

Comes up when pressing push button(21) of the operating panel. RPM speedof the engine is displayed graphically.The present fuel consumption is alsodisplayed in l/h.

Stop

Comes up in the case of emergency stopbutton of the operating panel (7) or re-mote control (54o) is pressed.

Paving information

Comes up during paving and shows theactual speed of paving. RPM speed ofthe engine is displayed graphically. Inaddition, the prevailing fuel consumptionin l/h and the distance covered in metres during a given operation are displayed.

Information of malfunction

Comes up in case of malfunction.

- Diagnosing and detecting of the errorby pressing push button (F).

- To leave this menu press push button (A).

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32.3 Diagnosing and detecting malfunction

In the case of the display indicating malfunction select this menu by pressing pushbutton (F).

The following information is given.

Example:

Item Description

1 the part affected and its function

2 electrical malfunction

3 matching PLC module

4 controlled element

5 matching terminal strip

6 matching cable clamp

7 colour of the cable

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26

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Variations of malfunction (Pos 2)

Variations (Pos. 4)

Meaning Graphic

Parting of cable

Short circuit

Meaning Graphic

Ultrasound sensor/mechanical limit switch

Potentiometer

Valve

Electronics unit for automatic drive

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3Variations of malfunction (Pos 1)

Meaning Graphic

Auger L.H. lifting

Auger L.H. lowering

Auger R.H. lifting

Auger R.H. lowering

Levelling L.H. lifting

Levelling L.H. lowering

Levelling R.H. lifting

Levelling R.H. lowering

Hopper L.H. open

Hopper L.H. close

Hopper R.H. open

Hopper R.H. close

Screed charging

Screed relieving

Screed charging or relieving

Screed floating position

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Additional note "fuse"

Some error messages also make refer-ence to the relevant fuse (exampleF250.6). This should be checked first before initi-ating any other measures.

Meaning Graphic

Screed stop

Tamper function

Vibration function

Left remote control

Right remote control

Screed L.H. extend

Screed L.H. retract

Screed R.H. extend

Screed R.H. retract

Starting

Horn

Travel drive pump

neu_4.bmp

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3Variety of colours (Pos 7)

Example:

- Malfunction of the auger R.H. lower-ing.

- Short circuit of the valve Y35B at thePLC module A2

- Terminal strip X1, cable clamp 65, colour of the cable: green-red

Abbr. Meaning

bl blue

br brown

ge yellow

gn green

rs pink

rt red

sw black

vi lilac

ws white

Bild21.EPS

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Automatic drive error message

The electronics unit for the automaticdrive has failed. The data connection to the master mod-ule is interrupted.

A First check whether fuse F5.1 is still intact.

If the fuse has not caused the interrupt tothe data connection, the diesel enginecan be started (using an emergencystart):

- Engage button (1) (LED on).- Press start button (2).

neu6.bmp

A B C D

START

1

2

Element1_SPSC.cdr,Element2_SPSC.cdr

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3Further malfunction:

Slave error

- Slave defective (Example Slave A31)

Gateway

- Fault on the gateway

EMR

- Fault on the EMR engine electroniccontroller

Battery

- Potential to low

Travelling speed

- Potentiometer defective

Drive lever

- Potentiometer defective

Steering potentiometer

- Potentiometer defective

Sensor RPM engine

- Sensor defect

neubild4.EPS

Bild70.EPS

Bil871.EPS

Bild88a.EPS

Bild86a.EPS

Bild87c.EPS

Bild84c.eps

Bild85c.EPS

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Sensor caterpillar drive right

- Sensor defect

Sensor caterpillar drive left

- Sensor defect

Travelling motion

- Forward blocked

Travelling motion

- Backward blocked

Travelling motion

- Turning left blocked

Travelling motion

- Turning right blocked

Travelling motion

- Forward + backward blocked

Screed warning light

- Parting of cable or lamp defective

Screed warning light

- Short circuit

Bild95.EPS

Bil894.EPS

Bild089c.eps

Bild90c.EPS

Bild91c.bmp

Bild92c.eps

Bild93c.bmp

Bild70.EPS

Bil871.EPS

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32.4 Engine error messages

If an engine fault is detected, this is indi-cated by the relevant warning lamp (1)on the EMR electronic engine controllerand is also displayed simultaneously asa code on the display panel.

- Warning lamp (1) (yellow) continuous-ly lit: there is a fault in the engine. Themachine can continue to be operatedfor the time being. The error shouldhowever be rectified soon to prevent further damage.

- Warning lamp (1) (yellow) flashes: a serious malfunction has been detected in theengine which has either caused the engine to stop automatically or which requiresthis to be done to prevent further damage.

The error message which appears simultaneously on the display panel contains sev-eral error codes which, when decrypted, uniquely identify the malfunction:

- "ENGINE WARNING!" (2) appears on screen if a less serious fault has occurredand warning lamp (1) is then continuously lit.

- "!STOP ENGINE!" display(3) appears on screen if a serious fault requiring imme-diate engine shut-down has occurred and warning lamp (1) then flashes.

The SPN (4) and FMI (5) displays shown determine the component affected by theerror and the type of error occurring. The OC display (6) indicates the frequency withwhich the error displayed has already occurred.

A To determine the error using error code, refer to the "Malfunctions" section!

An error displayed on screen can be acknowledged by pressing the (A) key, causingit to disappear from screen. In cases where several faults occur at the same time,their error messages appear on screen in sequence following each press on the (A)key.

A To call acknowledged error messages back up again, you first need to switch the ig-nition off and back on.

- +

!

Kontrolelucht_SPSC.cdr

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Example:

Explanation:The flashing warning lamp indicates the presence of a serious malfunction in the en-gine which gives rise to automatic engine shut-down, or requires this to be done man-ually.Display indicator:SPN: 98FMI: 1OC: 3

Cause: The sensor indicates that the oil level is too low.Consequence: Engine shuts down whenever the engine protection disengagementfunction is enabled.Frequency: This fault has already occurred three times.

m Advise the After-Sales Service responsible for your paver finisher of this error mes-sage and they will then discuss with you how best to proceed.

Error message, "Coolant level too low"

This is displayed whenever an exces-sively low coolant level is detected.

m To prevent damage to the engine, imme-diately switch off the engine and top up with coolant in accordance with instructionsin the maintenance instructions.

- +

!?

012.bmp

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32.5 Remote control

AUTO

AUTO

AUTO

STOP

STOP

MANUAL

MANUAL

Remote_SPS_neu1.cdr

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6465

54

59

6263

57 56

55

58

58

61

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Item Designation Brief description

54Emergency stop button (o)

Function and application as with the emergency stop button (7) on the operating panel.Important for dangerous situations when the driver’s "sight" is restricted.

55 Horn Function as for push-button (30) on the operating panel.

56 Levelling cylinderLevelling cylinder Function and applications as for switch (25) on the operating panel- Switch must be set to "manual".

57

Button to switch on levelling cylin-der adjustment on the other side

By using this button, there will be the possibility to adjust the levelling cylinder on the other side. Indication on the other remote control switches automatic into switching state "manual".

58Buttons for direc-tions of movement

Functions in same way as buttons (27) on operating panel.

59 Conveyor Functions in same way as button (32) on operating panel.

60Adjuster for the capacity of flow

To adjust the capacity of flow, use the plus/minus but-tons. Indication by LED. Switch (59) must be set to "auto" to undertake the alternation.

61 AugerFunctions in same way as button (24) on operating panel.

62Buttons for con-veying direction of the auger.

By using this button, there will be the possibility to switch on the conveying function in both directions.- Switch (61) must be set to "auto".

63Adjuster for the capacity of flow

To adjust the capacity of flow, use the plus/minus but-tons. Indication by LED. Switch (61) must be set to "auto" to undertake the alternation.

64Extend/retract screed parts

Used to hydraulically extend or retract the extendable parts of the variable screed.

65 not used

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3Underside

Item Designation Brief description

66Socket for auto-matic levelling unit

Connect the cable for the grade control unit here.

67Socket for auger limit switch

Connect the cable for the material limit switch here.

68Cable for the remote control

Connect the plug to the screed(see operating instructions for the screed).

REMOTE_SPS_NEU1cdr

6766 68

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Emergency program for TDM-failure

To ensure the pavers operating ability during a display failure, an emergency programwill be started automatic.

Following setting and functions will beadjusted and switched on:

- Number of revolutions of the Dieselengine: 2100 rpm

- Traction drive (1) slow (Turtle)- Operating main switch (2) OFF- Tamper (3) switched on- Vibration (4) switched on

m Connected functions will not be indicat-ed by LED during a display failure!

A Tamper and vibration can be deactivat-ed by the associated rotary potentiome-ter (set to "zero"). The frequency of the tamper and vibra-tion can be read off the two associateddisplays (O).

A B C D

2100 min-1

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4

Cummins.tif,RPM.tif,Element1_SPS150C.cdr

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3Accessory the following function can beswitched by using the remote controls:

- Press button (1) to close the hopper.- Press button (2) to open the hopper.- Lifting the screed:

- Switch off the bar LED display for augerand conveyor (3) by pressing the rel-evant minus key (4).

- Lift the screed infinitely variable byusing the both Minus-buttons(4) si-multaneous.

- Switching the screed into readiness(floating position):- Switch the LED bar (3) of auger and

conveyor completely on by using theaccompanying Plus-buttons (5).

- Press both plus keys (5) to engage the screed float setting.

m The screed will be lowered at first when the drive lever is moved out of the centre position!

A To lift the screed out of floating position, the LED bar of auger and conveyor must bedeleted again.

Remote_SPS_neu1.cdr

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3

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2

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2.6 Special functions

Reversible conveyor

The direction of transport of the convey-or can be changed over to the oppositedirection to move material located just infront of the auger back slightly. Materiallosses, e.g. during transport operationscan therefore be avoided.

- Switch main function switch (16) overto "Off" switch position (LED off).

- Hold down one or both of the buttons(32) in the "STOP" switch position forapprox. 5 seconds. The system jumps into the "Manual"switch position and the conveyormoves approx. 1 metre towards thehopper. The system then jumps backinto the "Stop" switch position.

f If necessary, this process can be repeated as many times as required to allow theconveyor to move further in the opposite direction.

A B C D

Element1_SPS150C.cdr

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32.7 Controls 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 maintenance, referto Chapter "F"

m Heed the instructions when starting thefinisher externally. (see section "Startingthe paver finisher, External starting(starting aid)")

Battery main switch (72)

The main switch interrupting the circuitbetween the battery and the main fuse islocated under the left maintenance flap.

m Secure the hinged maintenance flapwith the respective support rods.

A For the assignment of all fuses, seechapter F, section 5.

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

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

71

Flap-l.EPS

Flap-l.EPS

72

F0077_A1.EPS/F0078_A1.EPS

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Transport safeguards for the hopper(73)

Before transport operations or to parkthe paver finisher, the hopper transportsafeguards must be in place with thehopper lids in their raised position.

f Do not enter the hopper while the engineis running! Danger of being caught by theconveyor!Without transport safeguards inserted,the hopper lids will slowly open; dangerof accidents during transportation!

Mechanical screed transport safe-guard (to the left and the right beneaththe driver’s seat) (74)

Used to protect the lifted screed from in-advertent lowering. The screed transportsafeguard must be engaged for transportoperations or when work finishes.

f Transportation with an unsecuredscreed bears the danger of accidents!

- Lift the screed. - Actuate the levers. - Check that the latches (to the left and to the right) engage in the crossbeams.

m ATTENTION!Insert screed lock only at crowning adjustment "zero"!Screed lock only for transportation!Do not enter or work under screed only secured with screed lock for transportation!Danger of accident!

73

F0076A_A1.EPS

F0083_A1.TIF

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

Telescoping seats (o) can be extendedbeyond the basic width of the paver fin-isher. They must be locked.

f The seats must not protrude from the ve-hicle during transportation. Push theseats back to the basic width of the pav-er finisher!

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

f The driver’s seat can move when the locking button is not engaged properly. Dangerof accidents during transportation!

F169_A1.EPS

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Separator fluid spraying system (80) o

Used to spray the parts coming into con-tact with asphalt with a separator emul-sion.

- The indicator lamp (81) lights up whenthe emulsion pump is running

- On/off switch (82) for the emulsionpump

- Quick-release coupling (83) for hoseconnection

m Only switch on the spraying systemwhen the diesel engine is running; other-wise, the battery will be discharged.Switch off after use.

A A permanent installed hose guide (83a)for the fluid spraying system is availableas an option.

Pull hose out of the guide till there is anaudible creak. The hose will engage inthis position after discharging.The hosewill be retracted automatic into the guideafter pulling and discharging again.

f Do not spray into open flame or on hot sur-face! Danger of explosion!

Emu2.tif

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3Pressure control valve for screedcharging/relieving (84) (o)

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

- Activation: see "screed charging/relieving device" (44).- For pressure display, refer to pressure gauge (84).

Pressure control valve for screedstop with pretensioning (84a)

This valve is located beneath the right-handbottom flap of the operator's platform.

This sets the pressure for "Screed stopwith pretensioning".

- Activation: see "screed charging/reliev-ing device" (20).

- Pressure display: see "pressure gauge"(84b).

Pressure gauge for screed charging/relieving and screed stop with preten-sioning (84b)

Displays the pressure for

- Screed stop with pretensioning, if drive lever is in neutral position (pressure setting with valve (84a));

- Screed charging / relieving, if drive lever is in third position (pressure setting with valve (84)).

F0105_A1.TIF

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A Further switch options for optionalequipment features may be located onthe central panel:

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

Actuate switch (a) to activate.

On/off switch for 230V sockets (85a)

If equipped with a 230V system, thesockets are actuated by means of switch(a). In the "I" switch position, the indica-tor lamp (b) lights up.

On / off switch for fuel tankfiller pump (85b)

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 engineand do not smoke. Do not fuel in en-closed spaces. Danger to health! Have afire extinguisher ready.

On / off switch special lighting (85c)

If the machine is equipped with additionalheadlights, these are actuated by meansof the switch (a). When switched to the"ON" position, the indicator lamp (b) lightsup.

m Switch the additional headlights and special lighting off when the engine is not run-ning, as the battery is otherwise discharged!

Schalt_betank.wmf/Schalt_230V.wmf/Schalt_Dachlicht.wmf/Schalt_Sonderlicht.wmf

85b

85a

85

85c

b a

b a

a

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3Folding roof locking brackets (on leftand right sides of roof console ) (86):

To lower the roof (for example duringtransport on a low-bed trailer):

- Loose the twistlock (86)- Draw the roof frame with the bow-type

handle (86a) to the front- Arrest the twistlock in the second lock-

ing hole.

Dach1.Tif/Dach.Tif

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87

Dach1.Tif/Dach.Tif

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Hydraulic folding roof (87) (o)

The hydraulically folding roof is securedby means of a latch (A) at the rear sus-pension on the left and right sides of themachine. This must be released prior tolowering and raising. Once it hasreached its terminal position, the roofmust be secured with the latch again.The hydraulic unit and the key-operatedswitch (A) for actuating the folding roofhydraulic system are located on the leftside of the paver finisher's rear panel.

A The roof can be raised and lowered with-out having to start the drive motor.

- In order to lower the roof, turn the key-operated switch (B) to the right untilthe roof has been lowered to its mini-mum level.

f Danger of crushing! Ensure that nobodyinserts their fingers or hands into the jointareas or are placed at risk by the loweringroof during the folding procedure.

- In order to raise the roof again, turnthe key-operated switch (B) to the leftuntil the roof has been raised to itsmaximum height.

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

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

2

A

B

C D

E

Dach_Hydr.wmf

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3Conveyor limit switches

The mechanical conveyor limit switches(89) or the ultrasonic conveyor limitswitches (89ao) control the materialflow at the respective conveyor half. Theconveyors should stop when the materi-al has roughly reached the area belowthe auger tube.

A This requires that the auger height hasbeen adjusted correctly (see chapter E).

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

A The limit switches control the material flowat the respective auger half.

The ultrasonic sensor is mounted bymeans of an appropriate leverage to theside plate. Loose clamping lever for ad-justment and modify angle / height of thesensor.The connecting cables are connected tothe remote controls on either side of thescreed (socket (59)).

A We recommend to adjust the limit switchpositions while the material is distributed.

F114_A1.EPS/Ultra3.EPS

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89a

Ultschall.tif

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Sockets for the remote control (leftand right) (91)

Connect the cable (60) of each large re-mote control unit to socket (91).

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

Connect the working lights (24 V) here.

- Power is present when the mainswitch (77) is switched on.

A As an option, one socket can be used toprovide power for an electrically heatedseat.

F171_A1.TIF

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32.8 Switch cabinet for the spraying system

Bild-5a.TIF

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Item Designation Brief description

93Spraying ramp con-trol computer

Computer for calculating the standstill period of the ramp in the automatic mode. The standstill period is derived from the values entered for parameters PR1 and PR2 in dependence of the working speed.

94Selector switch, spraying ramp con-troller

Auto: The computer controls the spraying ramp.Semi auto: A timer relay is used for controlling the spraying ramp. - Basic setting: Ramp stands still for 2 seconds.

Speed of approx. 5 m/min.

95Selector switch, Spraying ramp movement

Fixed: The lateral movement of the spraying ramp is disabled. Manually spraying of emulsion or cleaning of the nozzles is possible.

A If sprayed manually, the working speed of the sprayedemulsion quantity is adjusted to match.

Stop: Emulsion spraying is disabled and the extendable parts of the spraying ramp can be retracted or extended.Auto: The spraying ramp control mode is the one that has been selected with the spraying ramp controller selector switch.The left-hand extendable part for the spraying ramp extends by approx. 0.2 m.

A Retract the extendable spraying ramp parts to the basicwidth when work is finished (see "Stop").

96Selector switch, spraying direction

Forward (left): Sprays while the spraying ramp moves from the left to the right.Forward + backward (centre): Sprays in both directions.Backward (right): Sprays while the spraying ramp moves from the right to the left.

97Mains isolator for spraying ramp movement

Main switch for the spraying ramp movement

98Switch,compressor

Switch for switching the compressor on and off

99Switch,emulsion pump

Switch for switching the emulsion pump on and off

100Main switch, emul-sion spraying sys-tem

Switches the entire spraying system on or off.

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Item Designation Brief description

101Selector switchcompressed air cleaning

Selector switch for cleaning the individual emulsion circuits to prevent clogging of the emulsion pipes.Return to tank (left): Cleans the internal circuits to the tank in dependence of the compressed air valves.Off (centre): Compressed air cleaning switched off. Spraying ramp ground (right): Cleans the spraying nozzles.

f Repeat this procedure several (3-4) times. During theprocedure, wait until the pressure gauge drops to ap-prox.2-3 bar. Then repeat the cleaning procedure.

102Switch,compressed air valves

Switches compressed air valves 1-5 on/off for the various operational and cleaning circuits.

f A minimum pressure of approx. 3 bar is necessary tocontrol the compressed air valves!

f The emulsion pump should start to run as soon as thecompressed air valves are switched on.

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32.9 Operating panel, paver finisher

Item Designation Brief description

14Switch for the height adjustment of the frame

The switch controls the two drive cylinders via a hydraulic valve. These cylinders move the frame to the desired height.The optimum position is displayed by means of the indicator lamp.

48Indicator lamp for frame adjustment

Indicator lamp shows the optimum position of spraying ramp relative to ground.If this lamp is not lit (on uneven ground), the frame must be raised/lowered using the height adjustment switch until the lamp lights back up.

A B C D

Elemet3_SPS150C.cdr/Element1_SPS150C.cdr

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2.10 Remote control of emulsion spraying system, right side

Item Designation Brief description

103Switch,spraying nozzles of extendable part

On/off switch for the spraying nozzles of the right-hand extendable part. The nozzles at the margin can be separately switched on or off when the right-hand extendable part has been extended. If the nozzles are switched on, the indicator lamps above them light up to indicate this.

A When the extendable part is retracted, the nozzlesswitch off automatically.

104Switch,spraying nozzles of extension part

Switch for switching the spraying nozzles in the right-hand extension parts on and off.

105Switch,spraying nozzlesof main ramp

Switch for switching the spraying nozzles in the right-hand main ramp on and off.

106

Switch,retracting and extending ofextendable part

Switch for hydraulically extending and retracting the extendable part.

A Extending or retracting the extendable part is only possiblewhen the compressed air system has reached its op-erating pressure.

m The extendable part must be retracted during transportoperations. Danger of accidents!

107Indicator lampIdeal positionExtendable part

If the extendable part is extended, this should only be as far as strictly necessary for working width, and only to a point where the indicator lamp remains lit.

m The best position is important for the correct surfacespray volume (metering) without causing the emulsionto start overlapping.

BILD-4-gb.TIF

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32.11 Remote control of emulsion spraying system, left side

Item Designation Brief description

108Switch,spraying nozzles of extendable part

On/off switch for the spraying nozzles of the left-hand extendable part. The nozzles at the margin can be separately switched on or off when the left-hand extendable part has been extended. If the nozzles are switched on, the indicator lamps above them light up to indicate this.

A When the extendable part is retracted, the nozzles switchoff automatically.

109

Switch,retracting and extending ofextendable part

Switch for hydraulically extending and retracting the extendable part.

A Extending or retracting the extendable part is only possi-ble when the compressed air system has reached its op-erating pressure.

m The extendable part must be retracted during transportoperations. Danger of accidents!

110Indicator lampIdeal positionExtendable part

If the extendable part is extended, this should only be as far as strictly necessary for working width, and only to a point where the indicator lamp remains lit.

m The best position is important for the correct surface sprayvolume (metering) without causing the emulsion to startoverlapping.

111Switch,spraying nozzles behind the drive

On/off switch for the spraying nozzles behind the right-hand and left-hand drive.

112Switch,spraying nozzles in front of the drive

On/off switch for the spraying nozzles behind the right-hand and left-hand drive.

113Switch,spraying nozzlesof main ramp

Switch for switching the spraying nozzles in the left-hand main ramp on and off.

114Switch,spraying nozzles of extension part

Switch for switching the spraying nozzles in the left-hand extension parts on and off.

BILD-3-gb.TIF

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113

112

111 110

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108

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2.12 Compressed air indicator

Item Designation Brief description

115Pressure gauge,compressed air

Compressed air pressure gauge, indicating the operating pressure of the emulsion spraying system.

116Thermometer/ tem-perature presetting

Indicates the current emulsion temperature.Presets the temperature of the emulsion (red needle).

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32.13 Switch cabinet for emulsion heating

Item Designation Brief description

117Switch,heating circuit 2

380 V: Heating circuit 2 is supplied from the external heating system (switch in left-hand setting)Off: Heating circuit 2 is switched off.Generator: Heating circuit 2 is supplied from the integrated generator (switch in right-hand setting)

117 A

Indicator lamp "Heating from exter-nal power supply"

Lights up as soon as the heating for this circuit is provided from an external source.

117bIndicator lamp "Heating by gener-ator"

Lights up as soon as the heating for this circuit is provided from a generator.

118Switch,heating circuit 1

380 V: Heating circuit 1 is supplied from the external heating system (switch in left-hand setting)Off: Heating circuit 1 is switched off.Generator: Heating circuit 1 is supplied from the integrated generator (switch in right-hand setting)

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118b118 A

117b117 A

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118 A

Indicator lamp "Heating from exter-nal power supply"

refer to (117a)

118bIndicator lamp "Heating by gener-ator"

refer to (117b)

aFuses in heating circuit 1

A For fuse assignment, refer to Chapter F.

b

Fuses in heating circuit 2 and electrical sys-tem

A For fuse assignment, refer to Chapter F.

CEngagement of electrical system

A Refer to section "230 Volt electrical system"

Item Designation Brief description

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32.14 Switch cabinet for remote power supply

Item Designation Brief description

119Remote power sup-ply socket

Connection socket for external power supply to heating systems

120Safety switch for remote power sup-ply

The safety switch stops the diesel engine of the paver finisher as soon as the switch cabinet door opens.

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2.15 Left-hand tank side

Item Designation Brief description

121Safety switch,emulsion tank

Switches off the heating units if less than 500 litres of emulsion are left in the tank

122Filling level indica-tor, emulsion tank

The safety switch stops the diesel engine of the paver finisher as soon as the switch cabinet door opens.

123Switch, pump capacity

Switch for setting the capacity of the emulsion pumpFast: For loading and unloading the emulsion tankSlow: For operation

124EMERGENCY STOP

EMERGENCY STOP switch for the emulsion pump

125Filler neck,emulsion tank

Connection for filling and draining the emulsion tank

126Drain cock on emulsion tank

Drain cock for completely draining the emulsion tank

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125 124 123

122

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32.16 Manual spraying device, rear

Item Designation Brief description

127Compressed air valve, rear

Compressed air valve for supplying the manual spraying lance

128Shut-off valve,compressed air, rear

Shut-off valve for compressed air supply to the manual spraying lance

129Connection for rear manual spray-ing device

Screw connection for hose on manual spraying device

130Shut-off valve,emulsion, rear

Emulsion stop cock for manual spraying device

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2.17 Manual spraying device, front

Item Designation Brief description

131Compressed air valve, front

Compressed air valve for supplying the manual spraying lance

132Shut-off valve,emulsion, front

Emulsion stop cock for manual spraying device

133Shut-off valve,compressed air, front

Shut-off valve for compressed air supply to the manual spraying lance

134Connection for front manual spraying device

Screw connection for hose on manual spraying device

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33 230 Volt electrical system

3.1 230 Volt sockets on left and right sides

There is a socket on either side of the machine with an integrated insulation tester.

Item Designation Brief description

1Protective contact socket I, 230 Volt

Socket with spray protection for 230 Volt consumers.

m Seal socket with protective cap when not in use.

2Protective contact socket II, 230 Volt

Socket with spray protection for 230 Volt consumers.

m Seal socket with protective cap when not in use.

3 Test button For carrying out the insulation test.

4Cancel button and display for "Insulation error"

To cancel the simulated fault after the insulation test (display with error lamp in the button).Press this button and hold down for several seconds.

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On/off switch for 230V sockets

There is a switch for engaging the sock-ets in the electrical system switch cabi-net or on the middle panel of the paverfinisher.

A This switch may also be located on theemulsion heating system switch cabinet.

- The sockets are engaged usingswitches (a). In switch position "I" theindicator lamp (b) lights up.

- Switching off the sockets in switch position "0".Indicator lamp (b) is OFF.

3.2 Insulation test

A The insulation test must be undertaken every day when the machine is running andthe sockets are activated.

- Press test button (3) - "Insulation error" display must light up.- Press delete button (4) - display for insulation error goes out.

f If the test is completed successfully, work can proceed with the electrical system andexternal consumers can be used.However if the "Insulation error" indicator lamp displays an error even before the testbutton is pressed, work cannot proceed with the electrical system or with the externalequipment connected up. If an insulation error occurs, the sockets are automaticallyde-energised (i.e. electrically isolated).If no errors are displayed during simulation, do not carry out any work on the electricalsystem.

f If malfunctions arise, the electrical system must be checked by an electricianand/or repaired. This must be done before work can proceed on this systemand the equipment.

f Danger from electric voltageFailure to comply with the safety precautions and safety regulations can resultin electrical shock injuries from the electrical system.Danger to life!All maintenance and repair work on the screed's electrical system must alwaysbe carried out by an electrician.

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34 Operation

4.1 Preparing for 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 extension parts- Diesel fuel- Engine oil, hydraulic oil, lubricants- Separating agents (emulsion) and manual injector- Two filled propane gas bottles- Shovel and broom- Scraper bars 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 water scales + 4 m straightening bar- Levelling wire- Protective clothing, fluorescent jacket, gloves

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

- Heed the safety instructions. - Check the personal protective equipment. - Walk around the paver finisher and look out for any leaks and/or signs of damage. - Reinstall any parts removed for transport or ‘for overnights’. - Open bottle valves, shutoff valves on dual output and main non-return cock of gas-

fired screed heating system. - Carry out an inspection using the "Checklist for the machine operator"

(refer to Section 3.1).

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Checklist for the machine operator

Check! How?

Emergency stop button – on control panel – on both remote control units (optional)

Push in the button. The diesel engine and all running drives must stop immediately.

SteeringThe paver finisher must immediately follow every steering wheel movement in a precise manner. Check straight running.

Horn - on the operating panel - on the two remote control units (option)

Briefly press the horn button. The horn must sound.

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

Hazard warning lights of the screed(with vario screeds)

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

Gas heating system (O):- Bottle holders- Bottle valves - Pressure reducer - Hose break safety devices - Closing valves on dual output- Main shut-off valve - Connections - Indicator lamps of the switch box

Check: - Secure seat - Cleanliness and tightness- Working pressure 1.5 bar - Function - Function - Function - Tightness - All lamps must light up when the

system is switched on

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

Screed covers and walkways

For larger working widths, the walkway plates must be extended. Hinged walkway plates must be swung down. Check that the side shields, the side plates and the covers are securely seated.

Screed transport safeguard

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

Hopper transport safeguard

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

Protective roofBoth locking bolts must be in the provided bore hole.

Miscellaneous: - Engine hood - Lateral flaps

Check that the hoods and flaps are securely seated.

Accessories: - Wedges - Warning triangle - First-aid kit

The accessories must be in the provided holders.

Check! How?

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4.2 Starting the paver finisher

Before starting the paver finisher

Before starting the diesel engine and beginning operation, the following steps mustbe performed:

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

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

- Check the safety devices and protective devices.

"Normal" starting

Set the drive lever (9) to the centre posi-tion and the speed adjuster (10) to mini-mum.

- Insert the ignition key (5) in position"0". The lights should be switched offduring starting to reduce the currentdrain on the battery.

A Starting is not possible when the drivelever is not in the centre position or whenan emergency stop button (7) or (54o)on the remote control unit has beenpressed. ("STOP" in the LC-display).

- Press the starter button (11) to start the engine. Do not let the starter run perma-nently for more than 20 seconds; allow for a break of 1 minute after every attempt!

START

10

9

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11

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3External starting (starting aid)

A The engine can be started with the help of an external power source if the batteriesare 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:

- Switch on the ignition, set the drive le-ver (9) to the centre position.

- Use appropriate cables to connect theexternal power source.

m Observe the polarity! Always connectthe negative cable last and disconnect itfirst!

A Starting is not possible when the drivelever is not in the centre position or whenan emergency stop button (7) or (54o)on the remote control unit has beenpressed ("STOP" in the LC-display).

- Press the starter button (11) to start the engine. Do not let the starter run perma-nently for more than 20 seconds; allow for a break of 1 minute after every attempt!

When the engine is running:

- Disconnect the power source.

START

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After starting

To increase the engine speed:

- Set the drive lever (9) to position 1(slightly off the centre position).

- Increase the engine speed by press-ing button (21) on the operating panel.The engine speed will be increased tothe preselected value.

m Let the paver finisher warm up for ap-prox. 5 minutes if the engine is cold.

A B C D

START

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3Observe indicator lamps

The following indicator lamps must be observed under all circumstances:

For further malfunctions, refer to Operating instructions for the engine.

Coolant check (43)

Must go out after starting.

m If lamp fails to go out or if it lights up dur-ing operation:Switch off engine and check coolant lev-el.

For other potential faults, refer to Operating instructions for the engine (Engine oper-ating instructions).

Oil pressure indicator lamp for thediesel engine (45)

- Must go out shortly after the engine hasbeen started.

m If lamp fails to go out or if it lights up duringoperation: Immediately remove the igni-tion key and switch off the engine. Check the engine oil level.

For further malfunctions, refer to Operating instructions for the engine.

Oil pressure indicator lamp for thetraction drive (44)

- Must go out after starting.

m If the lamp does not go out:Do not switch on the traction drive! Oth-erwise, the entire hydraulic system couldbe damaged.

- +

!

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When the hydraulic oil is cold:

- Set the conveyor switch (32) to "manual"and the auger switch (24) to "auto".

- The remote control has to be connect-ed and the same function have to beset to "auto"

- Set the drive lever (9) to position 1- Press button (21) to increase the en-

gine speed, the conveyor and the au-ger start operating.

- Let the hydraulics warm up until the in-dicator lamp goes out.

A The lamp goes out when the pressuredrops below 2.8 bar = 40 psi.

For further possible malfunctions, referto section 4.

Battery charge indicator (47)

Must go out after starting when theengine revs up.

m If lamp fails to go out or if it lights up dur-ing operation: briefly increase the enginespeed. Switch off the engine and determine the cause for the malfunction if the lamp doesnot go out.

For further possible malfunctions, refer to the section "Malfunctions".

A B C D

START

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35 Starting the spraying system

A Perform the daily maintenance steps (see chapter F) before starting the emulsionspraying system.Check the operating hour counter to determine whether or not additional mainte-nance work (such as monthly or yearly maintenance) must be performed on the emul-sion spraying system.

5.1 Compressed air system

- Start the paver finisher (see the oper-ating instructions for the paver finish-er).

- Switch on the power supply: Main switch (97) "ON".

- Close all manual valves of the com-pressed air system to build up an op-erating pressure of 5.5 bar.

- Switch on the compressor switch (98).

A The maximum diesel engine speed is nec-essary to build up the operating pressure.

- Press button for compressor operation(22). The engine speed is now in-creased even when the drive lever isnot deployed, and pressure builds upin the spraying system.

A As soon as the compressor is running,the indicator lamps above the switch(98) and on the control panel (53) lightup.

A This early pressure buildup enablesemulsion spraying to start at the sametime as paving operations!

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5.2 Loading the emulsion tank

Open the tank lid on top of the emulsiontank to watch the filling procedure whenthe main compressor is switched on andan operating pressure of 5.5 bar is avail-able.

f Danger of burning by overflowing emul-sion or emulsion spurting out.

- Connect the flexible hose to the fillerneck (125) and open the hand wheel.

- Switch on compressed air valves 2and 5 (102).

- Switch (101) must be switched off!- Open the manual valve of the supply tank.- Switch on the emulsion pump using

switch (100).

A The EMERGENCY STOP switch (124)must not be pressed.

As soon as the emulsion pump starts op-erating, the red indicator lamp above theswitch lights up.

- Increase the emulsion pump capacitywith the switch (123).

m Reduce the pump capacity if the emul-sion tank contains mostly foam (set thepump capacity switch (123) to "slow").

- When approx. 2,650 l have been load-ed, switch the emulsion pump off bypressing the EMERGENCY STOP but-ton and set the pump capacity switchto "slow".

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3- Close the manual valve of the supply

tank.- Pull out the emergency stop button.- Switch on the emulsion pump.- Carefully unfasten the flexible hose on

the supply tank and fill with air to emptythe hose.

m Danger of burning by spilled emulsion!Wear protective clothing!

- Switch off the emulsion pump.- Close the manual valve of the filler

neck (125).- Close the compressed air valves

(102).

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6 Heating system

A To start the heating system, at least 500 l of emulsion must be in the tank.

6.1 Working temperatures

A The spraying temperature must be higher in percentage terms than the bitumen com-ponents.

6.2 Heating before the spray process

- Switch the heating system switches(117/118) to "generator".

- Increase the speed of the diesel en-gine.

- Switch on the compressed air valves(102) 1 and 2 to start the tank circuit.

- Switch on the emulsion pump.- Set the operating temperature of the

thermometer (116).- To switch on the heating system, pro-

ceed in reverse order.

Standard emulsion

Loading at least 70 °C

Spraying at least 60 °C

Elastomere emulsion

Loading at least 80 °C

Spraying at least 70 °C

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36.3 Heating during spraying

- only heating system 1; set switch(118) to "Generator".

6.4 During work interruptions (remote power supply)

m Warning: Dangerous voltage (380 V)!

A The stipulations of the local power sup-pliers must be heeded.The following standards must be heeded: DIN VDE 0100, part 704; DIN VDE 0100,part 737

- Open the switch cabinet door.

A Opening the switch cabinet door causesthe safety switch (120) to stop the dieselengine.

- Use the socket (119) to connect theremote power source.

- Set the heating system switches 1 and 2 to "380 V".

A Use the reverse sequence of steps to switch the heating system off.

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7 Emulsion circuit

Item Designation

1 Tank

2 Air filter

3 Manual valve

4 Emulsion filter

5 Emulsion pump

6 Spraying frame

7 Compressed air valves (1, 2, 3, 4, 5)

8 Return valve - tank

1 5

2 4

36

Emulsion.eps

Filter

Pump

Manual valve

Air filter

Tank

Spraying ramp

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37.1 Tank circuit

To prevent the emulsion in the uppersection of the tank from cooling, theemulsion in the emulsion pump muststart moving.

- Switch on the heating system 1 and 2(117/118).

- Switch on the compressed air systemand check whether an operating pres-sure of 5.5 bar is available (see sec-tion 4.1).

- Switch on the compressed air valves 1and 2 (102).

Use the switch (100) to switch the emul-sion pump on.

7.2 Spraying ramp circuit

m The spraying ramp circuit must beswitched on at least 5 minutes before thestart of operations in order to heat up thehoses leading to the spraying ramp andthe spraying ramp itself.

- Start the tank circuit.- Open compressed air valve 3.- Close compressed air valve 2.

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7.3 Preparations for paving

Separating agent

Spray the parts coming into contact withasphalt (hopper, screed, auger, pushroller) with a separator emulsion.

f Do not use diesel oil because it can dis-solve bitumen (prohibited in Germany!).

Screed heating system

Switch on the screed heating system approx. 15–30 minutes (depending on the am-bient temperature) before paving begins. Warming up prevents the material fromsticking to the screed plates.

A Refer to section 3 for instructions on how to operate the heating system.

Direction marks

To ensure straight paving, a directionmark 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 thebumper (arrow) and adjust it accord-ingly.

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3Loading/distributing material

- Button (16) has to be switched off.- Use switch (13) to open the hopper.

Instruct the truck driver to dump thematerial.

- Set the switches for the auger (24) andthe conveyor (32) to "auto".

- Press button (15) to fill the machine forpaving.

- Switch the conveyors on. The limit switches for the conveyors(89) or (89ao) must switch off whenthe material has reached the area be-neath the auger crossbeam.

- Check that the material is conveyedproperly. Manually switch on or off the conveyorif the material is not conveyed properlyuntil a sufficient amount of material liesin front of the screed.

A B C D

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7.4 Starting for paving

A B C D

AUTO

AUTO

AUTO

STOP

STOP

MANUAL

MANUAL

START

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3Set the switches, levers and controls listed below to the specified positions when thescreed has reached its operating temperature and a sufficient amount of material liesin front of the screed:

- Push the drive lever (9) all the way to the front and start driving.Screed floating po-sition 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 5–6 meters and correct if nec-

essary.

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

Item Switch Position

17 Traction drive fast/slow Tortoise-operating speed

10 Preselector traction drive Mark 6-7

33 Preparation for screed floating position LED ON

23 Vibration LED ON

20o Tamper LED ON

24/56 Auger left/right Auto

32/54 Conveyor left/right Auto

51 Levelling Auto

A Speed regulator, vibration approx. mark 40-60

B Speed regulator, tamper approx. mark 40-60

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7.5 Checks during paving

The following points must be constantly observed during paving:

Paver function

- Screed heating system- 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 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.

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37.6 Paving with screed stop and screed charging/relieving device:

General

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

- Screed stop with and without pretensioning on a stationary paver/finisher,

- Screed charging or relievingwith 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 thecompaction ratio. (To be used with light-weight screeds in exceptional cases.)

Screed charging/relieving

This function charges or relieves the screed regardless of its own dead weight.

Switch (34) has the following positions:

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

Switch positions "Screed charging/reliev-ing" are only effective when the paver fin-isher moves. When the paver finisherstops, "screed stop" is automatically se-lected.

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Screed stop

The "screed stop" function is used to block the screed hydraulics to prevent thescreed from lowering when the paver finisher stops during paving.

The switches (34) have to be switchedoff

- Automatic screed stop when the drivelever is in its central position.

- To lift the screed press button (33A)- To lower the screed press 1.5 sec.

button (33B)

m The screed block function is not sufficient as a safeguard during transport or mainte-nance work! In such a case, the screed transport safeguard must be inserted.

Screed stop with pretensioning

As for charging/relieving, a pressure of 2-50 bar can be individually applied to thescreed lifting cylinders. This pressure can neutralise the weight of the screed to pre-vent the screed from sinking into the freshly laid material, thus supporting the screedstop function, especially in those situation where the screed relieving function is used.

The pressure to be applied depends on the load-bearing capacity of the material. Ifnecessary, the pressure must be readjusted or changed as required during the firststops until the lower edge of the screed no longer leaves any marks when the finishermoves on again.

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

A When combining the "screed stop" and "screed relieving" functions, make sure thatthe pressure difference between the two functions does not exceed 10-15 bar.

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

A For paving with "Screed relieving", no screed stop with pretensioning should be em-ployed.

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34

B

A33

D 99

D_F

150C

.GB

.fm. 9

9-12

2 01

.120

3Adjusting the pressure (o)

Pressure adjustments can only be madewhile the diesel engine is running.Therefore:

- Start the diesel engine and set the trac-tion controller (10) to zero (precautionagainst inadvertent advancing).

- Set switch (33) to the floating position.

For screed stop with pretensioning:

- Set the drive lever (9) to the centre po-sition.

- Set switch (16) to position (LED OFF)and switch (21) to position (LED OFF).

- Use control valve (93a) (below thebottom plate of the operator's plat-form) to adjust the pressure and readit from the pressure gauge (93b). (Basic setting: 20 bar)

For screed charging/relieving

- Set the drive lever (9) to the centre po-sition.

- Set switch (16) to position (LED OFF)and switch (21) to position (LED ON).

- Set switch (34) to position (LED ON)(relieving 34a) or (charging 34b).

- Use control valve (93) (on the rear panel of the paver finisher) to adjust the pressureand read it from the pressure gauge (93b).

A When screed charging/relieving is nec-essary and automatic levelling is used(grade control and/or slope control), thecompacting performance changes (layerthickness).

A The pressure can also be set or correct-ed during paving. (Max. 50 bar)

A B C D

START

Element1_SPS150C.cdr/Element2_SPSC.cdr

10

33 16

21

34b 34A34

9

F0103_A1.EPS/F0167_A1.TIF

93a93b

F0103_A1.EPS/F0105_A1.EPS

93b 93

D 100

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7.7 Spraying

- Start the spraying ramp circuit.- Set the switch "Spraying ramp move-

ment" (95) to "Auto".

A When "Auto" has been selected, the left-hand extendable part of the sprayingramp extends by approx. 0.2 m to allowthe spraying ramp to perform crosswisemovements.

A Use the left-hand remote control to re-tract the extendable part to the basicwidth of the spraying ramp.

- Set switch for spraying system (96) tothe selected operating position (for-wards, reverse, forwards + reverse),refer to Chapter E.

- Enter the new parameter for PR1/PR2, see chapter E.

- Set the spraying width on the remote controls.- Engage spray nozzles ahead of the

drives (112) or behind the drives (111)using the left-hand remote controlpanel.

- Before starting work, set the main switch(97) "Spraying ramp movement" to "ON".

- Use the switch (14) on the operatingpanel to set the spraying ramp height.The optimum position of the sprayingramp relative to the floor is indicatedby the indicator lamp.

- Move the paver finisher with thespraying ramp to the point where workis to start.

- Switch off the spraying nozzles beforeand behind the drives.

- Move the paver finisher forward until thescreed is at the point where work is tostart. The distance covered is sprayed.The area of the drives remains un-sprayed.

- Align the screed. Switch on the spray-ing nozzles behind the drives whenthe paver finisher is ready for opera-tion.

95

Bild-5a.TIF

96

97

BILD-3-gb.TIF

112 111

A B C D

Element1_SPS150C.cdr

14

D 101

D_F

150C

.GB

.fm. 1

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037.8 Emptying the spraying ramp (end of paving)

- 1 metre before the end of the pavingarea, bring the paver to a stop.

- Close compressed air valve 1.- Set the switch (101) "Air cleaning" for

2 minutes to the "Return to tank" posi-tion.

- Then switch to the "Spraying rampground" position

- Set the switch (94) "Spraying rampcontroller" to the "Semi auto" position.

- Advance paver until spraying ramp is lo-cated at the end of the paving area.

- Switch off all spray nozzle switcheswith the exception of switch (111) for"Rear drive spray nozzles".

- Move the paver finisher out of the pav-ing area. Only the area behind thedrives is sprayed now.

- Once the paver finisher has reachedthe end of the paving stretch, all sprayfunctions are shut down.

- Drive the paver finisher to the cleaningsite.

- Clean the spraying nozzles and theemulsion filters to prevent clogging ofthe parts.

94

Bild-5a.TIF

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BILD-3-gb.TIF

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D 102

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.GB

.fm. 1

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7.9 Cleaning the spraying nozzles

- Repeat the cleaning procedure sever-al (3-4) times.

- Check the operating pressure(min. 5.5 bar).

- Switch the "Air cleaning" switch (101)to the "Spraying ramp ground" posi-tion.

- Allow the operating pressure to lowerto 2-3 bar.

- Switch the "Air cleaning" switch (101)to "OFF".

- Repeat the procedure.

7.10 Cleaning the emulsion filter

Refer to chapter F for cleaning the emul-sion filter.

- Let the system run for some seconds.This process should be carried out forany extended stationary period, e.g.overnight stops etc., after which youshould add another 3 litres of dieselfuel to the emulsion filter (139) to pre-vent the emulsion pump from settingsolid.

Bild-5a.TIF

101

BILD13.TIF

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D 103

D_F

150C

.GB

.fm. 1

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037.11 Notes on handling the spraying equipment

General

m Use the "Calculation sheet for spraying nozzles behind the drives" in chapter "Set-up"to select the correct nozzle size behind the drives.

Do not use the 110.04 nozzle type for polymer emulsions. To prevent frequent cloggingof the nozzles, sizes smaller than 110.06 should not be selected.

m The semi-automatic mode is a safety mode. To use this mode, the following is re-quired:- Determine the weight of the test area and measure with T1 = 2 sec. of the working

speed.- T = Set the timer to reach correct metering rate.

Equation: T = (Dosbase x T1) / Dos

T1 = 2 sec. (basic setting)

Dosbase= basic value in kg/m

Dos = nominal amount in kg/m, see chapter "Set-Up"

7.12 Finishing work with the sprayingequipment

- Move the finisher with the sprayingramp to the start.

- Switch off the spraying nozzles beforeand behind the drives.

- Move the paver finisher forward until thescreed is at the point where work is tostart. The distance covered is sprayed.The area of the drives remains un-sprayed.

- Align the screed. Switch on the spray-ing nozzles behind the drives whenthe paver finisher is ready for opera-tion.

Start of paving

Road

D 104

D_F

150C

.GB

.fm. 1

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1.12

03

7.13 Finishing work with the sprayingequipment

- Stop 1 m before the end of paving. Switchoff compressed air valve 1 and set the"Air cleaning" switch to "Return to tank".Switch on for 2 minutes.

- Set the "Air cleaning" switch to the"Spraying ramp ground" position andthe "Spraying ramp movement" switchto "semi auto"; set the timer relay to 2seconds.

- Advance the paver until the sprayingramp is at the end of its paving area.

- Switch off all switches for the sprayingnozzles, with the exception of switches "spraying nozzles behind the drive".

- Switch off all spraying functions when the paver finisher has reached the end of thepaving stretch.

- Drive the paver finisher to the cleaning site. Clean the spraying nozzles with com-pressed air to prevent clogging of the nozzles.

A Refer to chapter "Maintenance" for cleaning the emulsion filter.

m Heed the cleaning instructions to prevent clogging of the parts.

End of paving

Road 1 m

D 105

D_F

150C

.GB

.fm. 1

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1.12

037.14 Interrupting/terminating operation

During paving breaks (e.g. a delay insupply of material by trucks)

- Determine the approximate duration.- If there are grounds for believing that

the material might drop below the min-imum paving temperature, empty thepaver and position the leading edge atthe end of the paving section.

- Set the drive lever (9) to the centre po-sition.

During extended interruptions (e.g. lunch break)

- Drive lever (9) into centre position, RPM speed adjustment (10) to minimum posi-tion.

- Switch off ignition. - Switch off screed heating system.- When screed is operated with the optional gas heating system, close the valves of

the bottles.

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

START

9

Element2_SPSC.cdr

10

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.GB

.fm. 1

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03

When work is finished

- Run the paver finisher empty and stopit.

- Lift the screed by using button (33).- Retract the screed parts to the basic

screed width and lift the auger. Whereapplicable, completely extend the lev-elling cylinders.

- Insert the mechanic screed transportsafeguard (74) on both screed liftingcylinders. - While operating the tampers at a low

speed, let any material residues dropout.

- Set the drive lever (9) to the centre po-sition and the speed adjuster (10) to min-imum

- Switch off the ignition (5). - Switch off screed heating system.- When screed is operated with the op-

tional gas heating system, close themain shut-off valves and the valves ofthe bottles.

- Remove the levelling units and stowthem away in the boxes, close all flaps

- Remove all parts that extend beyondthe paver finisher contour or securethem if the paver finisher is to be trans-ported over public roads on a low-bedtrailer.

- Read and check the operating hourmeter to determine whether mainte-nance work must be performed (seechapter F).

- Cover and lock the operating panel.- Remove material residues from the

screed and the paver finisher and spray all parts with separator fluid.

Bohlensch.Tif

33

F0083_A1.TIF

74

START

9

Element2_SPSC.cdr

10

5

qsb_096.bmp

D 107

D_F

150C

.GB

.fm. 1

07-1

22 0

1.12

038 Malfunctions

8.1 Engine error codes

Explanation:

FMI: Failure Mode Identifier

SPN: Suspect Parameter NumberE

rro

r gr

ou

pE

rro

r n

o.

(in

SE

RD

IA)

Err

or

loca

tio

n /

desc

rip

tio

n o

f er

ror

Fla

sh c

od

eF

MI

SP

NC

ause

Co

mm

ents

Rem

edia

l act

ion

shor

t 0

.4 s

long

0.8

ssh

ort

0.4

s

Zer

o de

fect

s di

spla

y-

No

erro

rs2

--

3152

4287

No

activ

e er

rors

pre

sent

Rec

ordi

ng o

f en

gine

spe

ed /

road

spee

d

01S

peed

sen

sor

12

11

819

0

Se

nsor

faile

d. D

ista

nce

to

gear

too

grea

t. A

dditi

onal

er

ror

impu

lse.

Cab

le c

on-

nect

ion

inte

rrup

ted.

Con

trol

ler

in e

mer

gen

cy

mod

e (

if se

nso

r 2

is

ava

ilabl

e).

Em

erge

ncy

sh

utd

own

(if s

ens

or 2

is

not a

vaila

ble

or

has

faile

d).

Ch

eck

dist

anc

e. C

heck

ca

ble

conn

ectio

n. C

heck

se

nsor

and

rep

lace

if n

ec-

ess

ary.

02S

peed

sen

sor

22

12

819

0

Con

trol

ler

in e

mer

gen

cy

mod

e (

with

sen

sor

1).

Em

erg

enc

y sh

utdo

wn

(if

sen

sor

1 is

not

ava

ilabl

e or

has

faile

d).

Sen

sors

06N

omin

al v

alue

se

nsor

2(m

anua

l thr

ottle

)2

22

220

1

Err

or o

n co

rre

spon

din

g se

nso

r in

put

(e.g

. sho

rt

circ

uit o

r ca

ble

bre

ak).

Ref

er to

Sec

tion

4.15

In-

flue

nce

of e

rror

res

pons

e.

If se

nso

r fa

ils, t

he a

sso-

ciat

ed m

onito

ring

func

tion

is d

eact

ivat

ed.

Ch

eck

sens

or c

able

. C

hec

k se

nso

r and

repl

ace

if

nece

ssa

ry. C

heck

err

or

limits

for

sens

or.

07C

harg

ed a

ir pr

essu

re2

23

210

2

08O

il pr

essu

re2

24

210

0

09C

oola

nt te

mpe

ratu

re2

25

211

0

10C

harg

ed a

ir te

mpe

ra-

ture

22

62

105

D 108

D_F

150C

.GB

.fm. 1

08-1

22 0

1.12

03

Act

uato

r

50F

eedb

ack

25

1

12S

ID 2

4

Act

uato

r n

ot c

onn

ecte

d.

Err

or in

act

uato

r fe

edb

ack.

Em

erge

ncy

shut

dow

n.

Con

trol

ler

cann

ot b

e op

-er

ate

d.

Ch

eck

actu

ator

an

d re

-p

lace

if n

ece

ssa

ry. C

heck

ca

ble.

Che

ck e

rro

r lim

its

for

"fee

dbac

k".

52R

efer

ence

feed

back

13S

ID 2

4C

hec

k ac

tuat

or; i

f nec

-e

ssar

y: r

epla

ce. C

heck

ca

ble.

Che

ck e

rro

r lim

its

for

"re

fere

nce

feed

back

".

53C

ontr

ol s

trok

e va

ri-an

ce7

SID

23

Fue

l inj

ectio

n p

ump

/ ac

-tu

ato

r ja

ms

or is

not

con

-ne

cted

. Var

ianc

e b

etw

een

nom

inal

/act

ual c

ontr

ol

stro

ke >

10

% o

f tot

al

cont

rol s

trok

e.

Err

or

mes

sage

(di

sap-

pear

s o

nce

var

ianc

e is

<

10%

).

Ch

eck

actu

ator

/ a

ctua

tor

linka

ge /

fuel

inje

ctio

n p

ump,

rep

lace

if n

ec-

ess

ary.

Che

ck a

ctua

tor

cabl

e.

Har

dwar

e in

puts

/out

puts

67E

rror

Han

d S

etp1

26

211

91

68E

rror

CA

N S

etp1

289

8

Com

mun

ica-

tion

70C

AN

bus

con

trol

ler

27

1

12S

ID 2

31

CA

N c

ontr

olle

r fo

r C

AN

bu

s is

sues

err

or m

es-

sage

s. E

rro

r ca

nnot

be

perm

anen

tly r

ectif

ied

de-

spite

re-

initi

alis

atio

n.A

pplic

atio

n-de

pen

dent

Ch

eck

CA

N c

onn

ectio

n,

out

put r

esis

tan

ce (

refe

r to

se

ctio

n 1

2.4)

, che

ck

cont

rol u

nit.

71C

AN

inte

rfac

e S

AE

J

1939

9S

ID 2

31O

verf

low

in r

ecep

tion

buffe

r or

a m

ess

age

cann

ot b

e se

nt b

y (d

ata)

bu

s.

74C

able

bre

ak, s

hort

cir-

cuit

or s

erio

us b

us

erro

r14

SD

231

Ch

eck

CA

N c

onn

ectio

n,

cabl

e co

nnec

tion.

Che

ck

sens

or a

nd r

epla

ce if

nec

-e

ssar

y.

Err

or g

rou

pE

rro

r n

o.

(in

SE

RD

IA)

Err

or lo

cati

on

/d

escr

ipti

on o

f err

or

Fla

sh c

od

eF

MI

SP

NC

ause

Com

men

tsR

emed

ial a

ctio

n

shor

t 0.

4 s

lon

g0.

8 s

shor

t0.

4 s

D 109

D_F

150C

.GB

.fm. 1

09-1

22 0

1.12

03

Mem

ory

76P

aram

eter

pro

gram

-m

ing

(writ

e E

EP

RO

M)

28

1

12S

ID 2

53E

rror

dur

ing

par

amet

er

prog

ram

min

g in

con

-tr

olle

r's h

ard

disk

.

Em

erge

ncy

shut

dow

n.

Eng

ine

cann

ot b

e st

arte

d.

Sw

itch

igni

tion

off a

nd

bac

k on

aga

in. C

heck

a

gain

. If e

rror

occ

urs,

in

form

DE

UT

Z s

ervi

ce d

e-p

artm

ent.

77C

yclic

pro

gram

test

12S

ID 2

40

On

goin

g m

onito

ring

of

prog

ram

mem

ory

issu

es

erro

r m

essa

ges

(co

m-

mon

ly r

efer

red

to a

s "F

lash

tes

t").

78C

yclic

RA

M te

st2

SID

254

On

goin

g m

onito

ring

of

RA

M (

vola

tile

mem

ory)

is

sues

err

or m

essa

ges.

No

te d

own

val

ues

of p

a-

ram

ete

rs (

389

5 an

d 3

896)

. Sw

itch

ign

ition

off

and

bac

k o

n ag

ain.

Che

ck

aga

in. I

f err

or o

ccur

s,

info

rm D

EU

TZ

ser

vice

de-

par

tmen

t.

Con

trol

uni

tha

rdw

are

80P

ower

sup

ply

(act

ua-

tor)

29

12

SID

254

Pow

er

supp

ly fo

r co

n-tr

olle

r no

t with

in p

erm

is-

sibl

e r

ang

e.

Err

or

mes

sage

(di

sap-

pear

s on

ce p

owe

r re

turn

s to

nor

mal

ran

ge).

Sw

itch

igni

tion

off a

nd

bac

k on

aga

in. C

heck

a

gain

. If e

rror

occ

urs,

in

form

DE

UT

Z s

ervi

ce d

e-p

artm

ent.

83R

efer

ence

vol

tage

12

82

2S

ID 2

54

Ref

eren

ce v

olta

ge fo

r co

ntro

ller

not w

ithin

per

-m

issi

ble

rang

e.

Err

or

mes

sage

(di

sap-

pear

s o

nce

vol

tage

re

-tu

rns

to n

orm

al r

ange

).

Bac

kup

va

lue

5 V

.

Ch

eck

volta

ge

supp

ly.

Sw

itch

igni

tion

off a

nd

bac

k on

aga

in. C

heck

a

gain

. If e

rror

occ

urs,

in

form

DE

UT

Z s

ervi

ce d

e-p

artm

ent.

84R

efer

ence

vol

tage

22

SID

254

85R

efer

ence

vol

tage

42

SID

254

86In

tern

al te

mpe

ratu

re2

92

1217

1In

tern

al te

mpe

ratu

re fo

r co

ntro

l un

it n

ot in

per

mis

-si

ble

ra

nge.

Err

or

mes

sage

(di

sap-

pear

s o

nce

tem

pera

ture

re

turn

s to

nor

mal

ra

nge)

.

Sw

itch

igni

tion

off a

nd

bac

k on

aga

in. C

heck

a

gain

. If e

rror

occ

urs,

in

form

DE

UT

Z s

ervi

ce d

e-p

artm

ent.

Err

or g

rou

pE

rro

r n

o.

(in

SE

RD

IA)

Err

or lo

cati

on

/d

escr

ipti

on o

f err

or

Fla

sh c

od

eF

MI

SP

NC

ause

Com

men

tsR

emed

ial a

ctio

n

shor

t 0.

4 s

lon

g0.

8 s

shor

t0.

4 s

D 110

D_F

150C

.GB

.fm. 1

10-1

22 0

1.12

03

Pro

gram

logi

c

90

Par

amet

er e

rror

(in

ter-

roga

te E

EP

RO

M a

nd/

orch

eck

tota

l inc

or-

rect

).

210

1

2S

ID 2

53

No

data

foun

d or

ch

eck

tota

l for

dat

a in

corr

ect.

(N

ote:

err

or o

nly

occu

rs

durin

g pa

ram

eter

set

ting

/ sa

ving

and

/or

rese

t).

Eng

ine

cann

ot b

e st

arte

d.

Ch

eck

data

for

corr

ect

setti

ng. S

ave

par

am-

ete

rs. S

witc

h ig

nitio

n o

ff a

nd b

ack

on

agai

n. C

heck

a

gain

. If e

rror

occ

urs,

in

form

DE

UT

Z s

ervi

ce d

e-p

artm

ent.

93S

tack

ove

rflo

w2

SID

240

Inte

rnal

com

putin

g e

rror

(c

omm

only

ref

erre

d to

as

"Sta

ck o

verf

low

" er

ror)

.

Em

erge

ncy

shut

dow

n.

Eng

ine

cann

ot b

e st

arte

d.

No

te d

own

val

ues

of p

a-

ram

ete

rs (

389

7 an

d 3

898)

. Sw

itch

ign

ition

off

and

bac

k o

n ag

ain.

Che

ck

aga

in. I

f err

or o

ccur

s,

info

rm D

EU

TZ

ser

vice

de-

par

tmen

t.

94In

tern

al e

rror

2S

ID 2

54

Err

or g

rou

pE

rro

r n

o.

(in

SE

RD

IA)

Err

or lo

cati

on

/d

escr

ipti

on o

f err

or

Fla

sh c

od

eF

MI

SP

NC

ause

Com

men

tsR

emed

ial a

ctio

n

shor

t 0.

4 s

lon

g0.

8 s

shor

t0.

4 s

D 111

D_F

150C

.GB

.fm. 1

11-1

22 0

1.12

03

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D 112

D_F

150C

.GB

.fm. 1

12-1

22 0

1.12

03

8.2 Problems during paving

Problem Cause

Wavy surface("short waves")

- 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

(inertia setting is too high)- bottom plates of the screed are loose- bottom plates of the screed are warped or not uniformly worn- screed does not work in the floating position- too much play in the mechanical screed link/suspension- finisher speed is too high- augers are overloaded- changing material pressure against the screed

Wavy surface("long waves")

- change in the material temperature- demixing- roller has stopped on the hot material- roller has turned or roller speed has been changed too fast- incorrect operation of the roller- incorrectly prepared foundation- truck brake is applied too tight- long standstill times between loads- grade control reference line is not suitable- 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

Cracks in the layer(over the entire width)

- material temperature is too low- change in the material temperature- moisture on the foundation- demixing- wrong material composition- wrong layer height for the maximum grain size- cold screed- bottom plates of the screed are worn or warped- finisher speed is too high

Cracks in the layer(centre strip)

- temperature of the material- cold screed- bottom plates are worn or warped- wrong crowning

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Cracks in the layer(outer strip)

- temperature of the material- screed extension parts are incorrectly installed- limit switch is not correctly set- cold screed- bottom plates are worn or warped- finisher speed is too high

Coating composition uneven

- 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- long standstill times between loads- vibration is too slow- screed extension parts are incorrectly installed- cold screed- bottom plates are worn or warped- screed does not work in the floating position- finisher speed is too high- auger is overloaded- changing material pressure against the screed

Marks in the surface

- truck hits too much against the finisher while aligning to the fin-isher

- too much play in the mechanical screed link/suspension- truck brake is applied- vibration is too high while standing on a spot

Screed does not react to corrective measures as expected

- temperature of the material- change in the material temperature- wrong layer height for maximum grain size- incorrect installation of the grade control- vibration is too slow- screed does not work in the floating position- too much play in the mechanical screed link- finisher speed is too high

Problem Cause

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8.3 Malfunctions on the paver finisher or screed

Malfunction Cause Remedy

At the diesel engine Diverse See operating instructions for the engine

Diesel engine does not start

Batteries empty See "External starting"(start assistance)

Diverse See "Towing"

Tamper or vibration does not operate

Tamper is obstructed by cold bitumen Properly heat the screed

Hydraulic oil level in the tank is too low Top up the oil

Pressure limiting valve is defective

Replace the valve; if necessary, repair and adjust the valve

Leak in the suction line of the pump

Seal or replace the connections

Tighten or replace the hose clamps

Oil filter is soiled Clean the filter; if necessary, replace the filter

Conveyor or augers run too slowly

Hydraulic oil level in the tank is too low. Top up the oil

Power supply is interrupted Check fuses and cables; replace if necessary

Switch is defective Replace the switch

One of the pressure limiting valves is defective Repair or exchange the valves

Pump shaft broken Replace the pump

Limit switch does not switch or regulate correctly

Check the switch; replace and adjust the switch if necessary

Pump is defective Check the high pressure filter for dirt particles; replace if necessary

Oil filter is soiled Replace the filter

Hopper cannot be swung open

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 defective Replace

Leaking seals of the hydrau-lic cylinder Replace

Control valve is defective Replace

Power supply interrupted Check fuse and cables; replace if necessary

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.GB

.fm. 1

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22 0

1.12

03

Malfunction Cause Remedy

Hoppers lowers inadvertently

Control valve is defective Replace

Leaking seals of the hydraulic cylinder

Replace

Screed cannot be lifted

Oil pressure too low Increase the oil pressure

Leaking seal Replace

Screed relieving or charg-ing is switched on

Switch must be in the centre position

Power supply is interruptedCheck fuse and cables; replace if necessary

Crossbeams cannot be lifted or lowered

Switch on the remote con-trol is set to "auto"

Set the switch to "manual"

Power supply is interruptedCheck fuse and cables; replace if necessary

Switch on the operating panel defective

Replace

Excess pressure valve defective

Replace

Flow rate regulator defec-tive

Replace

Seals defective Replace

Crossbeams lower inadvertently

Control valves defective Replace

Pilot-controlled non-return valves defective

Replace

Seals defective Replace

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.fm. 1

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22 0

1.12

03

Malfunction Cause Remedy

Traction does not work

Traction drive fuse defec-tive

Replace (fuse panel on the control panel)

Power supply is interruptedCheck potentiometer, cables, connectors; replace if necessary

Traction drive monitoring (type-specific) defective

Replace

Electro-hydraulic servo unit of the pump defective

Replace the servo unit

Insufficient supply pressure

Check and adjust if necessary

Check the suction filter; replace the supply pump and the filter if necessary

Drive shaft of hydraulic pumps or engines broken

Replace pump or engine

Engine speed une-ven, engine stop not functioning

Fuel level too lowCheck the fuel level; refill fuel if necessary

Fuse "engine speed con-trol" defective

Replace (fuse panel on control panel)

Defective power supply cables (cables broken or short-circuited)

Check potentiometer, cables, connectors; replace if necessary

D 117

D_F

150C

.GB

.fm. 1

17-1

22 0

1.12

038.4 Malfunctions on the emulsion spraying equipment

Malfunction Cause Remedy

Computer does not count

Loose computer connector Check and fasten the connector if necessary

Error in the computer program

Check the computer program

No power supply Check and, if necessary, replace the fuses

Sensor in the right-hand traction drive motor defective

Check sensor/sensor circuit, replacing if necessary

Spraying ramp can no longer be controlled

The figures displayed by the computer are higher than parameter PR2

Press the "R" key on the computer to reset the figures

Spraying ramp does not move

Switches "Spraying ramp movement", "compressor", "Spraying ramp", "Feeding" or "emulsion pump" in the wrong position

Check the switch positions

Insufficient diesel engine speed

Increase the diesel engine speed

No computer function Check the computer functions and correct if necessary

Left-hand spraying ramp not extended

Set the "Spraying ramp" switch to "Auto"

Micro switch on the drive lever defective

Check the micro switch

Micro switch of the left-hand spraying ramp defective

Check the micro switch and replace it if necessary

Relays 1, 2 (switch cabinet) or 4 (box on the emulsion tank) defective

Check the relays and replace them if necessary

Spraying ramp does not work

Switch in the wrong position

Check the switch position

No computer function Check the computer functions

Incorrect spraying ramp movement

Check the spraying ramp movement

Micro switch of the spraying ramp defective

Check the micro switches

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.fm. 1

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03

Spraying ramp continues spraying even when the movement has stopped

Micro switch for the respec-tive lateral movement defec-tive or incorrectly set

Check the micro switches; adjust or correct in longitudinal direction

One nozzle does not work

Nozzle is clogged Clean the nozzle

Insufficient air pressure in the control lines

Check the air pressure and the control line

If the air pressure is OK, the nozzle housing then needs to be cleaned

Air pressure is too low

Manual valve is open Close all manual valves

Leaks in the compressed air system

Check the system for leaks

"Air cleaning" switch is defective

Check the switches

"Compressor" switch is defective

Check the switch

Diesel engine speed too low Increase the diesel engine speed

Timer relay incorrectly set or defective

Readjust the timer relay (10 sec.) or replace it

Insufficient pressure in the emulsion circuit

Switches for the compressed air valves defective

Check the switches

Filter clogged Clean the filter

Filter sucks in air Check the manual valve for the funnel and close it

Correct the position of the filter lid and close it firmly

Emulsion tank empty Top up

Emulsion pump works insufficiently

Check the pump and, if necessary, clean and repair it

Emulsion pump works sufficiently

Increase the pump speed for 10 sec.

Malfunction Cause Remedy

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.fm. 1

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03

A To reach the correct operating pressure, the diesel engine must run at a higher speed.Extending the spraying ramps is only possible when the correct operating pressure isavailable.

Heating system does not work

Fuses are blown Check the fuses and replace them if necessary

Incorrect switch position Check the switch position

Switch is defective Check the switch and replace it if necessary

Incorrect temperature setting

Check and readjust if necessary

Power supply malfunction (generators/remote power supply)

Check the power supply

Power supply from the generators: increase the diesel engine speed

Metering rate changes between two work steps

Insufficient emulsion temperature

Check the temperature and correct it if necessary

Incorrect nozzle size Check the nozzle sizes to determine whether or not they were changed

Insufficient operating pressure in the emulsion circuit

Check the emulsion circuit

Bad appearance of the sprayed layer

Insufficient emulsion temperature

Check the temperature and correct it if necessary

Incorrect nozzle angle Adjust the nozzle angle; turn the nozzles by 90° if necessary

Incorrect spraying ramp height

Check the height and readjust it if necessary

Micro switch on the spraying ramp defective

Check the micro switch

Nozzle sizes do not match the emulsion type or the metering rate

Check the nozzle sizes; replace the nozzles if necessary

Malfunction Cause Remedy

D 120

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.GB

.fm. 1

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1.12

03

9 Emergency device/steering, drive system

In case of a male function in the electronic drive system it is possible to override thesystem by an emergency device. This emergency device is included in the tool set ofevery crawler machine.To install the emergency device all plugs of the drive pump servo valves have to bereplaced by the plugs of the emergency device. (short screw driver is necessary.)The connector for the hydraulic brake valve is replaced by the corresponding connec-tor in the emergency equipment.The power supply is restored by the terminal strip on the diesel tank.The cable shoe is pushed onto terminal 1 and the cable lug is screwed onto the studbolt in the cover.The steering unit has to be mounted onto the operator desk.The plug connections are then attached in accordance with the circuit diagram onpage D90.

120

121

122

123

122

D 121

D_F

150C

.GB

.fm. 1

21-1

22 0

1.12

03The control unit houses the following functions

Function

If the emergency device is connected all functions like engine speed, conveyor, auger,tamper and vibration have to be controlled by the forward reverse lever.

Starting up for paving

- Preselect the speed with turning knob (142)- Push switch (141) in forward direction- Engage forward reverse lever like under normal conditions - All other functions (143, 144) have to be in the position described in the instruction

manual (Operation)

Transport

- Adjust turning knob (142) to a low speed- Push switch (141) to the recommended direction and engage the forward reverse

lever to forward direction.- If the recommended direction is reverse push switch in reverse,

but still the forward reverse lever should be moved to forward direction- Adjust the driving speed with turning knob (142)- All other functions have to be in the position described in the instruction manual

(Operation)- Switch (144): Function as described in the operating instructions

Item Designation

140 Mounting screws for holder plate

141 Switch for preselection of the zero position and forward reverse movement

142 Adjustment knob for speed control (Replace speed preselector)

143 Rotary knob for the steering system (replaces the steering unit)

144 Switch for turning on the spot (replaces the switch for turning on the spot)

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Steering unit

Servo valve

black

gray

gray

black

Pump for right caterpillar drive

Pump for left caterpillar drive

24 V

Ground/earth

E 1

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E 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 astandstill!

- To protect the paver finisher against inadvertent starting: Set the drive lever to the centre position and set the preselector to zero; if applica-ble, remove the drive traction fuse from the operating panel; remove the ignition keyand the battery main switch.

- Secure lifted machine parts (e.g. screed or hopper) against lowering by means ofmechanical 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-pressurise 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 working width of the

screed. The foldaway walking platform (option on Vario screeds) must only be folded up un-der the following conditions:

- When paving next to a wall or a similar obstacle. - During transportation on a low-bed trailer.

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2 Auger

2.1 Height adjustment

The height of the distributor auger (1)should be – measured from its loweredge – be min. 50 mm (2 inches) abovethe material paving height, dependingon the material mixture involved.

Example: Layer height 10 cm Adjustment 15 cm from

the ground

An incorrect height adjustment can re-sult in the following problems:

- Auger too high:Too much material in front of the screed; material overflow. When operating withlarger working widths, demixing and traction problems may occur.

- Auger too low:Not enough material that can be precompacted by the auger. Irregularities resultingfrom 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 fixedposition

- Lower the screed onto a suitable sup-port (e.g. squared timbers).

- Completely extend both levelling cylin-ders.

- Hook lifting chains (2) for lifting the au-ger crossbeam into the hooks of thecrossbeams.

- Unfasten retaining screws (3) on the auger crossbeam.- Retract the levelling cylinders until the

auger crossbeam has reached the de-sired height.

- Tighten the fixing screws (3) of the augercrossbeam.

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2.3 With mechanical adjustment withratchet (option)

- Adjust ratchet driver pin for clockwiseor anticlockwise rotation. Turning anti-clockwise lowers the auger, turningclockwise lifts the auger.

- Set the desired height by alternatinglyadjusting the right-hand and the left-hand side.

- The current height can be read fromthe scale in cm or inches (cm = left-hand column, inches = right-hand col-umn).

2.4 With hydraulic adjustment (option)

- Define the current setting for the augercrossbeam – left and right sides – onthe scale.

- Press the switches (4) on the operat-ing panel up or down to extend or re-tract the hydraulic cylinders.

m Actuate both switches simultaneously toavoid warping of the auger crossbeam.

- Check whether the heights on the leftand on the right are identical.

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2.5 Auger extension

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

A Auger and screed extension must match. Refer to the relevant chapter "Set-up and modification" in the Operating instructionsfor the screed): – Screed extension chart,– Auger extension chart.

To attain the desired working width, the respective screed extension parts, sideplates, augers, tunnel plates or cut-off shoes must be mounted.

For working widths of more than 3.00 m, the auger should be fitted with extension partson 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!

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2.6 Mounting extension parts

- Loosen the clamping screws (6) onthe support tube. Then turn in the cen-tre expanding screw (5) to expand theclamping joint.

- Pull the telescopic tube out of the sup-port tube (7).

- Mount the required extension parts.

m Observe the guide groove of the spline!Make sure that the shaft end is clean!

- Slide in telescopic tube, ensuring thatthe auger gear is pushed firmly by thestub axle on the auger extension sec-tion and that the auger threads areproperly aligned.

- Remove the expansion screw (5). Then tighten the clamping screws (6). Finallytighten the expansion screw by hand.

m Before tightening the clamping screws (6) back down, always ensure that the expand-ing screw (5) is retracted far enough! Failure to do this makes it impossible to secure the telescopic tube properly and themeshing shaft sections may then break.

f When clamped insufficiently, the telescopic tube can slide out of the support tube.Danger of accidents during transportation!

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2.7 Mounting support tube extensions

If the working width exceeds 7.50 m, anauger crossbeam extension must bemounted.

The support tube extension of the augercrossbeam consists of two halves (8)and is attached to the existing supporttube by using a total of 5 screws. Afterthe two halves have been screwed to thesupport tube, they also must be linked toeach other by means of screwed con-nections.

The telescopic tube is clamped by tight-ening the screw connections which holdtogether the carrier tube extensionhalves (9).

If the working width exceeds 7.50 m thehydraulic hoses (10) for the auger mo-tors must be replaced with longer ones. These long hoses are included in thescope of delivery for this working width.

f When connecting or disconnecting hy-draulic hoses, hydraulic fluid can spurtout at a high pressure. Switch off the finisher and de-pressurisethe hydraulic circuit! Protect your eyes!

m When installing the hoses, make surethat the area around the connections isclean. Any dirt that enters the hydraulic system can cause malfunctions.

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2.8 Installing tunnel plates

To ensure an optimum material flow –especially in the case of large workingwidths – so-called tunnel plates (11)must be installed. These are located directly above the au-ger distributor and, working in conjunc-tion with the auger, they form anoptimum material transport system.

When operating with working widths ofmore than 3.90 m, two or more com-bined tunnel plates (13) must be used. In this case, additional stabilising sup-ports (12) must be attached to the tele-scopic tube.

The tunnel plates must be directlyscrewed to the sockets provided for thispurpose (14); they are located on the au-ger frame sides and can thus be adjust-ed in height.

Refer to the auger extension chart to de-termine which parts of the conveyor sys-tem are required for the desired workingwidth.

A For an auger extension chart, refer to theOperating instructions for the screed).

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2.9 Installing additional braces

When operating with working widths ofmore than 7.25 m the augers must beprovided with an additional support.

To do so, attach two braces on both theleft-hand and the right-hand side, be-tween the tunnel plate support and thebracket provided on the finisher.

The braces are included in the scope ofdelivery for this working width.

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Pendulum drive system

For the following purposes, the entirefront section of the vehicle chassis canbe raised or lowered by means of a hy-draulic cylinder:

- Adjust to suit the application depth ofthe material conveyor or its tyre size

- For driving on to the low-bed trailer

f Danger of crushing! Before actuating thenon-return valves, close the hopper.Install the hopper transport guard!

Raising the chassis:

- Close the hopper using the switch /button (1) control and install the hop-per transport guard.

- Open both non-return valves (A) andpress switch / button (1) until the de-sired height is reached.

- Close both non-return valves (B).

Lower the chassis

- Close the hopper using the switch /button (1) control and install the hop-per transport guard.

- Open both non-return valves (A) untilthe chassis has been lowered to thedesired height.

- Close both non-return valves (B).

A Neutral setting is reached once thenotch (2) on the guide frame is level withthe upper edge of the guide plate (3).

Pendeltr1.cdr/Pendeltr2.cdr/Pendeltr3.cdr/Pendeltr4.cdr

2

A

B

3

1

E 10

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3 Screed

A All work involved in installing, setting up and widening the screed are described in theOperating instructions for the screed.

4 Electrical connections

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

4.1 Remote controls

to socket (15) (on the screed).

4.2 Grade control

to socket (16) (on the remote controlunit)

4.3 Auger limit switches

to socket (17) (on the remote controlunit)

4.4 Working lights

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

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5 Operating principle for the spraying system

Compared to a conventional emulsion spraying device, spraying from a paver finisherinvolves three problems:

- the metering rate can be very low: from 250 g/m² onwards- the speed is very low: from 2 m/min onwards- the speed can be varied but the metering rate must remain identical.

When these three points are taken together, it is then impossible to work with a nor-mal standard system because the nozzle bores would then have to be so small thatthey would block all the time.

To find a solution, ACMAR has patented the "Alternate Spraying Process". Thespraying ramp opens for a brief moment only.

Thus it is possible to use nozzle sizes that allow to spray viscous bitumen or emul-sions.

At the same time, the ramp (consisting of a single part) moves rhythmically across theentire surface. Regardless of the paver finisher speed, the speed of the ramp move-ment always remains constant.

The speed of the spraying ramp is significantly higher than that of the paver finisher.

The distance covered is used to control the movement of the spraying ramp.

The spraying ramp moves as follows: The ramp moves, for example, from the left tothe right, stops at the turning point for a certain time and returns to the left where itstops again. The stop period of the ramp is negatively proportional to the paver fin-isher speedy. The higher the paver finisher speed, the shorter are the stop periods ofthe ramp. A change of the paver finisher speed also causes the spraying ramp fre-quency to change proportionally in relation to the paver finisher speed.

This principle makes it possible to maintain continuous and uniform metering of sprayaction even if the paver speed alters (between 0-15 m/min).

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A switch (19) enables the operator topreselect one of two different spray proc-esses (F, F+R).

- F = Spraying while the sprayingramp moves from the left tothe right (or from the right tothe left)

- F+B = Spraying in both directions

The ramp sprays in both cases while itmoves 20 cm to one side. Then it stopsand starts spraying again with the nextmovement.

The two methods result in different me-tering rates

- F for low rates- F+R for increased metering > 500 g/

m²(if the F value is doubled, the meteringrate does not alter)

See the table on the next page.

The nozzle type determines the metering rate:

- Model 727:low rate - from 450 g/m² to 600 g/m²high rate F+R - from 600 g/m²

- Model 647:low rate - from 250 g/m² to 450 g/m²high rate F+R - from 450 g/m²

There is another way to alter parameters PR1 and PR2: this is by means of an elec-tronic computer. The gap between two spray processes is defined by means of pa-rameter PR1. PR2=2xPR1. If parameters PR1 and PR2 are increased, this gives riseto reduced metering action. Reducing these parameters increases the metering rate.Adjusting the parameters makes it possible to adapt the metering rate to suit everyspray process (F or F+R).

All metering rates can be selected.

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F

F + B

F

F + B

F

F + B

5.1 Selecting the nozzles and the method

Operating pressure = 1.3 bar F – forward F + B – forward and backward

Possibility for all noz-

zles

Metering rate

[g/m2]

Working speed

12

34

56

78

910

1112

1314

1516

1718

1920

2122

2324

2526

2728

2930

632.647

Ø 2.2 mm

250300350400450500600700800900

1000

632.727

Ø 2.8 mm

500550600650700750800900

100011001200

632.807

Ø 3.6 mm

750800850900950

100010501100120013001400

Metering rate

[g/m2]

Select between - 632.647- 632.727

Metering rate

[g/m2]

Select between - 632.647- 632.807

Selection:Recom-mended nozzles

250to

450632.647

250to

700632.647

500to

1400632.727

750to

1400632.807

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5.2 Explanations

The emulsion is circulated by means of a pump running at a constant speed. Duringspraying the backflow line to the tank is closed. The pressure relief valve is constantlyoperated as the pump capacity is higher than required for spraying. This means thatthe constant spraying pressure results from the start-up regulation of the pressure re-lief valve.

m Never change the setting of the pressure relief valve!

Spraying occurs at a constant pressure. To assure a constant flow rate through thespray nozzles at this pressure, the emulsion must always retain the same viscosity.The only parameter which affects this is temperature.

Heed the following temperatures when using an ACMAR system:

- Standard emulsion temperature: at least 60 °C- Elastomer emulsion temperature: at least 70 °C

m When filling the tank, the temperature must be 10 °C higher.

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6 Programming the computer

- Switch on the paver finisher ignition.

- Switch (21) 24 V electrical powerswitch to "On".

- Switch (20) spraying ramp: Select"Auto" setting on the fixed Stop-Autoswitch.

- Pull the computer rack halfway out ofits housing. "Pro" then appears on thedisplay screen.

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- Press the "P1" key.Display: Fct

CPt

- If a different display appears onscreen, select the correct setting us-ing the marked button.

- Press the "P1" key.Display: MOdE

- If a different value is displayed, usethe highlighted key to select the cor-rect setting.

- Press the "P1" key.Display: SPEEd

- If a different display appears onscreen, select the correct setting us-ing the marked button.

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- Press the "P1" key.Display: CYCLE

- If a different display appears onscreen, select the correct setting us-ing the marked button.

- Press the "P1" key.Display: Prot

- If a different display appears onscreen, select the correct setting us-ing the marked button.

- Press the "P1" key.Display: P1

- If a different display appears onscreen, select the correct setting us-ing the marked button.

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- Press the "P1" key.Display: P2

- Using the highlighted keys, set the fig-ures for time "t" on either side of the dec-imal point. Every time a key is pressed,the relevant numeral increases by "1".

A T must be set to 0.1 s.

- Press the "P1" key.Display: 0 0 0 0 0 0

- If a different display appears onscreen, select the correct setting us-ing the marked button.

- Press the "P1" key.Display: MEMO

- If a different display appears onscreen, select the correct setting us-ing the marked button.

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- Press the "P1" key.Display: 0 1 . 0 0 0 0

- Using the highlighted keys, set the co-efficient values to either side of thedecimal point. Every time a key ispressed, the relevant numeral in-creases by "1".

A K must be set to 1.0 s.

- Press the "P1" key.Display: ProG

- Slide the computer rack back into itshousing until it locks into position.

- The display is shown on the right sideof the screen. P1 represents parameterPR1 and P2 for parameter PR2.

- The parameters for PR1 and PR2 areset using the highlighted keys. Everytime a key is pressed, the relevant nu-meral increases by "1".

- Press key "P1" to toggle between pa-rameters PR1 and PR2. The selectedparameter flashes on the screen dis-play.

- Select parameter PR1 for program-ming purposes. Enter the impulse val-ue for spraying ramp movement. Thebasic setting is 700.

- Select parameter PR2 for programming purposes and set the corresponding value.The basic setting is 1400.

A The value for the PR2 impulse is always twice the amount of the PR1 impulse.

- To complete the programming operation, initiate a reset by pressing the "RST" key.

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6.1 Setting parameters for automatic op-eration

- Set the switch (22) for Ramp Move-ment to its Semi Auto position.

Parameters PR1 and PR2 are importantfor automatic operation. The basic set-tings are:- PR1=700- PR2=1400

Before calculating the parameters:- Prepare and weigh emulsion for three

test areas (use scales with a 10 g divi-sion).

- Spray test areas in front of the paverfinisher.

- Collect and weigh the test areas.- Determine the area in m² .- Calculate the base value according to

the equation below.

Calculating the base value

Equation: DOSbase = (W2 - W1) / S(m² )

A Dosbase = basic value in kg/m²(is required for the parameter equation)

- W2 = weight after spraying in kg- W1 = weight before spraying in kg- S(m² )= test area in m²

Example:

DOSbase = (1.6 – 1.5) kg / 0.25 m²

Base value = 0.40 kg/m²

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Calculating the parameters

Parameter equation: PR1 = DOSbase x PR1base / DOS

- PR1 = parameter value to be set- Dosbase = basic value in kg/m²- PR1base = set value- DOS = nominal rate in kg/m²

Example:

PR1 = 0.4 x 700 / 0.8 = 350

350 is the value to be set for PR1.

A The value for PR2 is obtained by doubling up the value for PR1. In the above exam-ple, the value for PR2 = 700.

A The smaller the values for parameters PR1 and PR2, the higher the metering rate perm² .

m When using an emulsion with polymer, enter the parameters as calculated.When using an emulsion without polymer, add 10% to the calculated values of pa-rameters PR1 and PR2.

- Enter the calculated values as described in section "Programming the computer".

A The following page contains a "Calculation sheet for the automatic mode" where therelevant values can be entered.

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6.2 Calculation sheet for the automatic mode

CALCULATION SHEET FOR THE AUTOMATIC MODE

CUSTOMER:

Date:All emulsion spraying systems

TypePaver finisher

Type

Spraying function

PR1 PR2Pres-sure

Nozzles Metering rate

Emulsion type

Remark

Forward

+

Backward

Base values

Forward

or

Backward

Base values

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6.3 Settings for semi-automatic operation

A A timer relay (23) replaces the sensorand the electronic computer in the semi-automatic mode.(default setting = 2 secs. This representsa uniform metering rate at an operatingspeed of approx. 5 m/min.)

Completing the calculation sheet

A Calibration must be performed by aweighing process in order to achieve thebasic values.

Calibration – step one:- Choose forward and backward.- Set a basic value of Tb = 2 seconds at

the timer relay.

A The following applies to nozzle type632.727: working speed Sb = 5 m/min.

This results in a basic value (in kg/m² )after weighing.

Equation: DOSbase = (W2 - W1) / S(m² )

- W2 = weight after spraying in kg- W1 = weight before spraying in kg- S(m² )= test area in m²

The calculated value allows to completethe part of the calculation sheet that re-fers to - Nozzle type 632.727- Spraying forward and backward

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The values in the table can be calculated using the following equation: DOS = DOSbase x Tb x Sb / T x S

- Dosbase= basic value in kg/m²- Tb = base time in sec.- Sb = base speed

(working speed)m/min

- T = time for DOS- S = speed for DOS

Calibration – step two:- Choose forward and backward.- Set a basic value of Tb = 2 seconds at the timer relay.

The calculations for this table are the same.

A Calibration for the different nozzle types is the same for the "forward" mode.

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6.4 Calculation sheet for the semi-automatic mode (FORWARD + BACKWARD)

CALCULATION SHEET FOR SEMI-AUTOMATIC MODEFORWARD + BACKWARD

Metering rate Working speed - S (m/min)

Selec-tion

Noz-zle

type

Time T for adjustment

2 3 4 5 Sb

6 7 8 9 10 11 12 13

Forward

+

Back-ward

727

2 Tb

4

6

8

10

647

2 Tb

4

6

8

10

continued... 14 15 16 17Sb

18 19 20 21 22 23 24 25

727

2 Tb

4

6

8

10

647

2 Tb

4

6

8

10

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6.5 Calculation sheet for the semi-automatic mode (FORWARD only)

CALCULATION SHEET FOR SEMI-AUTOMATIC MODEFORWARD ONLY

Metering rate Working speed - S (m/min)

Selec-tion

Noz-zle

type

Time T for adjustment

2 3 4 5 Sb

6 7 8 9 10 11 12 13

Forward

Forward

727

2 Tb

4

6

8

10

647

2 Tb

4

6

8

10

continued... 14 15 16 17Sb

18 19 20 21 22 23 24 25

727

2 Tb

4

6

8

10

647

2 Tb

4

6

8

10

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7 Performing a set-up before work starts

- Select the "Working speed" column on the calculation sheet- Find the appropriate metering rate in this column

The following details (relative to the emulsion type used) are available on this line:

- the timer relay setting- the nozzle type to be installed- the selected method

A The calculation sheet only contains 5 figures for time "T". The timer relay uses a po-tentiometer for setting the time. If the figures on the calculation sheet do not yield anexact DOS value, the following equation can be used to calculate the correct timerrelay setting: T = DOSbase x Tb x Sb / DOS x S

A If an increase during DOS paving is required at constant speed, the T factor must bereduced. If DOS is being reduced, T needs to be increased.

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7.1 Calculation sheet for spraying nozzles behind the drives

CALCULATION SHEET FOR SPRAYING NOZZLESBEHIND THE DRIVES

Metering rate (g/m2) Working speed (S)

Nozzletype

For pressure = 1.7 bar

Nozzle flow ratein l/min.

4 5 6 7 8 9 10 11 12 13 14

110 04 1.10 687 550 458 393 344 306 275 250 229 212 196

110 06 1.62 1012 810 675 578 506 450 405 368 337 311 289

110 08 2.21 1381 1105 921 789 691 614 553 502 460 425 395

110 10 2.72 1360 1133 971 850 755 680 618 567 523 486

632 647 3.40 1417 1214 1062 944 850 773 708 654 607

110 15 4.08 1457 1275 1144 1020 927 850 785 728

632 727 5.36 1595 1395 1240 1117 1015 930 859 797

632 807 8.49 1473 1361 1262

632 847 10.61 1515

continued... 15 16 17 18 19 20 21 22 23 24 25

110 04 1.10 183 172 161 152 144 137 131 125 119 114 110

110 06 1.62 270 253 238 225 213 202 193 184 176 169 162

110 08 2.21 368 345 325 307 291 276 263 251 240 230 221

110 10 2.72 453 425 400 377 358 340 324 309 295 283 272

632 647 3.40 567 532 500 472 448 425 405 387 370 354 340

110 15 4.08 680 637 600 567 537 510 486 464 443 425 408

632 727 5.36 745 698 657 621 588 559 532 508 486 466 447

632 807 8.49 1180 1106 1041 984 931 885 843 807 770 738 708

632 847 10.61 1417 1328 1250 1182 1118 1063 1012 969 925 886 850

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7.2 Explanations for the calculation sheet for the spraying nozzles behind thedrives

Several nozzle types are available to cover the broadest possible range. Enter the the-oretical flow rates in the calculation sheet.

The same calculation formula applies to all nozzles:

DOS = nozzle flow rate / 0.4 x S (nozzle flow rate in g/min)

- S = speed- 0.4 = nozzle size

The calculation sheet provided assumes that the theoretical pressure in the tubes is1.7 kg/cm² close to the nozzles.

It is however possible with the above formula to calibrate every type of nozzle in orderto enter the correct flow rate figure in the corresponding column of the calculationsheet.

A The calculation sheet shows that it is not possible to run at a metering rate of lessthan 500 g/m² at a speed of less than 5 m/min.

If the metering rate is to be less than 500 g/m² at a speed of less than 5 m/min, themain spraying ramp must be used.

m The nozzles behind the tracks must always be adjusted to suit the metering rate ofthe spraying ramp!

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F Maintenance

1 Notes regarding safety

Maintenance work: Maintenance work may only be carried out when the engine isat a standstill.

Secure the paver finisher and the attachments against inadvertent starting before be-ginning any maintenance work:- Set the drive lever to the centre position and the speed preselector to zero.- Remove the traction drive fuse from the operating panel. - Remove the ignition key and the battery main switch.

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

m Unreleased parts or spare parts, unsuitable tools or inexpert installation may causemalfunctions, cause damage to property and be a hazard for persons!

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

Re-commissioning: Mount all protective devices before re-commissioning the paverfinisher.

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; coverthem beforehand.

Working in closed environments: Exhaust gases must be directed outwards (i.e.vented to atmosphere). Propane 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.

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2 Maintenance intervals for the paver finisher

Schmier.pic

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21 212222

79 8

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2.1 Daily (or every 10 operating hours)

m Check the oil level twice a day during the run-in period of the diesel engine! When work has been performed on the hydraulic system: check all filters after20 operating hours and replace them where applicable!

Item Maintenance point

Nu

mb

er

Lu

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cati

on

Ch

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Oil

chan

ge

SubstanceFilling

volume

2 Air filter 1 x

3High pressure hydraulic filter

5 x

5 Conveyor centre bearing 1 x Grease 5 strokes

6 Auger outer bearing 2 x Grease 5 strokes

12 Diesel engine oil level 1 x Engine oilsee "Filling volumes"

13 Radiator fluid level 1 x

14 Chain tension conveyor 2 x Grease

15 Conveyor deflection roller 2 x Grease 5 strokes

18 Fuel tank filling level 1 x Diesel fuelsee "Filling volumes"

20Hydraulic oil reservoir filling level

1 x Hydraulic oilsee "Filling volumes"

23 Chain tension conveyor 2 x

35Filter mats in air intake ducts

3 x

36Check insulation monitoring function

x

General security check (see section 3.1)

Security check

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2.2 Weekly (or every 50 operating hours)

2.3 Every 100 operating hours

2.4 Every 250 operating hours

Item Maintenance point

Nu

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Lu

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Ch

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Oil

chan

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Substance Filling volume

4 Conveyor gear 2 x Gear oil 220see "Filling volumes"

8 Auger bevel gear 2 x Gear oil 90see "Filling volumes"

11 Pump distribution gear 1 x Gear oil 90see "Filling volumes"

16

Batteries:– Charge level– terminal clamps and cables

2 x Dist. water

17 Upstream fuel filter 1 x

21 Steel hopper flaps (option) 2 x Grease 2 strokes

22 Push rollers 4 x Grease 5 strokes

Item Maintenance point

Nu

mb

er

Lu

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cati

on

Ch

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Oil

chan

ge

Substance Filling volume

13Cooling system for engine and hydraulics

1 x

Item Maintenance point

Nu

mb

er

Lu

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cati

on

Ch

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Oil

chan

ge

Substance Filling volume

7 Auger centre bearing 1 x Grease 5 strokes

33 Engine suspensions x

40Guide for pendulum drive unit

4 x Grease 5 strokes

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3

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4

11 16

21 212222

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17 33

19

36

36

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2.5 Every 500 operating hours

2.6 Yearly (or every 1000 operating hours)

*) First oil change after 1000 hours, then every 1500 hours.

Item Maintenance point

Nu

mb

er

Lu

bri

cati

on

Ch

eck

Ch

ang

e

SubstanceFilling

volume

12 Engine lube oil 1 x Engine oilsee "Filling volumes"

12 A Oil filter (cup) l 1 x

Item Maintenance pointN

um

ber

Lu

bri

cati

on

Ch

eck

Oil

chan

ge

Substance Filling volume

1 V-belt of the engine x

2 Air filter x

4 Conveyor gear 2 x x Gear oil 220see "Filling volumes"

8 Auger bevel gear 2 x x Gear oil 220see "Filling volumes"

9 Auger, gear neck bearing 2 x Grease 5 strokes

10Caterpillar drive - planetary gear *

2 x x Gear oil 90see "Filling volumes"

11 Pump distribution gear 1 x x Gear oil 90see "Filling volumes"

17Fuel filterUpstream fuel filter

1 x

34 Hoses and hose clamps x

Diesel engine:Valve clearanceHeater plugs

Have the paver, screed and gas system inspected by a specialist

x

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3

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4

11 16

21 212222

79 8

17 33

19

36

36

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2.7 Every 2 years (or every 2000 operating hours)

*) Only use filters with a mesh size of 10 µ = 0.01 mm!

Item Maintenance point

Nu

mb

er

Ch

ang

e

Ch

eck

Oil

chan

ge

Substance Filling volume

1 V-belt of the engine x

2 Air filter x

13Water cooler and entire cooling system

1 x Cooling fluidsee "Filling volumes"

18 Fuel tank and system 3 x

19Suction/return hydraulic filter *

2 x

20Hydraulic oil reservoir – entire filling

1 x x Hydraulic oilsee "Filling volumes"

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3 Maintenance intervals for the emulsion spraying equipment

F151C.wmf

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27

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3.1 Daily (or every 10 operating hours)

All intervals given are maximum permissible maintenance intervals. The intervalsmust be shortened under aggravated conditions of use!

A For information on maintenance intervals and works on the screed, please refer to theScreed operating instructions.

m Only move the flexible emulsion hoses for lubrication when they are hot!

3.2 Weekly (every 50 operating hours)

A Must be performed in addition to the daily maintenance!

Item Maintenance point

Nu

mb

er

Lu

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cati

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Ch

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Oil

chan

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Cle

an Substance Filling vol-ume

24 Emulsion pump 4 x Grease 2 strokes

25 Emulsion filter 2 x Diesel fuel

27Rotary joints of the flexible emulsion hoses

12 x Grease 3 strokes

28 Spraying ramp 1 x

29

Drain the (con-densed) water in the compressed air vessels

2 x

32Oil level of the compressor

1 x Compressor oil

Item Maintenance point

Nu

mb

er

Lu

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cati

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Ch

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Oil

chan

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Cle

an Substance Filling vol-ume

25 Emulsion filter 2 x Score

30Compressor air filter

1 x

31Compressor oil cooler

1 x

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3.3 250 operating hours

A Must be performed in addition to the weekly maintenance!

3.4 Every 500 operating hours

A Must be performed in addition to the weekly maintenance!

3.5 Yearly (or every 1000 operating hours)

A Must be performed in addition to the weekly maintenance!

A 1) Remove prior to cleaning!

ItemMaintenance

point

Nu

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Lu

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cati

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Ch

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Oil

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Cle

an SubstanceFilling vol-

ume

32 Air compressorfirst oil change

1 x Compressor oil 4.3 l

Item Maintenance point

Nu

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Lu

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cati

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Ch

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Oil

chan

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Cle

an Substance Filling vol-ume

26Emulsion pump gear

1 x Gear oil 90

32

Compressor oil filter

1 x

Compressor 1 x Compressor oil 4.3 l

Item Maintenance point

Nu

mb

er

Lu

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Ch

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Cle

an Substance Filling vol-ume

31Compressor oil cooler

1 x 1)

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3.6 Every 2 years (or every 2000 operating hours)

A Must be performed in addition to the daily and monthly maintenance!

Item Maintenance point

Nu

mb

er

Rep

lace

Ch

eck

Oil

chan

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Cle

an Substance Filling vol-ume

26Emulsion pump gear

1 x Gear oil 90 3.5 l

28 Spraying ramp 1 x

29Compressed air vessels

2 x

30Compressor air filter

1 x

All screwed connections and adapters

x

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4 Checking, lubricating, oil drain points on the paver finisher

A The points for checking, lubricating and draining of oil are described in detail below.The item numbers given in the headers refer to the illustration above.

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4.1 Check points

Pump distributor gear (11)

This screw plug (1) can be used for check-ing the oil level.After unfastening the screw, a little oilshould escape. If it does not, top up oilthrough the filler bore (2).

A Make sure to clean the screw and the vi-cinity of the drain bore!

Caterpillar drive - planetary gear (10)

There is a checking plug (34) on the in-side of the gear. The oil level is correct if oil escapes fromthe inspection hole.

f When screwing out the plug hot oil canspurt out at high pressure. Always checkthe oil when the gear is cold!

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Conveyor gear (left/right) (4)

The conveyor gears are beneath the foot-board of the operator's platform. Checking oil level: only before startingwork. The oil level must reach the uppernotch of the dipstick (35). Top up oil: after removing the sealing cover(36) through the oil filler neck (37).

A 10 cm on the display equal about 0.25 lof oil. The conveyor gears are filled with Opti-mol Optigear 220 at the factory. Due to the high quality of this oil, it is notnecessary to replace the oil at regular in-tervals. All you need to do is to check the oil levelin the gear on a regular basis (refer tosection on maintenance intervals).

m The above applies if Optimol Optigear 220 or oil of a similar quality from another man-ufacturer is used.

Auger bevel gear (left/right) (8)

Screw (38) is used for checking the oillevel and for topping up oil. Clean the vicinity of the screw plug be-fore unscrewing it. The oil level is correctwhen a small amount of oil leaks out ofthe lateral opening.

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Engine lube oil (12)

Oil level check

Check the oil level with dipstick (1) everytime before work is started. Only check the oil level when the finisheris in a hoizontal position!

- If necessary, top up the oil levelthrough the filler bore (2).

m Too high an oil level destroys the sealsin the engine while too low an oil levelcauses the engine to be overheated anddestroyed.

Oil change

A Oil changes should always be carriedout at operating temperature.

- Unscrew and remove the screw capfrom the oil drain point (1) and attachthe hose provided for this purpose inthe accessories.

- Place end of hose in collection tank.- Open the shut-off valve with a wrench

and completely drain the oil.- Close the shut-off valve, remove the

hose and reinstall the screw cap.- Fill with engine oil at the specified

quality, viscosity and volume throughthe aperture in the engine compart-ment (2).

- Start up engine and run at idle speed.- Shut down engine again. Check oil

level once again correct if necessary.

A At every oil change, you should also re-place the filter cartridge (see followingsection).

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Engine oil filter (12a)

A The new filter is installed during the oilchange after the old oil has been drainedoff.

- Unfasten lube oil filter cover (1) with afilter belt or key on the hex head andunscrew anticlockwise.

- Carefully pull paper filter cartridge (3)upwards out of its guide (4).

- Catch any escaping oil.- Replace paper filter cartridge (3).- Clean any dirt off sealing surface of filter

carrier and lube oil filter cover (1) andguide (4).

- Replace rubber gasket (2) and apply alight coating of oil.

- Carefully insert a new paper filter car-tridge (3) in the guide (4).

- Tighten down lube oil filter cover (1)clockwise (25Nm)

A After installing a new oil filter, check theoil pressure gauge carefully during testoperation to ensure that good sealingaction is being provided. Check oil levelonce again.

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Cooling system for engine and hydraulics (13)

A The machine is equipped with a water, hydraulic and charge air cooler.

Water cooler (radiator)

The coolant level is checked while cold.Ensure that enough anti-freeze and cor-rosion inhibitor has been added (-25°C).

The optimum fill level is 6 cm below thesealing surface of the screw cover.

f System is pressurised when hot! Dangerof scalding when the system is opened!

Hydraulic cooler

The paver is equipped as standard witha hydraulic oil cooler. This cooler is es-sential for the operational safety of theentire hydraulic system.

Dirt in the oil cooler can cause damage:

- Unacceptably high oil temperature- More rapid ageing of the oil- Thinning of oil- Loss of lubricant capability and result-

ant wear to gaskets, O-rings, pumpsand motors

- Leakage problems- Check the hydraulic cooler, cooling pipework and cooling ribs on the engine for dirt

at regular intervals.- If necessary, clean the engine cooling system.

f Only clean the engine while it is cold!

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Fuel tank (18)

We recommend to always top up the fueltank before starting work to prevent thetank from "running dry" which wouldmake it necessary to ventilate the entirefuel system.

V-belts and ribbed V-belts (1)

- Refer to the Engine operating instruc-tions for inspection and adjustment ofbelts.

A New V-belts expand and need to be re-tensioned after approx. 15-20 minutes ofoperation.

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Air filter (2)

The amount of dirt in the air filter (1) isdetermined by the amount of dust in theambient air.

Filter maintenance is essential if the redService panel (3) is fully visible on themaintenance indicator (2) while the en-gine is switched off.

Dust extraction valve

- Empty the dust extraction valve (4) bycompressing the extractor slots in thedirection of the arrow.

- Remove any caked dust by compress-ing the upper section of the valve.

A Clean the extractor slot from time totime.

Filter cartridge:

- Open up the air filter housing (1)- Remove filter cover (5) and remove

the filter cartridge (6).- Clean the filter cartridge or replace it with

a new one.- Cleaning the filter cartridge:- Blast out from the inside outwards

using dry compressed air (max. 5bar),

- In emergencies, carefully tap the car-tridge to clean it. Avoid damaging thecartridge in this process.

- Check cartridge for signs of damageto the filter paper and inspect the gas-kets, replacing if necessary.

Safety cartridge:

- To replace the unit, unfasten the hexnut (8) and pull out the cartridge (7).

- Install a new cartridge, reinstall the hexnut and tighten back down.

- Install filter cartridge (6) and close the air filter housing (1).

A After every air filter maintenance operation, press the reset button on the mainte-nance indicator (2).

A Follow the instructions in the engine operating instructions!

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High pressure hydraulic filter (3)

m All filters of the hydraulic system must bechecked and replaced where necessary20 operating hours after repairs havebeen made!

Replace filter cartridges when mainte-nance indicator (40) turns red.

Drain the soiled oil that leaks out afterunscrewing the filter cap into a used oilcontainer. Take out the filter cartridge and have itdisposed of by specialists (danger of en-vironmental pollution!). Wash out the housing, replace theO-rings and apply a thin layer of oil tothem.Mount the filter housing with the filtercartridge again and tighten it properly.The red indicator (40) will then be auto-matically reset.

Suction/return flow hydraulic filter (19)

Change filter whenever the maintenanceindicator (41) or (42) reaches the redmark. Always replace filters when exchangingthe hydraulic oil.

Unscrew the lid of the filter housing onthe hydraulic oil reservoir and replacethe filter cartridge.

m Never clean and reuse old filters! Alwaysuse a new filters.

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Hydraulic oil reservoir (20)

Use dipstick (43) to check the oil level. With retracted cylinders, the oil levelmust reach the upper mark. Regularly clean the oil reservoir ventila-tion. Clean the oil cooler surfaces (alsorefer to the Operating instructions for theengine).

m Use recommended hydraulic oils only(see the section "Recommended hy-draulic oils").

Chain tension, conveyor (23)

A Adjusting screws (44) are located at thefront of the crossbeam.

The chains should not be too tight or tooslack. Too tight a chain can cause thechain to be stopped or to break whenmaterial falls into the space between thechain and the sprocket wheel. Too slack a chain can be caught at pro-truding objects and can thus be de-stroyed.

m For the daily visual check, peer horizon-tally below the bumper. The chain mustnot hang below the bottom edge of thebumper. If adjustment is required, measure de-flection from underside of floor panel tounderside of track (see illustration).

Grease tensioner on conveyor (O)

A There is the option of equipping the ma-chine with grease tensioners for the con-veyor.

The filler valves are located to the leftand right sides of the level control cylin-ders on the pendulum drive.

- Fill grease tensioners with greasepress through filler valve (1) until thedesired track tension is reached.

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Engine - fuel filter (17)

The fuel filter system consists of two fil-ters:

- Upstream filter with water separator(1) on the fuel tank

- Main filter (2) on the engine block

Upstream filter - draining off water:

There is a receiver (3) on the upstreamfilter which collects the escaping water.Use the drain valve (4) to empty this re-ceiver at regular intervals or wheneverthe engine control unit issues an errormessage.

Upstream filter - replacing the filtercartridge

- Drain off condensate water- Remove connector from water sensor (5)- Unfasten filter cartridge and receiver

with a filter wrench or strap and un-screw the unit

- Unscrew the receiver (3) from the filtercartridge and clean if necessary.

- Clean the sealing surface of the filterbracket

- Apply light coating of oil to the gasket on the receiver and tighten hand-tight underthe new filter cartridge

- Apply light coating of oil to the gasket on the filter cartridge and screw under the bracket- Reconnect the plug connection on the water sensor (5).

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Main filter - replacing filter cartridge

- Unfasten fuel oil filter cover (6) with afilter strap or key on the hex head andunscrew anticlockwise.

- Carefully pull paper filter cartridge (8)upwards and remove from guide (9).

- Catch any escaping fuel.- Replace paper filter cartridge (8).- Clean any dirt off sealing surface of filter

carrier and fuel filter cover (6) and guide(9).

- Replace rubber gasket (7) and apply alight coating of oil.

- Carefully insert a new paper filter car-tridge (8) in the guide (9).

- Tighten down fuel filter cover (6) clockwise (25Nm)

A After installing a new fuel filter, check the oil pressure gauge carefully during test op-eration to ensure that good sealing action is being provided.

m After fitting a new cartridge, check the filter for leakage with the engine running.

Bleeding the fuel system

Once the upstream fuel filter has beenreplaced, you need to bleed the fuel sys-tem.

- Unfasten the bleed screw (Allen key)(2) behind and to the right of the filterbracket.

- Operating manual pump (1) until fuelemerges from the bleed screw withoutany air bubbles.

- Tighten bleed screw (1) back down.

A To bleed the fuel system after replacingthe main filter, refer to the Engine oper-ating instructions.

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Batteries (16)

When supplied, the batteries are filledwith the correct amount of acid. The acid level should reach the uppermark. If necessary, top up with distilled water! The poles must be free of oxide. Protectthem with special pole grease.

Chain tension - caterpillar drive (14)

The chain tensioner for the caterpillardrive chain is filled via the grease nipple(46) provided on the side of the caterpil-lar drive.

The chain tension is correct if the chainsags by approx. 105 mm between thechain plates and the chassis.

Move the finisher forward or backwardand measure again to check the setting.

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General visual checks

The daily routine should comprise a visual inspection around the entire paver finisher.The following items must be checked:

- Are components or controls damaged? - Any leaks on engine, hydraulic system, gear etc.? - Are all fastening points (conveyor, auger, screed, etc.) in order?

m Immediately take actions to correct any detected malfunction to avoid damages, dan-gers or environmental hazards!

Checks by a specialist

A Have the paver, screed and gas system inspected by a specialist

- when required (according to the operating conditions and the nature of application), - however, at least once a year, check that they are all in good operational condition.

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4.2 Lube points on paver

Push rollers (22)

Lubricate the push rollers on both sides(47).

A The crossbeam is pivoted at the centreand needs not be lubricated.

Steel hopper flaps (option) (21)

The spring-loaded steel hopper flapseach have a central lube nipple.

Conveyor deflection rollers (15)

The deflection rollers for the conveyor arelubricated with grease nipples (48) locatedbehind the cross beam.

A These centre bearings are lubricated bythe external grease nipples.

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Centre auger bearing (7)

The centre bearing must be lubricatedon the left-hand side of the auger. To do so, the bevel gear unit must bepulled off.

A The centre bearing must be lubricatedwhen in a warm state to force out any bi-tumen residues.

Auger external bearing (6)

The grease nipples are located on eitherside above the external auger mountingpoints. These nipples must be lubricatedeach time work is finished.

A The auger outer bearings must be lubri-cated when in a warm state to force outany bitumen residues.

Auger, gear neck bearing (9)

Remove the Allen screw plug from thegear neck and replace the screw locatedunderneath with a 10x1 grease nipple.Using a grease gun, inject 10 strokesinto it.

A Remove the grease nipple and screw both screws back in. The gear bearing is sealedat the underside and is exclusively lubricated with grease.

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Centre conveyor bearing (5)

The grease nipple is located on the right-hand side of the rear wall, above theconveyor gear. From this nipple, a lubri-cation line leads to the bearing. Lubricat-ing the bearing is thus facilitated.

4.3 Oil drain points on the paver finisher

m Collect used oil and have it disposed ofproperly.

A For the filling volumes, see the section "Fill-ing volumes".

Pump distributor gear (11)

Draining the oil:

- Remove screw cap. - Fit hose (accessories).

Route the hose end into a used oilcontainer.

- Open the shut-off valve with a suitablewrench and completely drain the oil.

A Filling with oil: refer to section "Inspec-tion points / pump distributor gear".

Diesel engine (12)

- Drain the transmission oil in the same manner as the pump distribution gear (seeabove).

- Replacing the engine oil filter. The filter is located on the right side and can be accessed by removing the sealingcover from the cooling air suction intake.

Caterpillar-drive planetary gear (10)

Screw out the oil drain plug (49) and collectthe used oil in a container.

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Auger bevel gear (8)

To drain the oil, unscrew the lower screw(50). When returning the screw make sure touse a new seal.

m Make sure to clean the screw and the vi-cinity of the drain bore!

A For filling in oil, refer to the section"Check points/pump distribution gear".

Hydraulic oil reservoir (20)

To drain the hydraulic oil, unscrew drainplug (51) and collect the oil in a suitablecontainer using a spout. When returning the screw, make sure touse a new seal.

A For filling in oil, refer to the section"Check points/hydraulic oil reservoir".

Engine mounting (33)

Check the engine mounting for any signs of damage, and check that it is securely at-tached.If necessary, replace any damaged components.

A Follow the instructions in the Engine operating instructions!

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Hoses and hose connections (34)

Carefully check all hoses on the engineand all hydraulic hoses for signs of dam-age and also check that they are proper-ly secured.

m Immediately replace any damaged hoses.

f Ageing hoses become porous and mayburst! Danger of accidents!

A A number stamped on the hydraulicscrew connection on these hydraulichoses provides information on the dateof manufacture (1) and the maximumpermitted pressure (2) for each hose.

f Never install hoses on top of one another and always ensure that they are at the cor-rect pressure.

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Filter mats (35)

The filter mats used for cleaning intake air for engine and generator needs to be checkedfor signs of contamination every day before work starts.

There three filter mats, one each:

- behind the air intake on the left side flap- behind the air intake on the right side flap- below the right air intake duct on the top of the machine.

m Immediately replace badly contaminated filter mats because the paver finisher canonly operate reliably if the engine and generator have an unobstructed supply of air.

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Insulation test (36)

A The insulation test must be undertakenevery day when the machine is runningand the sockets are activated.

- Activate electrical system using switch(1), telltale (2) lights up.

- Press test button (3) - "Insulation er-ror" display must light up.

- Press delete button (4) - display for in-sulation error goes out.

f If the test is completed successfully, workcan proceed with the electrical system andexternal consumers can be used.However if the "Insulation error" indicatorlamp displays an error even before the testbutton is pressed, work cannot proceedwith the electrical system or with the ex-ternal equipment connected up. If an in-sulation error occurs, the sockets areautomatically de-energised (i.e. electri-cally isolated).If no errors are displayed during simula-tion, do not carry out any work on the electrical system.

f If malfunctions arise, the electrical system must be checked by an electricianand/or repaired. This must be done before work can proceed on this systemand the equipment.

f Danger from electric voltageFailure to comply with the safety precautions and safety regulations can resultin electrical shock injuries from the electrical system.Danger to life!All maintenance and repair work on the screed's electrical system must alwaysbe carried out by an electrician.

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5 Checking, lubricating, oil drain points on the emulsion spraying equipment

A The points for checking, lubricating and draining of oil are described in detail below.The item numbers given in the headers refer to the illustration above.

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5.1 Emulsion pump (24)

The emulsion pump is greased internallyand externally (55) by means of 2 pairsof grease nipples.

5.2 Emulsion filter (25)

There are two steel filter cartridges in thefilter housing (54). Clean these cartridg-es with diesel fuel after every paving job.

- Unfasten the cover clamping screw(56) and remove the cover, then rinsein diesel fuel in the cleaning tank to re-move all residual traces of emulsion.Use a burner to score the steel filtercartridges once a week.

m When burning off the steel filter insertsensure that the filter screens (meshes)do not melt or distort.Never place the steel filter cartridges on the ground because this may cause stonesto stick to the filter and damage the emulsion pump or clog the spraying nozzles.

- After cleaning the steel filter inserts, install them in the filter housing (54) and sealthe cover firmly by means of cover clamping screws (56).

- Open the manual shut-off valve (53) and fill in 3 litres of diesel fuel through the fun-nel (52). Run the emulsion pump for some seconds. Then add another 3 litres ofdiesel fuel. Close the manual shut-off valve (53).

f During operation or when filling with emulsion, the manual shut-off valve must beclosed!

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5.3 Emulsion pump gear (26)

Oil level check

A Check the oil level of the emulsion pumpgear every 500 operating hours.

- Unscrew the inspection plug (60). Whenthe oil level is correct, some oil will leakout. Otherwise, top up with oil.

Oil change

A Change the oil in the emulsion pumpgear every two years or after 2000 oper-ating hours.

- Unscrew the drain plug (59).

A The transmission oil drains easier whenit is warm.

- Fit the drain plug with a new seal (58)and tighten it firmly.

- Fill in the required amount of transmis-sion oil (see the section "Filling vol-umes") at the filler plug (57).

A Replace the seals of plugs that were opened.

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5.4 Rotary joints of the flexible emulsionhoses (27)

- The rotary joints must be greased sep-arately (6 grease nipples on each side(61)).

m Only move the flexible emulsion hoseswhen they are hot!

5.5 Spraying ramp (28)

A Check the guide system of the sprayingramp for wear every two years or after2000 operating hours.

5.6 Compressed air vessels (29)

- Open the manual drain valves (63) ofthe compressed air vessels (62) todrain the condensed water after work.

- Close the manual drain valves (63)before starting work.

A Check the system for leaks and overallcondition every two years or after2000 operating hours.

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5.7 Compressor air filter (30)

A Clean/replace the air inlet filters everyweek or after 50 operating hours.

- Unscrew and remove the screw (64)with the seal (65).

- Take off the cap (68).- Remove the filter element (67).- Clean the filter (67) using clean dry

low-pressure air.

m Replace the filter if it cannot be cleanedsatisfactorily.

- Clean the inside of the filter carrier(66) and the filter cap (68).

- Mount the filter cartridge (67) on thecarrier (66).

- Mount the cap (68) and secure it withthe screw (64) and the seal (65).

m Every two years or every 2000 operatinghours, install a new filter element (67)and a new gasket (65)!

5.8 Compressor oil cooler (31)

A Clean the radiator honeycomb every50 operating hours.

- Use compressed air to blow dust de-posits off the radiator honeycombs(69).

A Remove the compressor every1000 operating hours or at least once a year and clean it from dust deposits.

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5.9 Compressor (32)

Oil level check

A Check the compressor oil level everyday. The sight glass (70) should be halfcovered.

m Ensure that the compressor is depressu-rised. The pressure gauge must registerzero.

- To top up oil, unscrew the filler plug(71) and add compressor oil.

- Tighten the filler plug with a new seal(72).

m Do not unscrew the filler plug any furtheruntil the compressor is no longer underpressure if oil or air leaks occur.

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Oil change

A Change the oil every 500 operating hours.

f Danger of burns!We recommend to perform the oil changeright after switching off the compressor aswarm oil drains more conveniently.Heed all safety regulations pertaining tothe handling of hot fluids. Wear appropriateprotective clothing to prevent burns causedby hot oil!

- Ensure that the compressor is depres-surised. The pressure gauge mustregister ZERO.

A Slowly unscrew the filler plug (71). Donot continue unscrewing the filler pluguntil the compressor is no longer underpressure if oil or air leaks occur.

- Unscrew the filler plug (71). Place asuitable oil pan under the filler plug(74) to collect the old oil. Unscrew thedrain plug (74). Drain the old oil intothe oil pan.

- Fit a new seal (73), screw in the drainplug (74) and tighten it.

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Oil filter change

A Clean the oil filter (75) after havingchanged the compressor oil.

- Slowly remove two Allen screws (78),remove the filter cover (77) and ensurethat the O-ring groove is not damaged.

- Take out the filter cartridge (79) andwash it with methylated spirit or paraf-fin. Then dry it with compressed air.

- Clean the filter bore (80).- Insert the filter cartridge (79).- Use a new O-ring (76) for the filter lid

(77).- Fasten the filter lid with the two Allen

screws (78).- Fill the compressor with compressor

oil until the oil reaches the top of theviewing glass (70).

- Use a new seal (72) with the filler plug(71); tighten the filler plug.

- Run the compressor for approx.10 seconds and check the oil level.Top up if necessary.

m After the test run, the oil level should reachhalf way up the sight glass!If necessary, top up again with oil!

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6 Lubricating agents and operating substances

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

Only use containers which are clean inside and out for filling with oil or fuel.

A Heed the filling volumes (see the section "Filling volumes").

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

BP Esso Total Fina(Total)

Mobil Renault Shell Wisura

Grease Multi-purpose

grease L2

ESSOMulti-

purpose grease

TotalMultis EP 2

Mobilux 2Mobiplex 47

Multi-purpose grease

SHELL Alvania

grease EP(LF) 2

Retinax A

Engine oil Refer to Operating instructions for the engine. Factory-filled with Shell Rimula Super-FE 10 W 40.

Hydraulic oil See section 4.1Shell Tellus Oil 46 has been filled in at the factory.

Gear oil 90 BP MultiEP SAE 90

ESSOGP 90 Total EP 90

MOBILGX 90

TranselfEP 90

SHELLSpirax G80 W - 90

Gear oil 220 BPEnergol

GR-XP 220

ESSOSpartanEP 220

Total CarterEP 220

MOBILMobilgear

630Mobil-gearSHC 220

ChevronNL Gear

Compound220

SHELLOmala 220

OptimolOptigear

220

Optimol Optigear 220 has been filled in at the factory.

Dist. water

Diesel fuel

Brake oil/Brake fluid

BP Blue original

Brake fluid

Ate Disk brake fluid Total HB F 4

ELF

Coolant Cooling liquid (anti-freeze and corrosion protection)

F 46

F F

150C

.GB

46-

54 1

2.03

6.1 Filling volumens for paver finisher

Substance Filling volume

Volume Diesel fuel210 litres55.4 US gallons46.1 British gallons

Hydraulic oil reservoir Hydraulic oil185 litres48.8 US gallons40.6 British gallons

Diesel engine(with oil filter change)

Engine oil13.0 litres3.4 US gallons2.9 British gallons

Cooling systemCoolant40% anti-freeze

18.0 litres4.8 US gallons3.9 British gallons

Pump distribution gear Gear oil 904.5 litres1.2 US gallons0.98 British gallons

Caterpillar drive planetary gear *

Gear oil 220 4.0 litres1.05 US gallons0.88 British gallons

Conveyor gear(each side)

Gear oil 2201.5 litres0.4 US gallons0.32 British gallons

Auger bevel gear(each side)

Gear oil 900.6 litres0.15 US gallons0.13 British gallons

Central lubrication unit (option)

Grease

Batteries Distilled water

F 47

F F

150C

.GB

47-

54 1

2.03

7 Electric fuses

7.1 Main fuses (1) (beside the batteries)

7.2 Fuses in the terminal box (beside the fuel tank)

1.- F3.1 terminal box- F3.2 free

50 A100 A

1

Flap-l.EPS

...........

QSBFuse2.cdr

1

2

3

4

5

6

7

8

9

10

11

12

13

14

2

QSBFuse.tif

14

26

F 48

F F

150C

.GB

48-

54 1

2.03

Fuse carrier (2)

No. F5.1 - F5.8 A

1. Traction drive 10

2. Traction drive 1

3. Engine start, reversing buzzer (o)

4. Screed power supply 3

5. Sockets 10

6. Sockets 10

7. Sockets 10

8. Sockets 10

9. Sockets 10

F7.1 - F7.7

1. Slaves 10

2. Slaves 10

3. Slaves 10

4. Slaves 10

5. Slaves 10

6. Slaves, auxiliary functions 10

7. Electric heating 10

No. F50 - F64 A

F44 Traction drive 1

F45 Gateway power supply 5

F50 Auxiliary functions 30

F51 Auxiliary functions 3

F52 Auxiliary functions 3

F53 Auxiliary functions 5

F54 Auxiliary functions 3

F55 Auxiliary functions 10

F57 Auxiliary functions 15

F64 ACMAR power supply 25

F 49

F F

150C

.GB

49-

54 1

2.03

7.3 Fuses on the operating panel

Fuse carrier (3)

No. F1.1 - F1.8 A

1. EMERGENCY STOP 5

2. Monitoring equipment 3

3. Master, sensor belt, power converter, power supply display 10

4. Power supply to slaves 10

5. Power supply to slaves 105

6. not used

7. Screed power supply 5

8. EMR 3

- +

!

43

Element3_sps150C.cdr

1 2 3 4 5 6 7 8Fuse1.Tif

F 50

F F

150C

.GB

50-

54 1

2.03

Fuse carrier (4)

No. F2.1 - F 2.8 A

1. not used

2. Horn, spraying ramp control 3

3. Roof profile adjustment 3

4. High beam light 7.5

5. Low-beam light 3

6. Low-beam light 3

7. Parking light 3

8. Parking light, dashboard lighting, instrument panel lighting 3

1 2 3 4 5 6 7 8Fuse1.Tif

F 51

F F

150C

.GB

51-

54 1

2.03

8 Lubricant and operating fluids on emulsion spraying equipment

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

Only use containers which are clean on inside and outside for filling with oil or fuel.

A Heed the filling volumes (see the section "Filling volumes").

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

8.1 Grease

8.2 Transmission oil

Manufac-turer

Grease

BP Multi-purpose grease L2

Esso ESSO multipurpose grease

Fina FINA Marson L2

Mobil Mobilux 2 Mobiplex 47

Renault Multi-purpose grease

Shell SHELL Alvania grease R 3

Wisura Retinax A

Manufac-turer

Transmission oil

BP BP Multi EP SAE 90

Esso ESSO GP 90

Fina FINA Ponionic N SAE 90

Mobil MOBIL GX 90

Renault Tranself EP 90

Shell SHELL Spirax EP 90 Hypoit GL 4

F 52

F F

150C

.GB

52-

54 1

2.03

8.3 Compressor oil

8.4 Filling volumes

Manufacturer Compressor oil

BP BP Vanellus M 40

Esso Essolub HDX 40

Fina FINA Disal HD 2

Mobil MOBIL Delvac 1240

Shell SHELL Rimula X40

Castrol CASTROL CRI 40

Agricastrol AGRICASTROL 40

Golf Golflub Motor oil XHD 40

Texaco TEXACO Ursa oil Extra duty SAE 40

Chevron E.P. CHEVRON E.P. Industrial oil 68 X

Factory filling Hydrovane 2000

Substance Filling volume

Emulsion pump gear drives Gear oil 903.5 litres0.92 US gallons0.77 British gallons

Compressor Compressor oil4.3 litres1.13 US gallons0.94 British gallons

F 53

F F

150C

.GB

53-

54 1

2.03

9 Electrical fuses / relays on emulsion spraying equipment

9.1 Fuses/relays in the spraying system switch cabinet

A The fuses/relays are located behind the instrument panel.

Fuses

Relays

Item Protected unit(s) Rating

81 - Main fuse 10 A

82 - Spraying/ramp movement 3 A

83 - Valves for compressed air cleaning 3 A

84 - Emulsion pump/compressor 5 A

85 - Extendable parts of the spraying ramp 5 A

86 - Valves of the spraying nozzles 3 A

Item Function Basic setting

87 - Timer relay for the compressor approx. 10 s

88 - Timer relay for semi-automatic operation approx. 2 s

8887

81 82 8683 84 85

Bild-2.tif

F 54

F F

150C

.GB

54-

54 1

2.03

9.2 Fuses in the switch cabinet of the three-phase system (380 V)

A The fuses are located behind the instrument panel.

f Caution: High voltage: danger to life!

f Danger from electric voltageFailure to comply with the safety precautions and safety regulations can resultin electrical shock injuries from the electrical system.Danger to life!All maintenance and repair work on the screed's electrical system must alwaysbe carried out by an electrician.

Item Protected unit(s) Rating

89(F10)

- Heating circuit I via generator I 16 A

90(F11)

- Heating circuit II via generator II 16 A

91(F13)

- Upstream fuse on 230V electrical system 13 A

92(F14)

- Upstream fuse on 230V electrical system 13 A

93(F12)

- Remote power supply for heating circuits I and II35 A

(3 units)

SchaltschrF150_2.cdr/E-Schr_F150.jpg

92

Ultschall.tif

91

89

93