DYNAPAC F 150 C 769130 - Specification [PDF]

Zitiervorschau

Operating instructions 01-1203

Paver finisher 769..........................

F 150 C 900 98 07 28

Preface Safe operation of the machine requires specific knowledge that is imparted by the present operating instructions. The information is provided in a concise, clearly structured form. The individual chapters are arranged in alphabetical order Every chapter starts on page 1. The designation of pages consists of a letter denoting the chapter and 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 during operation and maintenance work the description appropriate to the machine option is used.

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

f

Precedes safety instructions that must be observed in order to prevent danger to personnel.

m

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

A

Precedes general notes and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

V 0001.GB 1-2 01.1203

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

V00.001.GB 2-2 1197

Table of contents A

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

B

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

1 2 2.1

Application ................................................................................................. 1 Description of assemblies and functions of the paver finisher ................... 2 Vehicle ....................................................................................................... 2 Construction ........................................................................................... 3 Description of assemblies and functions of the emulsion spraying system .......................................................................... 6 Construction ........................................................................................... 7 Safety ......................................................................................................... 8 Emergency stop button on paver finisher .................................................. 8 Emergency stop button on emulsion spraying system ............................... 8 Steering system ......................................................................................... 8 Horn ........................................................................................................... 8 Ignition key / lights ..................................................................................... 8 Safety switch, remote power supply .......................................................... 8 Residual dangers caused by the spraying system ..................................... 9 Main switch (36) ....................................................................................... 10 Hopper transport safeguards (37) ............................................................ 10 Screed transport safeguard ..................................................................... 10 Locking for protective roof (38) ................................................................ 10 Technical vehicle data ............................................................................. 12 Performance data .................................................................................... 12 Traction drive/chassis .............................................................................. 12 Engine ...................................................................................................... 12 Hydraulic system ...................................................................................... 13 Material compartment (hopper) ................................................................ 13 Weights (all weights in t) .......................................................................... 13 Material conveying ................................................................................... 14 Material distribution .................................................................................. 14 Screed lifting device ................................................................................. 14 Electrical system ...................................................................................... 14 Technical data for emulsion spraying system .......................................... 15 Dimensions .............................................................................................. 15 Electric system ........................................................................................ 15 Additional hydraulics ................................................................................ 15 Emulsion ................................................................................................. 16 Spraying nozzles ...................................................................................... 16 Dimensions (all dimensions in mm) ........................................................ 17 Location of instruction labels and identification labels ............................. 18 Identification label for the paver finisher (54) .......................................... 20 Identification label for spraying system (60) ............................................. 21

F150C.GBIVZ.fmI 1-8 - 01.03

2.2

3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5 5.1 5.2 5.3 5.4 5.5 5.6 6 6.1 6.2

I1

EN standards ........................................................................................... 22 Continuous sound level ............................................................................ 22 Operating conditions during measurement .............................................. 22 Measuring point configuration .................................................................. 22 Vibration acting on the entire body .......................................................... 23 Vibrations acting on hands and arms ....................................................... 23 Electromagnetic compatibility (EMC) ....................................................... 23

C

Transportation ......................................................................... 1

1 2 2.1 2.2 2.3 3 3.1 3.2 4 5 5.1 5.2 6 6.1

Safety regulations for transportation .......................................................... 1 Transportation on low-bed trailers ............................................................. 2 Preparations ............................................................................................... 2 Driving onto the low-bed trailer .................................................................. 3 After transportation .................................................................................... 3 Transportation on public roads .................................................................. 4 Preparations ............................................................................................... 4 Driving on public roads .............................................................................. 5 Loading by crane ....................................................................................... 6 Loading the dismounted emulsion spraying system .................................. 6 Loading by crane ....................................................................................... 7 Loading by fork-lift truck ............................................................................. 7 Towing ....................................................................................................... 8 Safely parking the vehicle ........................................................................ 10

D

Operation ................................................................................. 1

1 2 2.1 2.2

Safety regulations ...................................................................................... 1 Controls ...................................................................................................... 2 Operating panel ...................................................................................... 2 Operating the input and display terminal ................................................. 24 Display keyboard ................................................................................. 24 Working in the menu ............................................................................ 25 Diagnosing and detecting malfunction ..................................................... 35 Engine error messages ............................................................................ 43 Error message, "Coolant level too low" ............................................... 44 Remote control ......................................................................................... 45 Emergency program for TDM-failure ................................................... 48 Special functions ...................................................................................... 50 Reversible conveyor ............................................................................ 50 Controls on the paver finisher .................................................................. 51 Batteries (71) ....................................................................................... 51 Battery main switch (72) ...................................................................... 51 Transport safeguards for the hopper (73) ............................................ 52 Mechanical screed transport safeguard (to the left and the right beneath the driver’s seat) (74) ........................................................................... 52 Seat lock (behind the driver’s seat) (75) .............................................. 53 Separator fluid spraying system (80) o ................................................ 54 Pressure control valve for screed charging/relieving (84) (o) .............. 55 Pressure control valve for screed stop with pretensioning (84a) ......... 55 Pressure gauge for screed charging/relieving and screed stop with pretensioning (84b) ................................................................................... 55 On / off switch for additional

2.3 2.4 2.5 2.6 2.7

I2

F150C.GBIVZ.fm 2-8 - 01.03

7 7.1 7.2 7.3 7.4 7.5 7.6

2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 3 3.1 3.2 4 4.1

F150C.GBIVZ.fmI 3-8 - 01.03

4.2

5 5.1 5.2 6 6.1 6.2 6.3 6.4 7 7.1

headlight in the roof (85): ..................................................................... 56 On/off switch for 230V sockets (85a) ................................................... 56 On / off switch for fuel tank filler pump (85b) ................................................................................... 56 On / off switch special lighting (85c) .................................................... 56 Folding roof locking brackets (on left and right sides of roof console ) (86): .............................................................................................................. 57 Hydraulic folding roof (87) (o) .............................................................. 58 Conveyor limit switches ....................................................................... 59 Ultrasonic auger limit switches (90) (left and right) .............................. 59 Sockets for the remote control (left and right) (91) .............................. 60 Sockets for working lights (left and right) (92) ............................................................................... 60 Switch cabinet for the spraying system .................................................... 61 Operating panel, paver finisher ................................................................ 65 Remote control of emulsion spraying system, right side ..................... 66 Remote control of emulsion spraying system, left side ....................... 67 Compressed air indicator .................................................................... 68 Switch cabinet for emulsion heating ................................................... 69 Switch cabinet for remote power supply ................................................ 71 Left-hand tank side ................................................................................ 72 Manual spraying device, rear ................................................................. 73 Manual spraying device, front ................................................................ 74 230 Volt electrical system ........................................................................ 75 230 Volt sockets on left and right sides ................................................... 75 On/off switch for 230V sockets ............................................................ 76 Insulation test ........................................................................................... 76 Operation ................................................................................................. 77 Preparing for operation ............................................................................ 77 Required devices and aids .................................................................. 77 Before starting work (in the morning or when starting paving) ............................................. 77 Checklist for the machine operator ...................................................... 78 Starting the paver finisher ........................................................................ 80 Before starting the paver finisher ......................................................... 80 "Normal" starting .................................................................................. 80 External starting (starting aid) .............................................................. 81 After starting ........................................................................................ 82 Observe indicator lamps ...................................................................... 83 Coolant check (43) ............................................................................... 83 Oil pressure indicator lamp for the diesel engine (45) ......................... 83 Oil pressure indicator lamp for the traction drive (44) .......................... 83 Battery charge indicator (47) ............................................................... 84 Starting the spraying system .................................................................... 85 Compressed air system .......................................................................... 85 Loading the emulsion tank ....................................................................... 86 Heating system ........................................................................................ 88 Working temperatures .............................................................................. 88 Heating before the spray process ............................................................ 88 Heating during spraying ........................................................................... 89 During work interruptions (remote power supply) .................................... 89 Emulsion circuit ........................................................................................ 90 Tank circuit ............................................................................................... 91 I3

7.2 7.3

7.4 7.5

7.6

7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14

F150C.GBIVZ.fm 4-8 - 01.03

8 8.1 8.2 8.3 8.4 9

Spraying ramp circuit ............................................................................... 91 Preparations for paving ............................................................................ 92 Separating agent ................................................................................. 92 Screed heating system ........................................................................ 92 Direction marks .................................................................................... 92 Loading/distributing material ............................................................... 93 Starting for paving .................................................................................... 94 Checks during paving .............................................................................. 96 Paver function ...................................................................................... 96 Quality of the layer ............................................................................... 96 Paving with screed stop and screed charging/relieving device: ............... 97 General ................................................................................................ 97 Screed charging/relieving .................................................................... 97 Screed stop .......................................................................................... 98 Screed stop with pretensioning ............................................................ 98 Adjusting the pressure (o) .................................................................... 99 For screed stop with pretensioning: ..................................................... 99 For screed charging/relieving .............................................................. 99 Spraying ................................................................................................. 100 Emptying the spraying ramp (end of paving) ......................................... 101 Cleaning the spraying nozzles ............................................................... 102 Cleaning the emulsion filter .................................................................... 102 Notes on handling the spraying equipment ............................................ 103 General .............................................................................................. 103 Finishing work with the spraying equipment ......................................... 103 Finishing work with the spraying equipment ......................................... 104 Interrupting/terminating operation .......................................................... 105 During paving breaks (e.g. a delay in supply of material by trucks) .. 105 During extended interruptions (e.g. lunch break) ............................... 105 When work is finished ........................................................................ 106 Malfunctions ........................................................................................... 107 Engine error codes ................................................................................. 107 Problems during paving ......................................................................... 112 Malfunctions on the paver finisher or screed ......................................... 114 Malfunctions on the emulsion spraying equipment ................................ 117 Emergency device/steering, drive system ............................................. 120

I4

E

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

1 2 2.1 2.2 2.3 2.4

Special notes on safety .............................................................................. 1 Auger ......................................................................................................... 2 Height adjustment ...................................................................................... 2 Auger crossbeam installed in a fixed position ............................................ 2 With mechanical adjustment with ratchet (option) ..................................... 3 With hydraulic adjustment (option) 3 Auger extension ......................................................................................... 4 Mounting extension parts ........................................................................... 5 Mounting support tube extensions ............................................................. 6 Installing tunnel plates ............................................................................... 7 Installing additional braces ......................................................................... 8 Pendulum drive system ......................................................................... 9 Screed ...................................................................................................... 10 Electrical connections .............................................................................. 10 Remote controls ....................................................................................... 10 Grade control ........................................................................................... 10 Auger limit switches ................................................................................. 10 Working lights .......................................................................................... 10 Operating principle for the spraying system ............................................. 11 Selecting the nozzles and the method ..................................................... 13 Explanations ............................................................................................ 14 Programming the computer ..................................................................... 15 Setting parameters for automatic operation ............................................. 20 Calculating the base value ................................................................... 20 Calculating the parameters .................................................................. 21 Calculation sheet for the automatic mode ............................................. 22 Settings for semi-automatic operation ..................................................... 23 Completing the calculation sheet ......................................................... 23 Calculation sheet for the semi-automatic mode (FORWARD + BACKWARD) 25 Calculation sheet for the semi-automatic mode (FORWARD only) ...... 26 Performing a set-up before work starts .................................................... 27 Calculation sheet for spraying nozzles behind the drives ...................... 28 Explanations for the calculation sheet for the spraying nozzles behind the drives 29

2.5 2.6 2.7 2.8 2.9 3 4 4.1 4.2 4.3 4.4 5 5.1 5.2 6 6.1

6.2 6.3 6.4

F150C.GBIVZ.fmI 5-8 - 01.03

6.5 7 7.1 7.2

I5

I6

Maintenance ............................................................................ 1

1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1

Notes regarding safety ............................................................................... 1 Maintenance intervals for the paver finisher .............................................. 2 Daily (or every 10 operating hours) ............................................................ 3 Weekly (or every 50 operating hours) ........................................................ 5 Every 100 operating hours ......................................................................... 5 Every 250 operating hours ......................................................................... 5 Every 500 operating hours ......................................................................... 7 Yearly (or every 1000 operating hours) ..................................................... 7 Every 2 years (or every 2000 operating hours) .......................................... 9 Maintenance intervals for the emulsion spraying equipment ................... 10 Daily (or every 10 operating hours) .......................................................... 11 Weekly (every 50 operating hours) .......................................................... 11 250 operating hours ................................................................................. 13 Every 500 operating hours ....................................................................... 13 Yearly (or every 1000 operating hours) ................................................... 13 Every 2 years (or every 2000 operating hours) ........................................ 15 Checking, lubricating, oil drain points on the paver finisher ..................... 16 Check points ............................................................................................ 17 Pump distributor gear (11) ................................................................... 17 Caterpillar drive - planetary gear (10) .................................................. 17 Conveyor gear (left/right) (4) ................................................................ 18 Auger bevel gear (left/right) (8) ............................................................ 18 Engine lube oil (12) .............................................................................. 19 Oil level check ...................................................................................... 19 Oil change ............................................................................................ 19 Engine oil filter (12a) ............................................................................ 20 Cooling system for engine and hydraulics (13) .................................... 21 Water cooler (radiator) ......................................................................... 21 Hydraulic cooler ................................................................................... 21 Fuel tank (18) ....................................................................................... 22 V-belts and ribbed V-belts (1) .............................................................. 22 Air filter (2) ........................................................................................... 23 High pressure hydraulic filter (3) .......................................................... 24 Suction/return flow hydraulic filter (19) ................................................ 24 Hydraulic oil reservoir (20) ................................................................... 25 Chain tension, conveyor (23) ............................................................... 25 Grease tensioner on conveyor (O) ...................................................... 25 Engine - fuel filter (17) ......................................................................... 26 Upstream filter - draining off water: ...................................................... 26 Upstream filter - replacing the filter cartridge ....................................... 26 Main filter - replacing filter cartridge ..................................................... 27 Bleeding the fuel system ...................................................................... 27 Batteries (16) ....................................................................................... 28 Chain tension - caterpillar drive (14) .................................................... 28 General visual checks .......................................................................... 29 Checks by a specialist ......................................................................... 29

F150C.GBIVZ.fm 6-8 - 01.03

F

4.2

4.3

5 5.1 5.2 5.3

F150C.GBIVZ.fmI 7-8 - 01.03

5.4 5.5 5.6 5.7 5.8 5.9

6 6.1 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 9 9.1

9.2

Lube points on paver ............................................................................... 30 Push rollers (22) .................................................................................. 30 Steel hopper flaps (option) (21) ........................................................... 30 Conveyor deflection rollers (15) ........................................................... 30 Centre auger bearing (7) ..................................................................... 31 Auger external bearing (6) ................................................................... 31 Auger, gear neck bearing (9) ............................................................... 31 Centre conveyor bearing (5) ................................................................ 32 Oil drain points on the paver finisher ....................................................... 32 Pump distributor gear (11) ................................................................... 32 Diesel engine (12) ................................................................................ 32 Caterpillar-drive planetary gear (10) .................................................... 32 Auger bevel gear (8) ............................................................................ 33 Hydraulic oil reservoir (20) ................................................................... 33 Engine mounting (33) .......................................................................... 33 Hoses and hose connections (34) ....................................................... 34 Filter mats (35) ..................................................................................... 35 Insulation test (36) ............................................................................... 36 Checking, lubricating, oil drain points on the emulsion spraying equipment 37 Emulsion pump (24) ................................................................................ 38 Emulsion filter (25) ................................................................................... 38 Emulsion pump gear (26) ....................................................................... 39 Oil level check ...................................................................................... 39 Oil change ............................................................................................ 39 Rotary joints of the flexible emulsion hoses (27) ..................................... 40 Spraying ramp (28) .................................................................................. 40 Compressed air vessels (29) ................................................................... 40 Compressor air filter (30) ......................................................................... 41 Compressor oil cooler (31) ....................................................................... 41 Compressor (32) ..................................................................................... 42 Oil level check ...................................................................................... 42 Oil change ............................................................................................ 43 Oil filter change .................................................................................... 44 Lubricating agents and operating substances ......................................... 45 Filling volumens for paver finisher ........................................................... 46 Electric fuses ............................................................................................ 47 Main fuses (1) (beside the batteries) ................................................. 47 Fuses in the terminal box (beside the fuel tank) ...................................... 47 Fuses on the operating panel .................................................................. 49 Lubricant and operating fluids on emulsion spraying equipment ............. 51 Grease ..................................................................................................... 51 Transmission oil ....................................................................................... 51 Compressor oil ......................................................................................... 52 Filling volumes ......................................................................................... 52 Electrical fuses / relays on emulsion spraying equipment ....................... 53 Fuses/relays in the spraying system switch cabinet ................................ 53 Fuses ................................................................................................. 53 Relays ................................................................................................ 53 Fuses in the switch cabinet of the three-phase system (380 V) .............. 54

I7

I8

F150C.GBIVZ.fm 8-8 - 01.03

A Correct use and application "Guidelines for the Correct Use and Application of Paver Finishers" compiled by A The Dynapac are included in the scope of delivery for this machine. The guidelines are part of the present operating instructions and must always be heeded. National regulations are fully applicable. The road construction machine described in these operating instructions is a paver finisher that is suited for laying mixed materials, roll-down concrete or lean-mixed concrete, track-laying ballast and unbound mineral aggregates for foundations for pavingThe emulsion spraying system is provided to apply an emulsion layer immediately prior to installing the material. The paver finisher and the emulsion spraying system must be installed, operated and maintained in accordance with the instructions in these operating instructions. No other form of usage is permitted and could cause injury to people or damage to the paver finisher and the emulsion spraying system, or to other material assets. Any usage other than the intended application described here constitutes a violation of these operating instructions and is therefore expressly prohibited! Especially in those cases where the paver finisher is to be operated on inclines or where it is to be used for special purposes (construction of dumps, dams), it is absolutely necessary to contact the manufacturer. Duties of the user: A "user" within the meaning of the present operating instructions is defined as any natural or legal person who either uses the paver finisher himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person who, in accordance with existing contractual agreements between the owner and the user of the paver finisher, is charged with the observance of the operating duties. The user must ensure that the paver finisher is only used in the stipulated manner and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions as well as the operating, servicing and maintenance guidelines are observed. The user must also ensure that all persons operating the paver finisher have read and understood the present operating instructions.

A_F150C.GB.fm. 1-2 01.1203

Mounting of attachments: The paver finisher must only be operated in conjunction with screeds that have been approved by the manufacturer. Mounting or installation of any attachments that will interfere with or supplement the functions of the paver finisher is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.

A1

A2

A F15C.F 2-2 0599

B Vehicle description 1

Application The DYNAPAC F 150 C is a caterpillar paver finisher that is used for laying bituminous mixed material, roll-down or lean-mixed concrete, track-laying ballast and unbound mineral aggregates for foundations for paving. The DYNAPAC emulsion spraying system is used in conjunction with the F 150 C paver finisher.

F151C.wmf

The hydraulically extendable emulsion spraying system has been designed for paving at variable working widths. For the technical specifications of the emulsion spraying system, see the section "Technical data".

B F150C.GB 1-24 12.03

A

B1

2

Description of assemblies and functions of the paver finisher

2.1

Vehicle

14

13

1

2

3 12 11

10

9

8

7

6

5

4

F151C.wmf

2 3 4 5 6 7 8 9 10 11 12 13 14

Designation t t t t t t t t t t t t t o

Material compartment (hopper) Truck push rollers Tube for sensor rod (direction indicator) and holder for levelling shoe Caterpillar drive Levelling cylinder for paving thickness Traction roller Arm traction rail Paving thickness indicator Arm Traction drive of the caterpillar drive Auger Screed Operator’s platform Protective roof

t = Standard equipment

B2

o = Optional equipment

B F150C.GB 2-24 12.03

Item 1

Construction The paver finisher has a welded steel frame on which the individual components are mounted. The caterpillar drives (4) compensate uneven areas on the ground; the suspension of the attached screed (12) additionally helps to attain a high paving precision. The continuously adjustable hydrostatic traction drive (10) allows the speed of the paver finisher to be matched to all work conditions. Operation of the paver finisher is faciliated by the automatic material handling system (1), the separate traction drives (10) and the clearly structured operating and control elements (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 engine. For further information please refer to the operating instructions for the engine. Caterpillar drive: Both caterpillar drives are directly driven by separate drives without 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 drives of the paver finisher via the attached distribution gear and its auxiliary drive shafts.

B F150C.GB 3-24 12.03

Traction drive: The continuously adjustable traction drive pumps are connected to the traction motors by means of high pressure hydraulic hoses. These oil motors drive the caterpillar chains via planetary gears that are mounted directly inside the drive wheels of the caterpillar chains.

B3

Steering system/operator’s platform: The independent hydrostatic traction drives allow the finisher to be turned on the spot. The electronic synchronisation, controlled from the operating panel, ensures that the finisher runs straight ahead. The operating panel can be secured in a position at the left-hand or the right-hand side of the paver finisher by means of a latch accessible from above. Push roller cross bar: The push rollers for material trucks are fastened to a cross bar that is pivoted at its centre. This cross bar allows to compensate for different distances to the rear wheels of material trucks. The paver finisher thus deviates less from its course and paving in curves is made easier. Material compartment (hopper): The hopper inlet is equipped with a conveyor system 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 of the hopper can be hydraulically moved (option). Material transfer: The paver finisher is equipped with two conveyors driven separately that transfer the material from the hopper to the augers. By scanning the filling height during the paving procedure, the transfer amount or speed is regulated fully automatically. Augers: The augers are driven and actuated independently from the conveyors. The left-hand and the right hand half of the auger can be controlled separately. The drive system is fully hydraulic. The conveyor unit can be used to direct material inwards or outwards with a choice of settings. This ensures that there is always a sufficient supply with material even if an excessive amount of material is required at one side. The auger speed is controlled 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 of augers ensure optimum adaptation to a wide range of paving thicknesses and widths. The basic configuration allows the height to be adjusted by attaching chains to the side arms and by actuating the hydraulic screed lifting device. When adjusting by means of ratchets (option), the height of the locking clamp spindles 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 hydraulic cylinders (option).

B F150C.GB 4-24 12.03

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

B4

Levelling system/slope control system: The slope control system (option) allows the traction point to be regulated at the left-hand or the right-hand side with a defined difference to the opposite side. To determine the actual value, the two traction arms are linked with a slope control rod. The slope control system always operates in conjunction with the screed height adjustment of the opposite side. By adjusting the height of the traction point of the arm (traction roller), the paving height of the material or the paving height of the screed can be controlled. Actuation occurs electro-hydraulically on both sides and can be controlled manually by means of toggle switches or automatically by means of an electronic grade control system. Screed lifting device: The screed lifting device is used to lift the screed during transportation. Lifting occurs electro-hydraulically on both sides by actuating the hydraulic cylinders on the arms and is controlled by means of toggle switches on the operating panel. Automatic screed stop and screed charging/relieving device: The automatic screed stop prevents the formation screed marks caused by a stopped screed. When the paver finisher stops (during a truck change), the control valves set to the floating position are shut and locked, thus preventing the screed from sinking during the stop.

B F150C.GB 5-24 12.03

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

B5

2.2

Description of assemblies and functions of the emulsion spraying system 20

21

22

23

24

25

19

18

17

29

Item

28

27

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

B6

26

o = Optional equipment

B F150C.GB 6-24 12.03

F151C.wmf

Construction Remote control for the spraying ramp The remote controls are located at the righthand 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 supply supplies 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 the operating and control elements for the spraying system. Switch cabinet for the heating system: The switch cabinet accommodates the fuses for heating circuits I and II and for the remote power supply. Compressor: The hydrostatically driven compressor supplies the nozzle, the valve and the pump controller (emulsion pump). Emulsion tank gauge: The gauge indicates the amount of emulsion in the tank. The safety switch automatically switches off the heating system if the tank contains less than 500 l of emulsion. EMERGENCY STOP switch for the loading and spraying pump (emulsion pump): Pressing this switch cuts out the loading and spraying pump in the case of malfunctions 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 example, 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. The amount 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 located behind each of the drives which extends across the width of the drive, covering the area not sprayed by the main ramp.

B F150C.GB 7-24 12.03

Emulsion tank: All the equipment required for the spraying process, e.g. loading and spraying pump, compressor, filter and heating, is fitted on the emulsion tank which has a capacity of approx. 2800 litres. The tank is filled through filler necks located on the left and right sides. This process involves switching over the spraying pump function, which now acts as a loading pump. The hydrostatically powered compressor supplies the pneumatic nozzle and pump control 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 covers the areas not sprayed by the spraying ramp.

B7

3

Safety Safe operation is only possible when all operating and control elements are functioning 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 finisher - on the operating panel - on the two remote control units (option)

F0005_A1.EPS

m

Pressing the emergency stop button switches off the engine, the drives and the steering 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 emulsion spraying system - on the left-hand side of the tank

m

Pressing the EMERGENCY STOP button switches the emulsion pump off.

3.3

Steering system

F0005_A1.EPS

F0069_A1.EPS

3.4

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

3.5

Horn_K.cdr/Horn_sps.cdr

Ignition key / lights

Light_K.cdr

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

A

B8

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

B F150C.GB 8-24 12.03

3.6

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

B F150C.GB 9-24 12.03

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

B9

3.8

Main switch (36)

36

F0077/0078_A1.EPS

3.9

Hopper transport safeguards (37)

37

F0076_A1.EPS

3.10

Screed transport safeguard

F0083_3A1.TIF

3.11

Locking for protective roof (38)

Techn.TIF

B 10

B F150C.GB 10-24 12.03

38

40 39 44 43 42 41

Techn.TIF

Item Designation 39 40 41 42 43 44

Engine hood Lateral flaps Walkway Screed coverings Auger covers Hazard warning lights of the screed

Accessories:

B F150C.GB 11-24 12.03

- Wedges - Warning triangle - First-aid kit

B 11

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

Screed used

Maximum working width (with extension parts)

Performance data Continuously hydraulically adjustable up to

4.1

Minimum paving width (with cut-off shoe)

Technical vehicle data

Basic width (without cut-off shoes)

4

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

Traction drive/chassis Drive Caterpillar drive Turning capacity Speed

4.3

Engine Make/type Model Capacity Volume of fuel tank

B 12

Hydrostatic drive, continuously controllable Two separately driven caterpillar drives with rubber grouser chains. Turning on the spot See above

Deutz BF6M 2012 6-cylinder diesel engine (water-cooled) 131 KW / 178 PS (at 2300 rpm) (see chapter F)

B F150C.GB 12-24 12.03

4.2

Transport speed

4.4

Hydraulic system Pressure generation

Pressure distribution

Hydraulic oil reservoir - volume

4.5

Material compartment (hopper) Volume Minimum inlet height, centre Minimum inlet height, outer

4.6

approx. 5.7 m3 = approx. 12.5 t 480 mm 600 mm

Weights (all weights in t) Paver finisher without screed 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 With extension parts for max. working width plus max. With filled hopper additionally max.

approx. 16.70

approx. 19.70 approx. 19.77 approx. 20.02 approx. 19.79 approx. 19.99 approx.19.92 approx. 1.40 approx. 12.50

For the weights of the screed and the screed attachments, see the operating instructions for the screed.

B F150C.GB 13-24 12.03

A

Hydraulic pumps via distribution gear (directly flanged to the engine) 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) (see chapter F)

B 13

4.7

Material conveying Conveyors Drive Conveying volume controller

4.8

Material distribution Augers Drive Conveying volume controller Auger height adjustment Auger extension

4.9

Left and right auger separately controllable Hydrostatic external drive, infinitely variable control independent of conveyor auger halves capable of contra-rotation Fully automatic via configurable switching points - mechanically via chain - mechanical (option) - hydraulic (option) With extension parts (see auger extension chart)

Screed lifting device

Special functions

Levelling system 4.10

Left and right auger separately controllable Hydrostatic, continuously controllable Fully automatic via configurable switching points

At standstill: - Screed stop - Screed stop with pretensioning (max. pressure 50 bar) During paving: - Screed charging - Screed relieving (max. pressure 50 bar) Mechanical grade control, optional systems with and without slope control

Electrical system 24 V 2 x 12 V, 88 Ah see chapter D, section 3

B F150C.GB 14-24 12.03

On-board voltage - Batteries - Fuses

B 14

5

Technical data for emulsion spraying system

F151C.wmf

5.1

Dimensions Spraying ramp: - basic ramp - hydraulically extendable up to - with extension parts: 0.4 m 0.6 m 1.0 m

5.2

m m

3.30 - 4.80 3.70 - 5.20 4.50 - 6.00

m m m

24

F

2 x10

KW

380

F

Electric system Operating voltage Generator Remote power supply

5.3

2.50 4.00

Additional hydraulics

Pumps

45 5.5

m3/h bar

B F150C.GB 15-24 12.03

Compressor - Capacity - Tank pressure

Compressor Spraying ramp adjustment Emulsion pump

B 15

5.4

Emulsion Emulsion tank Emulsion metering

5.5

2800 o 4000

l

Continuous 200 - 1000

g/m3

450 - 600

g/m3

600 and more

g/m3

250 - 450

g/m3

450 and more

g/m3

Spraying nozzles Model 727 - Low coverage (spraying in one direction) - High coverage (spraying in both directions)

B F150C.GB 16-24 12.03

Model 647 - Low coverage (spraying in one direction) - High coverage (spraying in both directions)

B 16

5.6

Dimensions (all dimensions in mm)

B

A

C D

E

I J

F G H

K L

Techn.pic

A B C D E F

G

B F150C.GB 17-24 12.03

H

I J K L

A

Designation Min. transportation height without roof and exhaust tail pipe Operator’s platform height Transportation height with roof swung down Overall height with roof Hopper length Caterpillar drive length - Length without screed walkway - VB 850 T/TV - VB 805 TV - VB 1105 TV - VB 805 TV Plus - VB 1105 TV Plus - VB 1005 - 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 Chain width External track width Overall/transportation width Max. width with open hopper

2825 1720 3200 3750 1900 3370 7210 7450 7450 7450 7450

7480 7620 7620 7620 7620 300 2200 2500 3400

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

B 17

6

Location of instruction labels and identification labels

45

46

47

48

49

54 51

50 53 52 51

55

56

57

58

B F150C.GB 18-24 12.03

59

B 18

60

B F150C.GB 19-24 12.03

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

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

B 19

6.1

Identification label for the paver finisher (54)

62 63 64 61 65 66 67 68 Fertiger2.tif

Item 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)

The punched vehicle identification number on the paver finisher must match the product identification number (68).

B F150C.GB 20-24 12.03

A

Designation

B 20

6.2

Identification label for spraying system (60)

76

75 79

77

78

TYP_Sch.TIF

Item

Designation Manufacturer

76

Machine type

77

Machine No.

78

Year of construction

79

Serial No.

B F150C.GB 21-24 12.03

75

B 21

7

EN standards

7.1

Continuous sound level

m

The operator always must use ear protection. The emission value at the ear of the driver varies depending on the materials used for paving and may even rise above 85 dB (A). If no ear protection devices are used, hearing can be impaired. The noise emission level of the finisher has been measured under free-field conditions according to prEN 500-6, dated March, 1997, and ISO 4872 at a normal engine speed of 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 Measuring point

2

4

6

8

10

12

Sound pressure level LAFeq (dB(A)) 7.2

Operating conditions during measurement The diesel engine was running at maximum speed. The screed was arrested in the transportation position. Conveyors, augers, tampers and vibration were running at least 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 centre. The measuring points had been assigned the following co-ordinates Measuring points 2, 4, 6, 8 X

Y

Z

X

Y

Z

±11.2

±11.2

1.5

-4.32 +4.32

+10.4 -10.4

11.36 11.36

B F150C.GB 22-24 12.03

Co-ordinates

Measuring points 10, 12

B 22

SCHALL.TIF

7.4

Vibration acting on the entire body When the machine is used properly, the weighted effective acceleration values at the driver’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 the driver’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 EMC guideline 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 610004-2/03.96 (ESD): The paver finisher did not show any discernible reactions to contact discharges of ± 4 KV and to air discharges of ± 8 KV. The modifications according to test criterion "A" are being met, i.e. the paver finisher continues to work without malfunction during the test. Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.

B F150C.GB 23-24 12.03

A

B 23

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 the spraying system to basic width. Remove all loose and protruding components (automatic level control unit, auger limit switch, limiting plates etc.). When transporting under a special permit, secure these parts! Close the hopper lids and engage the hopper transport safeguards. Lift the screed and engage the screed transport safeguards. Convert the protective roof and engage the latch. Check that the clamping device for the auger frame is fastened and that the telescopic tube cannot slide out (see chapter E, section 2.6). Stow all components not firmly attached to the paver finisher, screed and spraying system 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 transport. Disconnect the gas bottles from the gas system and protect them with their caps. Use a separate vehicle to transport them. When loading via ramps, the paver finisher may slip aside, tilt or topple over. Drive carefully! Keep the danger area free of persons! 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 public 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.

C F150C.GB 1-10 12.03

The operating panel must be moved to the side of the oncoming traffic and secured in this position. The driving lights must be properly adjusted. Only accessories and extension parts may be transported in the hopper, no material or gas bottles! If necessary, the operator must be assisted by a second person when driving on public roads – especially at road crossings and junctions.

C1

2

Transportation on low-bed trailers

m

Reduce the paver finisher and the screed to their basic widths; also remove any attached side plates. To prevent damages to the screed, the inclination of the ramp to be used must not exceed 11° (19%).

2.1

1 5 2

Preparations

A

B

C

D

3

4 - Prepare the paver finisher for operation (see chapter D, section 3). - Close hopper lids using buttons (1). - Engage both hopper transport safeguards (6). 6 - Raise screed with button (2). Retract the screed parts by using switch (3) in connection with the keys in the keyblock left until the screed matches the basic width of the paver finisher. Engage the screed transport safeguard (7). - Extend the levelling cylinders completely by using key (4) in connection with the keys in the keyblock right. - Press button (5) 7 - Set the preselector (8) to "zero". Set the drive lever (9) to the centre position. - Remove all protruding or loose parts from the paver finisher and the screed (see also the Operating instructions 9 for the screed). Store these parts in a 8 safe place. - When screed is operated with the optional gas heating system: - Remove the gas bottles for the screed heating system: - Close the main shut-off valves and Element1_SPS150C.cdr /F0076_A1.EPS/F0083_A1.TIF/Element2_SPSC.cdr 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 regulations. C F150C.GB 2-10 12.03

START

C2

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 on frame. When it is in the lower position, secure it with the bolts. - On models with a tarpaulin roof: remove tarpaulin weather protector prior to any extended journeys.

- Secure the paver finisher to the lowbed trailer: - Use only appropriate, approved attachment devices. - Use the provided four retaining points (9, 10). - Afterit has had time to cool down,remove the exhaust extension pipe. 2.3

After transportation

9

10

F0128_A1.TIF

C F150C.GB 3-10 12.03

- 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 secure it.

C3

3

Transportation on public roads

m

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

3.1

Preparations

1 5 2

- Prepare the paver finisher for operation (see chapter D, section 3). - Close hopper lids using buttons (1). 3 4 Engage both hopper transport safeguards (6). - Raise screed with button (2). Retract the screed parts by using switch (3) in connection with the keys in the keyblock left until the screed matches the basic 6 width of the paver finisher. Engage the screed transport safeguard (7). - Extend the levelling cylinders completely by using key (4) in connection with the keys in the keyblock right. - Press button (5) - Set the preselector (8) to "zero". Set the drive lever (9) to the centre position. - Remove all protruding or loose parts 7 from the paver finisher and the screed (see also the Operating instructions for the screed). Store these parts in a safe place. - When screed is operated with the optional gas heating system: 9 - Remove the gas bottles for the screed 8 heating system: - Close the main shut-off valves and the bottle valves. - Unscrew the valves on the bottles and remove the gas bottles from the screed. Element1_SPS150C.cdr /F0076_A1.EPS/F0083_A1.TIF/Element2_SPSC.cdr - Transport the gas bottles on a second vehicle; heed all pertaining safety regulations. A

B

C

D

C F150C.GB 4-10 12.03

START

C4

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 a dangerous situation arises!

9

START

8

12

A

B

C

D

C F150C.GB 5-10 12.03

Element1_SPS150C.cdr,Element2_SPSC.cdr

C5

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 accessories from the paver finisher and the screed until the basic width has been attained. - Remove all protruding or loose components and the gas bottles from the screed heating system (see Chapter D). - Attach crane lifting tackle to the four retaining points (9, 10).

m

9

10

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

F0048_A1.TIF

5

Loading the dismounted emulsion spraying system Protruding or loose parts must be removed. 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".

C F150C.GB 6-10 12.03

f

C6

5.1

Loading by crane Attach the hooks to the provided securing points (13, 14).

m

Oil, grease and/or emulsion may leak out if the emulsion spraying system is not attached exactly horizontally. Danger to the environment!

f

Suspended load! Do not step under the suspended load!

13

14 Trans.TIF

Loading by fork-lift truck

m

Always bear in mind that the centre of gravity for the spraying system or accessories box 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!

C F150C.GB 7-10 12.03

5.2

C7

6

Towing

f

Heed all regulations and apply all safety measures applicable for towing heavy construction 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 and the 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 to tow the machine. Pressure for releasing the traction system brakes is built up with the hand pump.

m

Only release the traction system brakes when the machine is sufficiently secured against accidental rolling or is already properly connected to the towing vehicle. - Release lock nut (2), screw threaded dowel (3) into pump as far as possible and secure with lock nut. - Actuate lever (4) of hand pump until sufficient pressure has been built up and traction system brakes have been released.

m

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

5

2 3

Following towing, unscrew the threaded dowel (3) a few turns again and lock with 4 the lock nut (2). The traction system brakes are no reac- Pumpe150.jpg tivated and the machine is secured against rolling. The pump lever should be locked when the upper cylinder (5) is retracted. Now carefully and slowly tow the paver finisher out of the construction area.

C F150C.GB 8-10 12.03

A

C8

- Remove spraying system. - Attach towbar rod to the trailer coupling (19) on the bumper. - Carefully and slowly tow the paver finisher out of the construction site or the danger area (use the shortest possible distance).

19

C F150C.GB 9-10 12.03

Schlepp.tif

C9

6.1

Safely parking the vehicle

m

When the paver finisher is parked at a location accessible to the public, it must be secured in such a way that unauthorised persons or paving children cannotdamage the vehicle. - Remove the ignition key and the main switch (1) and take them with you – do not hide them somewhere on the machine.

1

F0077/0078_A1.EPS

- Fit cover over operating panel (2) and lock it down. - Store loose parts and accessories in a safe place.

2

C F150C.GB 10-10 12.03

F144_A1.TIF

C 10

D Operation 1

Safety regulations

f

Starting the engine, the traction drive, the conveyor, the auger, the screed, the spraying 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 beneath 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 is running!

f

Never crawl into the auger tunnel or step into the hopper or onto the conveyor. Danger to life and limb! - Always make sure during operation that no-one is endangered by the machine! - Ensure that all protective covers and hoods are fitted and secured accordingly! - When damages are detected, eliminate them immediately! Operation must not be continued when the machine is defective! - Do not let any persons ride on the paver finisher or the screed! - Remove obstacles from the road and the work area! - Always try to choose a 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.

D_F150C.GB.fm. 1-122 01.1203

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

D1

2

Controls

2.1

Operating panel 2

1

C

A

B

4

3

C

B

A

A

B

C

D

Bed_SPS_C2.tif, Element1_SPSC.cdr, Element2_SPSC.cdr, Element3_SPS150C.cdr

D2

D_F150C.GB.fm. 2-122 01.1203

START

m

General notes on the observation of CE regulations All functions of self-engaging buttons which might provoke a risk during start-up of the diesel engine (conveying function of auger and conveyor) are set to STOP in case of an emergency stop or a control restart. Changes of settings which are performed when 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 The steering wheel movement is transferred electrohydraulically. 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 the spot).

1

Steering potentiometer

2

For securing the movable operating panel against inadvertent movement at the desired finisher height. Retaining bracket - Turn the knurled screw at the desired location into the for operating panel designated notch and secure with the knurled nut. When not secured, the operating panel can move. Danger of accidents during transportation!

f

3

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. Latch for operating Pull out the latch and move the operating panel; panel let the latch engage again. An unlatched operating panel can slide out of position. Danger of accidents during transportation!

f

Lights

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

D_F150C.GB.fm. 3-122 01.1203

4

D3

A

5

6

7

12 START

11 8

10

Element2_KC.cdr

D4

9A

D_F150C.GB.fm. 4-122 01.1203

9

Item Designation

5

Ignition lock and illumination switch

6

not used

Brief description Positions: 1 Ignition on 2 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

7

Emergency stop button

In the caseofan emergency(dangerto persons,possiblecollision 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.

8

Driver's cab: deploy (O)

To deploy the driver's cab hydraulically out beyond the outer edge of the vehicle. Watch out for oncoming traffic and obstacles!

D_F150C.GB.fm. 5-122 01.1203

f

D5

A

5

6

7

12 START

11 8

10

Element2_KC.cdr

D6

9A

D_F150C.GB.fm. 6-122 01.1203

9

Item Designation

9

Brief description

For switching on the paver finisher functions and for continuously regulating the traction speed – forward or reverse. Zero position: starting is possible; engine at idling speed; no traction drive To swivel outwards, pull ring (9a) upwards. Drive lever Depending on the position of the drive lever, the following (forward - reverse) 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. Preselector traction drive

11

Starter

Starting 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.

12

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

D_F150C.GB.fm. 7-122 01.1203

10

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 (during paving).

D7

B

15

16

17

18

14 A 13 A

19

14 13

20 21

34

22

33

23

24

32 A

C

B

31

D

25

30 26

Element1_SPSC.cdr

D8

28

27 D_F150C.GB.fm. 8-122 01.1203

29

Item Designation

Brief description

Open hopper

Push-button: Open left lid of hopper + open right lid of hopper

13 A Close hopper

Push-button: Close left lid of hopper + close right lid of hopper

13

14

Raise 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 A

Raise frame on spraying system

refer to Pos. (14) Self-engaging button with LED indication Operating requirements: button 16 "OFF"

15

Button 15 is used for the filling function: Filling the machine The diesel engine speed is increased to the preselected for paving 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. Self-engaging button with LED indication

16

Main function switch

Button 16 locks all functions necessary for paving. Although the individual functions are set to "Auto", they are not activated when the drive lever is moved. The set-up is retained, allowing the machine to be re-positioned and unlocked at the paving site. Paving can be continued by moving the drive lever. Button 16 is set to "ON" when restarting.

D_F150C.GB.fm. 9-122 01.1203

A

D9

B

15

16

17

18

14 A 13 A

19

14 13

20 21

34

22

33

23

24

32 A

C

B

31

D

25

30 26

Element1_SPSC.cdr

D 10

28

27 D_F150C.GB.fm. 10-122 01.1203

29

Item Designation

17

Traction drive fast/slow

Brief description Self-engaging buttons with LED indication Hare: transport speed When button 16 is set to OFF (stands for paving), button 17 has to be set to "tortoise". Tortoise: operating speed for paving Only change the speed when the paver finisher is at a standstill! A When restarting, the buttons are set to working speed (tortoise). Self-engaging buttons with LED indication A When restarting, the button is set to "Straight-ahead travel".

18

Straight-ahead travel

Normal position for straight-ahead travel. A If the button at the bottom has been inadvertently activated (with the steering knob (1) set to straight-ahead travel), the finisher does not move. This is often interpreted as a ‘malfunction’. Button 17 is set to "tortoise".

19

Turning on the spot

Self-engaging buttons with LED indication The 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 When the finisher turns, persons and objects next to the finisher are in extreme danger. Watch the area where the finisher turns!

f

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

D_F150C.GB.fm. 11-122 01.1203

20

21

Tamper (screed-specific)

Set-up operation

Switching function ON or OFF. The function is activated when moving the drive lever. Set-up operation is actuated in conjunction with button 21. When the machine is at a standstill, this button is used for the commissioning of all working functions which are only activated 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.

D 11

B

15

16

17

18

14 A 13 A

19

14 13

20 21

34

22

33

23

24

32 A

C

B

31

D

25

30 26

Element1_SPSC.cdr

D 12

28

27 D_F150C.GB.fm. 12-122 01.1203

29

Item Designation

Brief description

22

Self-engaging button with LED indication Increases the engine speed to nominal speed without needing Engine speed / to deploy the driving lever. compressor operaThe compressor cuts in and builds up pressure. tion A Makes it possible to spray emulsion directly, as soon as the paving operation commences.

23

Vibration

Operation and application: see button (20). Self-engaging buttons with LED indication

24

Auger left/right

Toggling between two switching conditions. Stop: Operational readiness Auto Reset to STOP in case of an emergency stop or a restart. Button 16 locks the conveying function.

25

26

Levelling cylinder left/right

Engine speed adjuster o

Self-engaging button with LED indication For 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 button 28 or 31. Adjustment of the levelling cylinders occurs by using the appropriate button in the pad (right) for the directions of movement (27). 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 speed Max. position: rated speed A For paving, select the rated speed; reduce the speed for transportation.

D_F150C.GB.fm. 13-122 01.1203

A

27

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

Pad (right) for Used in conjunction with buttons 25, 28 and 31; releases a directions of movemovement towards the indicated direction. ment

D 13

B

15

16

17

18

14 A 13 A

19

14 13

20 21

34

22

33

23

24

32 A

C

B

31

D

25

30 26

Element1_SPSC.cdr

D 14

28

27 D_F150C.GB.fm. 14-122 01.1203

29

Item Designation

Brief description Self-engaging button with LED indication Switched off by pressing the button again or by pressing button 25 or 31.

28

1. Move auger in "MANUAL" mode Requirements: button 24 must be set to "AUTO" "MANUAL" auger Using the buttons in the pad (left) for the directions of operationandlifting/ movement (29), the conveying speed of the automatic lowering the auger function can be exceeded with full conveying performance in the direction of the corresponding arrow. 2. Lifting/lowering the auger Using the buttons in the pad (right) for the directions of movement (27), the auger is lifted or lowered to the direction of the arrow.

29

Pad (left) for the Used in conjunction with buttons 25, 28 and 31; releases a directions of movemovement towards the indicated direction. ment

30

Horn

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

Extend / retract screed

Self-engaging button with LED indication Switched off by pressing the button again or by pressing button 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.

31

32

Conveyor left/right

Self-engaging buttons with LED indication To change between the three switching states, press the button again: STOP: Operational readiness AUTO MANUAL

D_F150C.GB.fm. 15-122 01.1203

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

D 15

B

15

16

17

18

14 A 13 A

19

14 13

20 21

34

22

33

23

24

32 A

C

B

31

D

25

30 26

Element1_SPSC.cdr

D 16

28

27 D_F150C.GB.fm. 16-122 01.1203

29

Item Designation

Brief description Push-button function Lift screed Self-engaging button with LED indication Lower screed/screed in floating position

33

Screed position

Screed floating position: Pressing the button turns the LED ON and prepares the screed for "floating position", which is activated 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 During paving, the screed must always be in the floating position. This also applies to brief stops and truck changes if the automatic screed stop function is used.

m

A

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

Self-engaging buttons with LED indication Switched off by pressing the button again or by toggling between the two buttons. Screed charging or relieving 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".

D_F150C.GB.fm. 17-122 01.1203

34

D 17

C

48

50

35

36

38

39

40

52 53

41

51

37

49

42

! - +

Element3_SPS150C.cdr, Kontrollleucht_SPSC.cdr

D 18

44

45

46

47

D_F150C.GB.fm. 18-122 01.1203

43

Item Designation

Brief description Display keyboard Button "Enter" starts the menu operation

35

TDM Control, input and display terminal

Buttons "Left/right" Buttons "Scroll up/down" Button "Escape" closes the menu

36

Temperature indicator for hydraulic oil

Normal display up to 120 °C = 248 °F. Stop the paver finisher when higher temperatures are encountered (drive lever (9) to the centre position), let the engine cool down while idling. Determine the cause and correct it if necessary.

37

Fuel gauge

Always heed the fuel gauge. Do not completely empty the diesel tank! Otherwise, the entire fuel system must be ventilated.

m

D_F150C.GB.fm. 19-122 01.1203

m

D 19

C

48

50

35

36

38

39

40

52 53

41

51

37

49

42

! - +

Element3_SPS150C.cdr, Kontrollleucht_SPSC.cdr

D 20

44

45

46

47

D_F150C.GB.fm. 20-122 01.1203

43

Item Designation

Brief description

Lights up if too much water is detected in the water separator on the fuel system. To avoid damaging the engine, drain off the separated water immediately as described in the Maintenance InWarning lamp for structions. "Water in fuel" (red)

m

38

A

39

Error 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, alternatively, 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 been switched on for checking purposes.

A

40

High beam indicator (blue)

41

not used

42

not used

43

Coolant check (red)

44

Oil pressure indicator for the hydraulic traction drive (red)

D_F150C.GB.fm. 21-122 01.1203

45

46

not used

47

Battery charge check (red)

For error diagnosis, refer to the section on "Engine error messages"

Lights up when the high beam is switched on (at the ignition key (18)). Avoid blinding the oncoming traffic!

f

Lights up whenever the coolant level is too low. If the lamp does not go out, switch off engine immediately. For further possible malfunctions, refer to Operating instructions for the engine.

m

Must go out shortly after the engine has been started. Observe warm running. The hydraulic oil is possibly too cold and stiff. Do not switch on the traction drive when the lamp does not go out (see the section "Malfunctions").

m

A Oil pressure check in diesel engine (red)

Lights up for a few seconds once the ignition has been switched on for checking purposes.

The lamp goes out when the pressure drops below 2.8 bar = 40 psi.

Must go out shortly after the engine has been started. If the lamp does not go out, switch off engine immediately. For further malfunctions, refer to Operating instructions for the engine.

m

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

D 21

C

48

50

35

36

38

39

40

52 53

41

51

37

49

42

! - +

Element3_SPS150C.cdr, Kontrollleucht_SPSC.cdr

D 22

44

45

46

47

D_F150C.GB.fm. 22-122 01.1203

43

Item Designation

Brief description

Indicator 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.

49

Engine temperature check (red)

Lights up whenever the engine temperature is too high. Engine power is automatically governed back. (still possible to drive vehicle). Stop paver finisher (drive lever in centre position), allow engine to cool down at idle speed. Establish cause of problem and remedy where necessary (refer to section on "Malfunctions"). After cooling to normal temperature, engine can once again operate at full power.

50

Fuse box

A

For assignment of fuse strips, refer to chapter F.

51

FuseboxII

A

For assignment of fuse strips, refer to chapter F.

52

Indicator lamp for emulsion 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 switch box also lights up.

53

Indicator lamp for compressor (green) (O)

Indicates that the compressor is running.

48

D_F150C.GB.fm. 23-122 01.1203

m

D 23

2.2

Operating the input and display terminal

A

B

C

D

E

F

TDM.cdr

Display keyboard Button "Escape" closes the menu

(B)/(C)

Buttons "Left/right"

(D)/(F)

Buttons "Scroll up/down"

(F)

Button "Enter" starts the menu operation

D_F150C.GB.fm. 24-122 01.1203

(A)

D 24

Working in the menu Once the ignition has been switched on and after a brief charging process, the main menu appears on the display: Various actual values are displayed here and operators can select from 6 sub-menus.

1

4

7

2

5

8

3

6

9

qsb_000_2.bmp

-

10

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 by pressing push button (D/E) (the arrow becomes black) and enter by pressing push button (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)

D_F150C.GB.fm. 25-122 01.1203

-

D 25

Transport volume/layer thickness (1) Transport volume of conveyor 1

As with the two remote controls, the transport speed of the two conveyors can be set separately. -

2

qsb_205.bmp

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 is shown 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 preset layer thicknesses. Fig 72.EPS

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

m

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

D_F150C.GB.fm. 26-122 01.1203

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

D 26

Operating hour meter (2) 2

Two different operating hours values are displayed: - Total operating hours (1) with engine running - Real operating hours (2) during paving

qsb_096.bmp

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

D_F150C.GB.fm. 27-122 01.1203

m

1

D 27

Heating control for electrical screed heating system (3) (o)

5 2

1

6

In this menu sub-item, the heating temperature for the following screed elements can be read off and can be jointly set for all screed elements: -

A

3

4

qsb_151.bmp

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)

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 black background 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 the sub-menu for selecting the activated consumers: Selection of activated electronic elements 1

This menu sub-item is used to set which electronic elements on the screed heating system switch cabinet can be activated:

qsb_204.bmp

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

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

D 28

D_F150C.GB.fm. 28-122 01.1203

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

Emergency function / screed stop and tamper start (4)

1

5

2

6

3

7

If a nominal value specification or actual 4 value measurement fails (e.g. sensor qsb_147.bmp defective, remote control failed), the performance of various functions can be set for automatic operations.

8

- 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 limit has elapsed. - The nominal value for the tamper start dynamics (6) can be set in the range of between 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 of between 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) button to 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 next sub-item or transfer the value modified and exit the menu sub-item by pressing the (F) button twice.

D_F150C.GB.fm. 29-122 01.1203

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

D 29

Automatic steering unit

A

1 2

No functions are saved in the wheeled paver program in this menu sub-item! qsb216.bmp

In this menu sub-item, the operator can use the selection (1) to set whether the automatic steering unit is to be activated or deactivated: - Selection 0: automatic steering unit deactivated - Selection 1: automatic steering unit activated. If the appropriate equipment (Sonic-Ski) is fitted, the finisher can independently travel along a reference body (e.g. securing rope) when the automatic steering unit is activated.

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).

D_F150C.GB.fm. 30-122 01.1203

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

D 30

Error memory

A

2

No functions are saved in the wheeled paver program in this menu sub-item!

1 qsb_213.bmp

Errors which have arisen and are saved in 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 be used to set whether the errors are to be shown one another in the display or whether this 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), make selection with button (F) and press the button (E) to set the value to "1". After confirming (by pressing button F again), the faults in memory are displayed on screen in sequence:

1

Example: There are two error messages in the memory.

D_F150C.GB.fm. 31-122 01.1203

-

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, refer to "Error diagnosis and error localisation" section

A

The errors saved can be called up again if the ignition is switched off and back on again.

qsb_000_2.bmp

D 31

Display showing various actual engine statuses (5) Several actual engine statuses can be monitored in this sub-item: -

1 2

6

3 4 007.bmp

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 is fitted in the paver can called up in this display.

qsb_206.bmp

D_F150C.GB.fm. 32-122 01.1203

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

D 32

Service program for workshop and mechanics (6) After choosing this subordinate a request for a password input appears in the display.

m

neubild2.EPS

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 following screed is called up and the PLC version (1) can be queried: - Return to the basic menu by pressing the (A) button

Settings can only be made in this screen if the correct numerical code has been entered.

D_F150C.GB.fm. 33-122 01.1203

A

1 wahl_f150c.bmp

D 33

Additional information and adjustments / showing up via LC-display Adjustment of the RPM speed of the engine Comes up when pressing push button (26) of the operating panel.

Bild79.EPS

- 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 and flashes), reset the value by working push button (D/E). To undertake the change press push button (F) and confirm by pressing button (A). To leave the level of subordinate press push button (26) again. Set-up operation Comes up when pressing push button (21) of the operating panel. RPM speed of the engine is displayed graphically. The present fuel consumption is also displayed in l/h.

qsb_078.bmp

Stop Comes up in the case of emergency stop button of the operating panel (7) or remote control (54o) is pressed.

Bild74.EPS

Paving information

Information of malfunction Comes up in case of malfunction. - Diagnosing and detecting of the error Bild1.EPS by pressing push button (F). - To leave this menu press push button (A).

D 34

D_F150C.GB.fm. 34-122 01.1203

Comes up during paving and shows the actual speed of paving. RPM speed of the engine is displayed graphically. In QSB_075_2.bmp addition, the prevailing fuel consumption in l/h and the distance covered in metres during a given operation are displayed.

2.3

Diagnosing and detecting malfunction In the case of the display indicating malfunction select this menu by pressing push button (F). The following information is given. Example: 1

4

7 3

5

6

2

Bild14.Tif

Item Description 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

D_F150C.GB.fm. 35-122 01.1203

1

D 35

Variations of malfunction (Pos 2)

Meaning

Graphic

Parting of cable

Short circuit

Variations (Pos. 4)

Meaning

Graphic

Ultrasound sensor/mechanical limit switch

Potentiometer

Valve

D_F150C.GB.fm. 36-122 01.1203

Electronics unit for automatic drive

D 36

Variations 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

D_F150C.GB.fm. 37-122 01.1203

Screed charging Screed relieving Screed charging or relieving Screed floating position

D 37

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

Some error messages also make reference to the relevant fuse (example F250.6). This should be checked first before initiating any other measures.

D 38

neu_4.bmp

D_F150C.GB.fm. 38-122 01.1203

Additional note "fuse"

Variety of colours (Pos 7)

Abbr.

Meaning

bl

blue

br

brown

ge

yellow

gn

green

rs

pink

rt

red

sw

black

vi

lilac

ws

white

Example:

D_F150C.GB.fm. 39-122 01.1203

- Malfunction of the auger R.H. lowering. - Short circuit of the valve Y35B at the Bild21.EPS PLC module A2 - Terminal strip X1, cable clamp 65, colour of the cable: green-red

D 39

Automatic drive error message The electronics unit for the automatic drive has failed. The data connection to the master module is interrupted.

A

neu6.bmp

First check whether fuse F5.1 is still intact. If the fuse has not caused the interrupt to the data connection, the diesel engine can be started (using an emergency start): - Engage button (1) (LED on). - Press start button (2).

START

2

1

A

B

C

D

D_F150C.GB.fm. 40-122 01.1203

Element1_SPSC.cdr,Element2_SPSC.cdr

D 40

Further malfunction: Slave error - Slave defective (Example Slave A31) neubild4.EPS

Gateway - Fault on the gateway Bild70.EPS

EMR - Fault on the EMR engine electronic controller Bil871.EPS

Battery - Potential to low Bild88a.EPS

Travelling speed - Potentiometer defective Bild86a.EPS

Drive lever - Potentiometer defective Bild87c.EPS

Steering potentiometer - Potentiometer defective Bild84c.eps

D_F150C.GB.fm. 41-122 01.1203

Sensor RPM engine - Sensor defect Bild85c.EPS

D 41

Sensor caterpillar drive right - Sensor defect Bild95.EPS

Sensor caterpillar drive left - Sensor defect Bil894.EPS

Travelling motion - Forward blocked Bild089c.eps

Travelling motion - Backward blocked Bild90c.EPS

Travelling motion - Turning left blocked Bild91c.bmp

Travelling motion - Turning right blocked Bild92c.eps

Travelling motion - Forward + backward blocked Bild93c.bmp

Screed warning light

Bild70.EPS

Screed warning light - Short circuit Bil871.EPS

D 42

D_F150C.GB.fm. 42-122 01.1203

- Parting of cable or lamp defective

2.4

Engine error messages If an engine fault is detected, this is indicated by the relevant warning lamp (1) on the EMR electronic engine controller and is also displayed simultaneously as a code on the display panel.

1

!

- + - Warning lamp (1) (yellow) continuously lit: there is a fault in the engine. The machine can continue to be operated Kontrolelucht_SPSC.cdr for the time being. The error should however be rectified soon to prevent further damage. - Warning lamp (1) (yellow) flashes: a serious malfunction has been detected in the engine which has either caused the engine to stop automatically or which requires this to be done to prevent further damage.

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

4

2

5

4

3

5

6

TDM.cdr

A

6

A

- "ENGINE WARNING!" (2) appears on screen if a less serious fault has occurred and warning lamp (1) is then continuously lit. - "!STOP ENGINE!" display(3) appears on screen if a serious fault requiring immediate engine shut-down has occurred and warning lamp (1) then flashes. The SPN (4) and FMI (5) displays shown determine the component affected by the error and the type of error occurring. The OC display (6) indicates the frequency with which the error displayed has already occurred.

D_F150C.GB.fm. 43-122 01.1203

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, causing it 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 ignition off and back on.

D 43

Example:

?

! - +

Explanation: The flashing warning lamp indicates the presence of a serious malfunction in the engine which gives rise to automatic engine shut-down, or requires this to be done manually. Display indicator: SPN: 98 FMI: 1 OC: 3 Cause: The sensor indicates that the oil level is too low. Consequence: Engine shuts down whenever the engine protection disengagement function is enabled. Frequency: This fault has already occurred three times. Advise the After-Sales Service responsible for your paver finisher of this error message and they will then discuss with you how best to proceed.

Error message, "Coolant level too low" This is displayed whenever an excessively low coolant level is detected.

m

D 44

012.bmp

To prevent damage to the engine, immediately switch off the engine and top up with coolant in accordance with instructions in the maintenance instructions.

D_F150C.GB.fm. 44-122 01.1203

m

2.5

Remote control 57

54

56

55

AUTO

58

58 MANUAL

STOP

59

AUTO MANUAL

60 STOP

AUTO

61

63

62

65

64

D_F150C.GB.fm. 45-122 01.1203

Remote_SPS_neu1.cdr

D 45

Item Designation

Brief description

Emergency stop button (o)

55

Horn

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

56

Levelling cylinder

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

57

Button to switch on levelling cylinder 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".

58

Buttons for direc- Functions in same way as buttons (27) on operating tions of movement panel.

59

Conveyor

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

60

Adjuster for the capacity of flow

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

61

Auger

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

62

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

63

Adjuster for the capacity of flow

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

64

Extend/retract screed parts

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

65

not used D_F150C.GB.fm. 46-122 01.1203

54

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.

D 46

Underside

66

68

67

REMOTE_SPS_NEU1cdr

Item Designation

Brief description

Socket for autoConnect the cable for the grade control unit here. matic levelling unit

67

Socket for auger limit switch

Connect the cable for the material limit switch here.

68

Cable for the remote control

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

D_F150C.GB.fm. 47-122 01.1203

66

D 47

Emergency program for TDM-failure To ensure the pavers operating ability during a display failure, an emergency program will be started automatic. Following setting and functions will be adjusted and switched on:

2100 min-1

- Number of revolutions of the Diesel engine: 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 indicated by LED during a display failure!

A

Tamper and vibration can be deactivated by the associated rotary potentiometer (set to "zero"). The frequency of the tamper and vibration can be read off the two associated displays (O).

2

1

3 4

A

B

C

D

D_F150C.GB.fm. 48-122 01.1203

Cummins.tif,RPM.tif,Element1_SPS150C.cdr

D 48

Accessory the following function can be switched by using the remote controls: - Press button (1) to close the hopper. 3 - Press button (2) to open the hopper. - Lifting the screed: - Switch off the bar LED display for auger and conveyor (3) by pressing the rel4 evant minus key (4). - Lift the screed infinitely variable by using the both Minus-buttons(4) si1 multaneous. - Switching the screed into readiness 2 (floating position): - Switch the LED bar (3) of auger and conveyor completely on by using the Remote_SPS_neu1.cdr accompanying Plus-buttons (5). - Press both plus keys (5) to engage the screed float setting.

5

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 be deleted again.

D_F150C.GB.fm. 49-122 01.1203

m

D 49

2.6

Special functions Reversible conveyor 16

The direction of transport of the conveyor can be changed over to the opposite direction to move material located just in front of the auger back slightly. Material losses, e.g. during transport operations can therefore be avoided. - Switch main function switch (16) over to "Off" switch position (LED off). - Hold down one or both of the buttons (32) in the "STOP" switch position for approx. 5 seconds. The system jumps into the "Manual" switch position and the conveyor moves approx. 1 metre towards the hopper. The system then jumps back into the "Stop" switch position.

A

B

C

D

Element1_SPS150C.cdr

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

D_F150C.GB.fm. 50-122 01.1203

f

32

D 50

2.7

Controls on the paver finisher Batteries (71) 71

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

A

For the specifications, refer to chapter B, "Technical Data". For maintenance, refer to Chapter "F"

m

Heed the instructions when starting the finisher externally. (see section "Starting the paver finisher, External starting (starting aid)") Flap-l.EPS

Battery main switch (72) 72

The main switch interrupting the circuit between the battery and the main fuse is located under the left maintenance flap.

m

Secure the hinged maintenance flap with the respective support rods.

A

For the assignment of all fuses, see chapter F, section 5. - For switching off, turn the key pin (72) to the left and pull it out.

A

Flap-l.EPS

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

D_F150C.GB.fm. 51-122 01.1203

72

F0077_A1.EPS/F0078_A1.EPS

D 51

Transport safeguards for the hopper (73) Before transport operations or to park the paver finisher, the hopper transport safeguards must be in place with the hopper lids in their raised position. 73

f

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

F0076A_A1.EPS

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

74

Used to protect the lifted screed from inadvertent lowering. The screed transport safeguard must be engaged for transport operations or when work finishes.

f

Transportation with an unsecured screed bears the danger of accidents! F0083_A1.TIF

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

D_F150C.GB.fm. 52-122 01.1203

m

D 52

Seat lock (behind the driver’s seat) (75) Telescoping seats (o) can be extended beyond the basic width of the paver finisher. They must be locked.

f

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

75

F169_A1.EPS

- Pull out the locking button and move the seat; let the locking button engage again. The driver’s seat can move when the locking button is not engaged properly. Danger of accidents during transportation!

D_F150C.GB.fm. 53-122 01.1203

f

D 53

Separator fluid spraying system (80) o 80

Used to spray the parts coming into contact with asphalt with a separator emulsion. - The indicator lamp (81) lights up when the emulsion pump is running - On/off switch (82) for the emulsion pump - Quick-release coupling (83) for hose connection

m

A

Only switch on the spraying system when the diesel engine is running; otherwise, the battery will be discharged. Switch off after use. A permanent installed hose guide (83a) for the fluid spraying system is available as an option.

81

82

83

Emu2.tif

83a

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

f

Do not spray into open flame or on hot surface! Danger of explosion!

D_F150C.GB.fm. 54-122 01.1203

Emul1.Tif

D 54

Pressure control valve for screed charging/relieving (84) (o) Used to adjust the pressure for additional charging/relieving of the screed.

84

F0105_A1.TIF

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

Pressure control valve for screed stop with pretensioning (84a)

84a 84b

Thisvalveislocatedbeneaththeright-hand bottom flap of the operator's platform. This sets the pressure for "Screed stop with pretensioning". - Activation: see "screed charging/relieving device" (20). - Pressure display: see "pressure gauge" (84b).

93 F0180_A1.Tif

84a

F0167_A1.TIF

Pressure gauge for screed charging/ relieving and screed stop with pretensioning (84b)

84b

D_F150C.GB.fm. 55-122 01.1203

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)).

F0103_A1.EPS

D 55

A

Further switch options for optional equipment features may be located on the central panel: 85

On / off switch for additional headlight in the roof (85): Actuate switch (a) to activate.

a

On/off switch for 230V sockets (85a) If equipped with a 230V system, the sockets are actuated by means of switch (a). In the "I" switch position, the indicator lamp (b) lights up.

85a

b

a

On / off switch for fuel tank filler pump (85b) If the pump is actuated with the switch (a), the indicator lamp (b) lights up.

f

85b

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

b

a

85c

On / off switch special lighting (85c) If the machine is equipped with additional headlights, these are actuated by means of the switch (a). When switched to the "ON" position, the indicator lamp (b) lights up.

a

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

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

D_F150C.GB.fm. 56-122 01.1203

m

b

D 56

Folding roof locking brackets (on left and right sides of roof console ) (86):

86

To lower the roof (for example during transport 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 locking hole.

87

D_F150C.GB.fm. 57-122 01.1203

Dach1.Tif/Dach.Tif

D 57

Hydraulic folding roof (87) (o) The hydraulically folding roof is secured by means of a latch (A) at the rear suspension on the left and right sides of the machine. This must be released prior to lowering and raising. Once it has reached its terminal position, the roof must be secured with the latch again. The hydraulic unit and the key-operated switch (A) for actuating the folding roof hydraulic system are located on the left side of the paver finisher's rear panel.

A

The roof can be raised and lowered without having to start the drive motor. - In order to lower the roof, turn the keyoperated switch (B) to the right until the roof has been lowered to its minimum level.

f

A

C

2

D

E

Danger of crushing! Ensure that nobody inserts their fingers or hands into the joint areas or are placed at risk by the lowering roof during the folding procedure. - In order to raise the roof again, turn the key-operated switch (B) to the left until the roof has been raised to its maximum height.

B Dach_Hydr.wmf

If it is necessary to raise the roof whilst the battery is discharged, a manual pump is available on the hydraulic unit. - Actuate the pump lever (C) until the roof can be secured with the latch bolt (A) in its uppermost position.

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

D 58

D_F150C.GB.fm. 58-122 01.1203

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

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

A

This requires that the auger height has been adjusted correctly (see chapter E). 89

89a

F114_A1.EPS/Ultra3.EPS

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

D_F150C.GB.fm. 59-122 01.1203

A

Ultschall.tif

The limit switches control the material flow at the respective auger half. The ultrasonic sensor is mounted by means of an appropriate leverage to the side plate. Loose clamping lever for adjustment and modify angle / height of the sensor. The connecting cables are connected to the remote controls on either side of the screed (socket (59)). 90

A

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

D 59

Sockets for the remote control (left and right) (91) Connect the cable (60) of each large remote control unit to socket (91). 91

F171_A1.TIF

Sockets for working lights (left and right) (92) Connect the working lights (24 V) here. - Power is present when the main switch (77) is switched on.

A

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

92

D_F150C.GB.fm. 60-122 01.1203

F124_A1.TIF

D 60

2.8

Switch cabinet for the spraying system

93 94

95

97

96

98

100

D_F150C.GB.fm. 61-122 01.1203

99

Bild-5a.TIF

D 61

Brief description

93

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

94

Auto: The computer controls the spraying ramp. Selector switch, Semi auto: A timer relay is used for controlling the spraying spraying ramp con- ramp. troller - Basic setting: Ramp stands still for 2 seconds. Speed of approx. 5 m/min.

Selector 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 sprayed emulsion 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 basic width when work is finished (see "Stop").

96

Selector 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.

97

Mains isolator for spraying ramp movement

Main switch for the spraying ramp movement

98

Switch, compressor

Switch for switching the compressor on and off

99

Switch, emulsion pump

Switch for switching the emulsion pump on and off

100

Main switch, emulsion spraying sys- Switches the entire spraying system on or off. tem

95

D 62

D_F150C.GB.fm. 62-122 01.1203

Item Designation

D_F150C.GB.fm. 63-122 01.1203

102 101

Bild-5a.TIF

D 63

Item Designation

101

Selector switch compressed 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. Repeat this procedure several (3-4) times. During the procedure, wait until the pressure gauge drops to approx. 2-3 bar. Then repeat the cleaning procedure.

Switch, compressed air valves

Switches compressed air valves 1-5 on/off for the various operational and cleaning circuits. A minimum pressure of approx. 3 bar is necessary to control the compressed air valves! The emulsion pump should start to run as soon as the compressed air valves are switched on.

f

f f

D_F150C.GB.fm. 64-122 01.1203

102

Brief description

D 64

2.9

Operating panel, paver finisher 48

14

A

B

C

D

Elemet3_SPS150C.cdr/Element1_SPS150C.cdr

Item Designation

D_F150C.GB.fm. 65-122 01.1203

14

48

Brief description

Switch 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.

Indicator 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.

D 65

2.10

Remote control of emulsion spraying system, right side

103

104

106

107

105

BILD-4-gb.TIF

Brief description

103

Switch, 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 nozzles switch off automatically.

104

Switch, spraying nozzles of extension part

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

105

Switch, spraying nozzles of main ramp

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

Switch, retracting and extending of extendable part

Switch for hydraulically extending and retracting the extendable part. A Extendingorretractingtheextendablepartisonlypossible when the compressed air system has reached its operating pressure. The extendable part must be retracted during transport operations. Danger of accidents!

Indicator lamp Ideal position Extendable 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. The best position is important for the correct surface spray volume (metering) without causing the emulsion to start overlapping.

106

107

D 66

m

m

D_F150C.GB.fm. 66-122 01.1203

Item Designation

2.11

Remote control of emulsion spraying system, left side

108

114

109

113

111

110

112 BILD-3-gb.TIF

Item Designation

Brief description

D_F150C.GB.fm. 67-122 01.1203

On/off switch for the spraying nozzles of the left-hand extendable part. The nozzles at the margin can be separately Switch, switched on or off when the left-hand extendable part has been 108 spraying nozzles of extended. If the nozzles are switched on, the indicator lamps extendable part above them light up to indicate this. A When the extendable part is retracted, the nozzles switch off automatically. Switch, retracting and 109 extending of extendable part

Switchforhydraulicallyextendingandretractingtheextendablepart. A Extending or retracting the extendable part is only possible when the compressed air system has reached its operating pressure. The extendable part must be retracted during transport operations. Danger of accidents!

Indicator lamp 110 Ideal position Extendable 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. The best position is important for the correct surface spray volume (metering) without causing the emulsion to start overlapping.

Switch, 111 spraying nozzles behind the drive

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

m

m

Switch, On/off switch for the spraying nozzles behind the right-hand and 112 spraying nozzles in left-hand drive. front of the drive Switch, 113 spraying nozzles of main ramp

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

Switch, Switch for switching the spraying nozzles in the left-hand 114 spraying nozzles of extension parts on and off. extension part D 67

2.12

Compressed air indicator

116

115 Bild-1_F150.tif

Item Designation

Brief description

Pressure gauge, compressed air

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

116

Thermometer/ tem- Indicates the current emulsion temperature. perature presetting Presets the temperature of the emulsion (red needle).

D_F150C.GB.fm. 68-122 01.1203

115

D 68

2.13

Switch cabinet for emulsion heating

a

118 A

118

118b

b

117 A

117

C 117b

SchaltschrF151_2.cdr

D_F150C.GB.fm. 69-122 01.1203

Item Designation

Brief description 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

Switch, heating circuit 2

117 A

Indicator lamp Lights up as soon as the heating for this circuit is provided "Heating from exterfrom an external source. nal power supply"

Indicator lamp Lights up as soon as the heating for this circuit is provided 117b "Heating by generfrom a generator. ator"

118

Switch, 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)

D 69

Item Designation 118 A

Brief description

Indicator lamp "Heating from exter- refer to (117a) nal power supply"

Indicator lamp 118b "Heating by gener- refer to (117b) ator" Fuses in heating circuit 1

A

For fuse assignment, refer to Chapter F.

A

For fuse assignment, refer to Chapter F.

b

Fuses in heating circuit 2 and electrical system

C

Engagement of electrical system

A

Refer to section "230 Volt electrical system"

D_F150C.GB.fm. 70-122 01.1203

a

D 70

2.14

Switch cabinet for remote power supply 120

119

BILD-7.TIF/Label_extern_Volt.cdr

Item Designation

Brief description

Remote power sup- Connection socket for external power supply to heating ply socket systems

120

Safety switch for The safety switch stops the diesel engine of the paver finisher remote power supas soon as the switch cabinet door opens. ply

D_F150C.GB.fm. 71-122 01.1203

119

D 71

2.15

Left-hand tank side 121

122

126

125

124

123

BILD-10.TIF

Item Designation

Brief description

Safety switch, emulsion tank

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

122

Filling level indica- The safety switch stops the diesel engine of the paver finisher tor, emulsion tank as soon as the switch cabinet door opens.

123

Switch, pump capacity

Switch for setting the capacity of the emulsion pump Fast: For loading and unloading the emulsion tank Slow: For operation

124

EMERGENCY STOP

EMERGENCY STOP switch for the emulsion pump

125

Filler neck, emulsion tank

Connection for filling and draining the emulsion tank

126

Drain cock on emulsion tank

Drain cock for completely draining the emulsion tank

D_F150C.GB.fm. 72-122 01.1203

121

D 72

2.16

Manual spraying device, rear

127

128

130

129

BILD-8.TIF, F151C.wmf

Item Designation

Brief description

127

Compressed air valve, rear

Compressed air valve for supplying the manual spraying lance

128

Shut-off valve, compressed air, rear

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

129

Connection for rear manual spray- Screw connection for hose on manual spraying device ing device

130

Shut-off valve, emulsion, rear

D_F150C.GB.fm. 73-122 01.1203

Emulsion stop cock for manual spraying device

D 73

2.17

Manual spraying device, front

131 132 133

134

BILD-9.TIF, F151C.wmf

Item Designation

Brief description

Compressed air valve, front

Compressed air valve for supplying the manual spraying lance

132

Shut-off valve, emulsion, front

Emulsion stop cock for manual spraying device

133

Shut-off valve, compressed air, front

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

134

Connection for front manual spraying device

Screw connection for hose on manual spraying device

D_F150C.GB.fm. 74-122 01.1203

131

D 74

3

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.

3

1

4

2

230V.wmf

D_F150C.GB.fm. 75-122 01.1203

Item Designation

Brief description

1

Protective contact socket I, 230 Volt

Socket with spray protection for 230 Volt consumers. Seal socket with protective cap when not in use.

2

Protective contact socket II, 230 Volt

Socket with spray protection for 230 Volt consumers. Seal socket with protective cap when not in use.

3

Test button

For carrying out the insulation test.

4

Cancel 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.

m m

D 75

On/off switch for 230V sockets There is a switch for engaging the sockets in the electrical system switch cabinet or on the middle panel of the paver finisher.

A

This switch may also be located on the emulsion heating system switch cabinet. - The sockets are engaged using switches (a). In switch position "I" the Schalt_230V.wmf indicator lamp (b) lights up. - Switching off the sockets in switch position "0". Indicator lamp (b) is OFF.

b

a

3.2

Insulation test

A

The insulation test must be undertaken every day when the machine is running and the sockets are activated. - Press test button (3) - "Insulation error" display must light up. - Press delete button (4) - display for insulation error goes out. If the test is completed successfully, work can proceed with the electrical system and external consumers can be used. However if the "Insulation error" indicator lamp displays an error even before the test button is pressed, work cannot proceed with the electrical system or with the external equipment connected up. If an insulation error occurs, the sockets are automatically de-energised (i.e. electrically isolated). If no errors are displayed during simulation, do not carry out any work on the electrical system.

f

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

f

Danger from electric voltage Failure to comply with the safety precautions and safety regulations can result in electrical shock injuries from the electrical system. Danger to life! All maintenance and repair work on the screed's electrical system must always be carried out by an electrician. D_F150C.GB.fm. 76-122 01.1203

f

D 76

4

Operation

4.1

Preparing for operation

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

Wheel loader for transporting heavy 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 gasfired screed heating system. - Carry out an inspection using the "Checklist for the machine operator" (refer to Section 3.1).

D_F150C.GB.fm. 77-122 01.1203

-

D 77

Checklist for the machine operator Check!

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

Steering

The paver finisher must immediately follow every steering wheel movement in a precise manner. Checkstraight running.

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

Briefly press the horn button. The horn must sound.

Lights

Switch 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

D_F150C.GB.fm. 78-122 01.1203

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

D 78

Check!

How? For 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 possible 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 roof

Both 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.

D_F150C.GB.fm. 79-122 01.1203

Auger covers

D 79

4.2

Starting the paver finisher Before starting the paver finisher Before starting the diesel engine and beginning operation, the following steps must be performed: - Daily maintenance of the paver finisher (see chapter F)

m

Check the operating hour counter to determine whether or not additional maintenance work (such as monthly or yearly maintenance) must be performed. - Check the safety devices and protective devices. "Normal" starting 5

Set the drive lever (9) to the centre position and the speed adjuster (10) to minimum. - Insert the ignition key (5) in position "0". The lights should be switched off during starting to reduce the current drain on the battery.

A

Starting is not possible when the drive lever is not in the centre position or when an emergency stop button (7) or (54o) on the remote control unit has been pressed. ("STOP" in the LC-display).

7

11 START

9 10

Element2_SPSC.cdr

D_F150C.GB.fm. 80-122 01.1203

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

D 80

External starting (starting aid)

A

The engine can be started with the help of an external power source if the batteries are empty and the starter no longer turns. Suitable power sources are: - Other vehicles with a 24 V system - Additional 24 V battery - Start device that is suitable for external starting (24 V/90 A).

m

Standard chargers or quick chargers cannot be used for external starting. To externally start the engine: 5

- Switch on the ignition, set the drive lever (9) to the centre position. - Use appropriate cables to connect the external power source.

m A

Observe the polarity! Always connect the negative cable last and disconnect it first! Starting is not possible when the drive lever is not in the centre position or when an emergency stop button (7) or (54o) on the remote control unit has been pressed ("STOP" in the LC-display).

7

11 START

9 10

Element2_SPSC.cdr

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

D_F150C.GB.fm. 81-122 01.1203

- Disconnect the power source.

D 81

After starting To increase the engine speed: - Set the drive lever (9) to position 1 (slightly off the centre position). START

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

m

9

Let the paver finisher warm up for approx. 5 minutes if the engine is cold.

21

A

B

C

D

D_F150C.GB.fm. 82-122 01.1203

Element1_SPS150C.cdr,Element2_SPSC.cdr

D 82

Observe 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 during operation: Switch off engine and check coolant level.

Kontrollleucht_SPSC.cdr

43

For other potential faults, refer to Operating instructions for the engine (Engine operating instructions). Oil pressure indicator lamp for the diesel engine (45) - Must go out shortly after the engine has been started.

m

Kontrollleucht_SPSC.cdr

If lamp fails to go out or if it lights up during operation: Immediately remove the ignition key and switch off the engine. Check the engine oil level.

45

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

Oil pressure indicator lamp for the traction drive (44)

!

- Must go out after starting. If the lamp does not go out: Do not switch on the traction drive! Otherwise, the entire hydraulic system could be damaged.

Kontrollleucht_SPSC.cdr

44

D_F150C.GB.fm. 83-122 01.1203

m

- +

D 83

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 connected and the same function have to be set to "auto" - Set the drive lever (9) to position 1 - Press button (21) to increase the engine speed, the conveyor and the auger start operating. - Let the hydraulics warm up until the indicator lamp goes out.

A

START

9

The lamp goes out when the pressure drops below 2.8 bar = 40 psi. For further possible malfunctions, refer to section 4.

21 32

24 A

B

C

D

Element1_SPS150C.cdr,Element2_SPSC.cdr

Battery charge indicator (47) Must go out after starting when the engine revs up.

If lamp fails to go out or if it lights up dur- Kontrollleucht_SPSC.cdr 47 ing operation: briefly increase the engine speed. Switch off the engine and determine the cause for the malfunction if the lamp does not go out. For further possible malfunctions, refer to the section "Malfunctions".

D 84

- +

D_F150C.GB.fm. 84-122 01.1203

m

!

5

Starting the spraying system

A

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

5.1

Compressed air system - Start the paver finisher (see the operating instructions for the paver finisher). - Switch on the power supply: Main switch (97) "ON". - Close all manual valves of the compressed air system to build up an operating pressure of 5.5 bar. - Switch on the compressor switch (98).

97

100

98

101

102

A

The maximum diesel engine speed is necessary to build up the operating pressure. - Press button for compressor operation (22). The engine speed is now increased even when the drive lever is not deployed, and pressure builds up in the spraying system.

A

D_F150C.GB.fm. 85-122 01.1203

A

As soon as the compressor is running, the indicator lamps above the switch (98) and on the control panel (53) light up. This early pressure buildup enables emulsion spraying to start at the same time as paving operations!

22

A

B

C

D

53 Bild-5a.TIF.TIF/Element1_SPS150C.wmf/Element3_SPS150C.wmf

D 85

5.2

Loading the emulsion tank Open the tank lid on top of the emulsion tank to watch the filling procedure when the main compressor is switched on and an operating pressure of 5.5 bar is available.

f

Danger of burning by overflowing emulsion or emulsion spurting out. 125

- Connect the flexible hose to the filler neck (125) and open the hand wheel. - Switch on compressed air valves 2 and 5 (102). - Switch (101) must be switched off! - Openthemanualvalveofthesupplytank. - Switch on the emulsion pump using switch (100).

123

Bild10.TIF, FOERDER.TIF

A

The EMERGENCY STOP switch (124) must not be pressed. As soon as the emulsion pump starts operating, the red indicator lamp above the switch lights up. 97

- Increase the emulsion pump capacity with the switch (123).

m

98

Reduce the pump capacity if the emulsion tank contains mostly foam (set the 102 pump capacity switch (123) to "slow").

101

Bild-5a.TIF.TIF

D_F150C.GB.fm. 86-122 01.1203

- When approx. 2,650 l have been loaded, switch the emulsion pump off by pressing the EMERGENCY STOP button and set the pump capacity switch to "slow".

100

D 86

- 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 empty the hose.

m

Danger of burning by spilled emulsion! Wear protective clothing! 125

- Switch off the emulsion pump. - Close the manual valve of the filler neck (125). - Close the compressed air valves (102).

124 123

D_F150C.GB.fm. 87-122 01.1203

Bild10.TIF, FOERDER.TIF

D 87

6

Heating system

A

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

6.1

Working temperatures Standard emulsion Loading

at least 70 °C

Spraying

at least 60 °C

Elastomere emulsion Loading

at least 80 °C

Spraying

at least 70 °C

A

The spraying temperature must be higher in percentage terms than the bitumen components.

6.2

Heating before the spray process - Switch the heating system switches (117/118) to "generator". - Increase the speed of the diesel engine. - 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, proceed in reverse order.

118

117

SchaltschrF151_2.cdr,Bild-1_F150.tif

102

Bild-5a.TIF

D 88

D_F150C.GB.fm. 88-122 01.1203

116

6.3

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

118

SchaltschrF151_2.cdr

6.4

During work interruptions (remote power supply)

m

Warning: Dangerous voltage (380 V)!

A

The stipulations of the local power suppliers must be heeded. The following standards must be heeded: DIN VDE 0100, part 704; DIN VDE 0100, part 737 - Open the switch cabinet door.

D_F150C.GB.fm. 89-122 01.1203

A

120

119

Opening the switch cabinet door causes the safety switch (120) to stop the diesel engine. - Use the socket (119) to connect the BILD-7.TIF remote 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.

D 89

7

Emulsion circuit

Air filter

Manual valve

1

5 Filter

Tank

Pump

2

4

6 Spraying ramp

3

Emulsion.eps

Druck-gb.tif

D 90

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

D_F150C.GB.fm. 90-122 01.1203

Item

7.1

Tank circuit To prevent the emulsion in the upper section of the tank from cooling, the emulsion in the emulsion pump must start moving. - Switch on the heating system 1 and 2 (117/118). - Switch on the compressed air system and check whether an operating pressure of 5.5 bar is available (see section 4.1). - Switch on the compressed air valves 1 and 2 (102). Use the switch (100) to switch the emulsion pump on.

118

117 SchaltschrF151_2.cdr

7.2

Spraying ramp circuit

m

The spraying ramp circuit must be switched on at least 5 minutes before the start of operations in order to heat up the hoses leading to the spraying ramp and the spraying ramp itself. - Start the tank circuit. - Open compressed air valve 3. - Close compressed air valve 2.

100

D_F150C.GB.fm. 91-122 01.1203

102

Bild-5a.TIF

D 91

7.3

Preparations for paving

Separating agent Spray the parts coming into contact with asphalt (hopper, screed, auger, push roller) with a separator emulsion.

f

Do not use diesel oil because it can dissolve bitumen (prohibited in Germany!).

Screed heating system

F147_A1.TIF

Switch on the screed heating system approx. 15–30 minutes (depending on the ambient temperature) before paving begins. Warming up prevents the material from sticking 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 direction mark must be present or established (road edge, chalk lines or similar).

F151C.wmf

D_F150C.GB.fm. 92-122 01.1203

- Slide the operating panel to the desired side and secure it. - Pull the direction indicator out of the bumper (arrow) and adjust it accordingly.

D 92

Loading/distributing material

15

13

- Button (16) has to be switched off. - Use switch (13) to open the hopper. Instruct the truck driver to dump the material. - Set the switches for the auger (24) and the conveyor (32) to "auto". - Press button (15) to fill the machine for paving.

16

24

32

A

B

C

D

Element1_SPS150C.cdr

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

89

D_F150C.GB.fm. 93-122 01.1203

89a

89

D 93

7.4

Starting for paving 17

20 33

23 24

32 A

B

C

D

START

10

9

51

AUTO

MANUAL

A

STOP

54

AUTO

B

Element1_SPS150C.cdr/Element2_SPSC.cdr/Tamprev.cdr/Vibrev.cdr/Remote_SPS_neu1.cdr

D 94

AUTO

56

D_F150C.GB.fm. 94-122 01.1203

MANUAL STOP

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

Switch

Position

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

- Push the drive lever (9) all the way to the front and start driving.Screed floating position is activated now. - Observe the distribution of the material and adjust the limit switches if necessary. - Set the compacting elements (tamper and/or vibration) according to the required compaction ratio. - Let the paving master check the layer thickness after 5–6 meters and correct if necessary. Carry out the check in the area of the drive chains or wheels as the screed tends to level an uneven ground. The reference points for the layer thickness are the drive chains or wheels. The basic setting of the screed must be corrected when the actual layer thickness deviates significantly from the values indicated by the scales (see the operating instructions for the screed). The basic setting is for asphalt material.

D_F150C.GB.fm. 95-122 01.1203

A

D 95

7.5

Checks during paving The following points must be constantly observed during paving: Paver function -

A

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 corrections to settings of the material switches for conveyor and auger.

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. See section 4 "Malfunctions, Problems during Paving" if the paving quality is poor.

D_F150C.GB.fm. 96-122 01.1203

A

D 96

7.6

Paving with screed stop and screed charging/relieving device: General The screed hydraulics can be influenced in two ways to attain optimum paving results: - Screed stop with and without pretensioning on a stationary paver/finisher, - Screed charging or relieving with the paver finisher driving.

A

Relieving reduces the screed weight and increases the traction force. Charging increases the screed weight, reduces the traction force, but increases the compaction ratio. (To be used with light-weight screeds in exceptional cases.) Screed charging/relieving This function charges or relieves the screed regardless of its own dead weight. Switch (34) has the following positions: A

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

34 B

Bohlensch.EPS

D_F150C.GB.fm. 97-122 01.1203

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

D 97

Screed stop The "screed stop" function is used to block the screed hydraulics to prevent the screed from lowering when the paver finisher stops during paving. The switches (34) have to be switched off - Automatic screed stop when the drive lever is in its central position. - To lift the screed press button (33A) - To lower the screed press 1.5 sec. button (33B)

m

34

33

A

B Bohlensch.Tif

The screed block function is not sufficient as a safeguard during transport or maintenance 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 the screed lifting cylinders. This pressure can neutralise the weight of the screed to prevent the screed from sinking into the freshly laid material, thus supporting the screed stop 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. If necessary, the pressure must be readjusted or changed as required during the first stops until the lower edge of the screed no longer leaves any marks when the finisher moves on again. A pressure greater than 10-15 bar neutralises the screed weight, thus preventing the screed from sinking into the material.

A

When combining the "screed stop" and "screed relieving" functions, make sure that the 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 as a start-up aid, there is a danger of uncontrolled floating when starting up again. For paving with "Screed relieving", no screed stop with pretensioning should be employed.

D_F150C.GB.fm. 98-122 01.1203

A

D 98

Adjusting the pressure (o) Pressure adjustments can only be made while the diesel engine is running. Therefore: START

- Start the diesel engine and set the traction controller (10) to zero (precaution against inadvertent advancing). - Set switch (33) to the floating position.

9

10

For screed stop with pretensioning: - Set the drive lever (9) to the centre position. - Set switch (16) to position (LED OFF) and switch (21) to position (LED OFF). - Use control valve (93a) (below the bottom plate of the operator's platform) to adjust the pressure and read it from the pressure gauge (93b). (Basic setting: 20 bar)

33

21

A

34

For screed charging/relieving

16

C

B

34b

D

34A

Element1_SPS150C.cdr/Element2_SPSC.cdr

93b

93a

D_F150C.GB.fm. 99-122 01.1203

- Set the drive lever (9) to the centre position. - Set switch (16) to position (LED OFF) and switch (21) to position (LED ON). - Set switch (34) to position (LED ON) F0103_A1.EPS/F0167_A1.TIF (relieving 34a) or (charging 34b). - Use control valve (93) (on the rear panel of the paver finisher) to adjust the pressure and read it from the pressure gauge (93b).

A

When screed charging/relieving is necessary and automatic levelling is used (grade control and/or slope control), the compacting performance changes (layer thickness).

A

The pressure can also be set or corrected during paving. (Max. 50 bar)

93b

93

F0103_A1.EPS/F0105_A1.EPS

D 99

7.7

Spraying - Start the spraying ramp circuit. - Set the switch "Spraying ramp movement" (95) to "Auto".

A

When "Auto" has been selected, the lefthand extendable part of the spraying ramp extends by approx. 0.2 m to allow the spraying ramp to perform crosswise movements. Use the left-hand remote control to retract the extendable part to the basic width of the spraying ramp.

97

95 96

- Set switch for spraying system (96) to the selected operating position (forwards, reverse, forwards + reverse), refer to Chapter E. - Enter the new parameter for PR1/ Bild-5a.TIF 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 control panel. - Before starting work, set the main switch (97)"Sprayingrampmovement"to"ON". - Use the switch (14) on the operating panel to set the spraying ramp height. The optimum position of the spraying ramp relative to the floor is indicated by the indicator lamp. - Move the paver finisher with the spraying ramp to the point where work is to start. BILD-3-gb.TIF - Switch off the spraying nozzles before and behind the drives. - Move the paver finisher forward until the screed is at the point where work is to start. The distance covered is sprayed. 14 The area of the drives remains unsprayed. - Align the screed. Switch on the spraying nozzles behind the drives when the paver finisher is ready for operation.

112 111

A

Element1_SPS150C.cdr

D 100

B

C

D

D_F150C.GB.fm. 100-122 01.1203

A

7.8

Emptying the spraying ramp (end of paving) - 1 metre before the end of the paving area, 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" position. - Then switch to the "Spraying ramp ground" position - Set the switch (94) "Spraying ramp controller" to the "Semi auto" position. - Advance paver until spraying ramp is located at the end of the paving area. - Switch off all spray nozzle switches with the exception of switch (111) for "Rear drive spray nozzles". - Move the paver finisher out of the paving area. Only the area behind the drives is sprayed now. - Once the paver finisher has reached the end of the paving stretch, all spray functions are shut down. - Drive the paver finisher to the cleaning site. - Clean the spraying nozzles and the emulsion filters to prevent clogging of the parts.

94

101

Bild-5a.TIF

111

D_F150C.GB.fm. 101-122 01.1203

BILD-3-gb.TIF

D 101

7.9

Cleaning the spraying nozzles - Repeat the cleaning procedure several (3-4) times. - Check the operating pressure (min. 5.5 bar). - Switch the "Air cleaning" switch (101) to the "Spraying ramp ground" position. - Allow the operating pressure to lower to 2-3 bar. - Switch the "Air cleaning" switch (101) to "OFF". - Repeat the procedure. 101

Bild-5a.TIF

7.10

Cleaning the emulsion filter 139

Refer to chapter F for cleaning the emulsion filter. - Let the system run for some seconds. This process should be carried out for any extended stationary period, e.g. overnight stops etc., after which you should add another 3 litres of diesel fuel to the emulsion filter (139) to prevent the emulsion pump from setting solid.

D_F150C.GB.fm. 102-122 01.1203

BILD13.TIF

D 102

7.11

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 clogging of 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 required: - 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 spraying equipment

Road

Start of paving

D_F150C.GB.fm. 103-122 01.1203

- Move the finisher with the spraying ramp to the start. - Switch off the spraying nozzles before and behind the drives. - Move the paver finisher forward until the screed is at the point where work is to start. The distance covered is sprayed. The area of the drives remains unsprayed. - Align the screed. Switch on the spraying nozzles behind the drives when the paver finisher is ready for operation.

D 103

7.13

Finishing work with the spraying equipment - Stop 1 m before the end of paving. Switch off compressed air valve 1 and set the Road 1m "Air cleaning" switch to "Return to tank". Switch on for 2 minutes. - Set the "Air cleaning" switch to the "Spraying ramp ground" position and the "Spraying ramp movement" switch End of paving to "semi auto"; set the timer relay to 2 seconds. - Advance the paver until the spraying ramp is at the end of its paving area. - Switch off all switches for the spraying nozzles, with the exception of switches "spraying nozzles behind the drive". - Switch off all spraying functions when the paver finisher has reached the end of the paving stretch. - Drive the paver finisher to the cleaning site. Clean the spraying nozzles with compressed air to prevent clogging of the nozzles. Refer to chapter "Maintenance" for cleaning the emulsion filter.

m

Heed the cleaning instructions to prevent clogging of the parts.

D_F150C.GB.fm. 104-122 01.1203

A

D 104

7.14

Interrupting/terminating operation During paving breaks (e.g. a delay in supply of material by trucks) - Determine the approximate duration. - If there are grounds for believing that the material might drop below the minimum paving temperature, empty the paver and position the leading edge at the end of the paving section. - Set the drive lever (9) to the centre position.

START

10

9

Element2_SPSC.cdr

During extended interruptions (e.g. lunch break) - Drive lever (9) into centre position, RPM speed adjustment (10) to minimum position. - Switch off ignition. - Switch off screed heating system. - When screed is operated with the optional gas heating system, close the valves of the bottles. The screed must be heated up to the correct paving temperature before paving may be restarted.

D_F150C.GB.fm. 105-122 01.1203

A

D 105

When work is finished - Run the paver finisher empty and stop it. - Lift the screed by using button (33). - Retract the screed parts to the basic screed width and lift the auger. Where applicable, completely extend the levelling cylinders.

33

Bohlensch.Tif

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

74

F0083_A1.TIF

5

START

10

Element2_SPSC.cdr

- Read and check the operating hour meter to determine whether maintenance work must be performed (see chapter F). - Cover and lock the operating panel. qsb_096.bmp - Remove material residues from the screed and the paver finisher and spray all parts with separator fluid.

D 106

9

D_F150C.GB.fm. 106-122 01.1203

- Set the drive lever (9) to the centre position and the speed adjuster (10) to minimum - Switch off the ignition (5). - Switch off screed heating system. - When screed is operated with the optional gas heating system, close the main shut-off valves and the valves of the bottles. - Remove the levelling units and stow them away in the boxes, close all flaps - Remove all parts that extend beyond the paver finisher contour or secure them if the paver finisher is to be transported over public roads on a low-bed trailer.

Sensors

2

Nominal value sensor 2 (manual throttle)

Charged air pressure

06

07

2 2

Oil pressure

Coolant temperature

Charged air temperature

08

09

10

2

2

2

Speed sensor 2

2

2

2

2

2

1

1

6

5

4

3

2

2

1

2

2

2

2

2

8

8

31

105

110

100

102

201

190

190

524287

SPN

Error on corresponding sensor input (e.g. short circuit or cable break).

Sensor failed. Distance to gear too great. Additional error impulse. Cable connection interrupted.

No active errors present

Cause

Refer to Section 4.15 Influence of error response. If sensor fails, the associated monitoring function is deactivated.

Controller in emergency mode (with sensor 1). Emergency shutdown (if sensor 1 is not available or has failed).

Controller in emergency mode (if sensor 2 is available). Emergency shutdown (if sensor 2 is not available or has failed).

Comments

Check sensor cable. Check sensor and replace if necessary. Check error limits for sensor.

Check distance. Check cable connection. Check sensor and replace if necessary.

Remedial action

Engine error codes Explanation:

2

-

0.4 s

short

FMI

8.1

02

Speed sensor 1

01

-

0.8 s

2

long

short 0.4 s

Flash code

Malfunctions

Recording of engine speed / roadspeed

No errors

Error location / description of error

-

(in SERDIA)

Error no.

FMI:

Zero defects display

Error group

D_F150C.GB.fm. 107-122 01.1203

8

Failure Mode Identifier

SPN: Suspect Parameter Number

D 107

D 108

Communication

Hardware inputs/outputs

Actuator

Error group

CAN interface SAE J 1939

Cable break, short circuit or serious bus error

71

74

CAN bus controller

70

2

7

1

2

Error CAN Setp1

6

68

2

Error Hand Setp1

14

9

12

2

11

7

67

1

53

5

Control stroke variance

2

13

Reference feedback

0.4 s

short

52

0.8 s

FMI

12

long

short 0.4 s

Flash code

Feedback

Error location / description of error

50

(in SERDIA)

Error no.

D_F150C.GB.fm. 108-122 01.1203

SD 231

SID 231

SID 231

898

91

SID 23

SID 24

SID 24

SPN

Overflow in reception buffer or a message cannot be sent by (data) bus.

CAN controller for CAN bus issues error messages. Error cannot be permanently rectified despite re-initialisation.

Fuel injection pump / actuator jams or is not connected. Variance between nominal/actual control stroke > 10% of total control stroke.

Actuator not connected. Error in actuator feedback.

Cause

Application-dependent

Error message (disappears once variance is < 10%).

Emergency shutdown. Controller cannot be operated.

Comments

Check CAN connection, cable connection. Check sensor and replace if necessary.

Check CAN connection, output resistance (refer to section 12.4), check control unit.

Check actuator / actuator linkage / fuel injection pump, replace if necessary. Check actuator cable.

Check actuator; if necessary: replace. Check cable. Check error limits for "reference feedback".

Check actuator and replace if necessary. Check cable. Check error limits for "feedback".

Remedial action

D 109

Control unit hardware

Memory

Error group

Reference voltage 2

Reference voltage 4

Internal temperature

84

85

86

2

2

9

8

2

2

12

2

2

2

Reference voltage 1

1

83

9

2

2

80

1

12

12

Power supply (actuator)

8

0.4 s

short

2

2

0.8 s

FMI

Cyclic RAM test

Cyclic program test

77

long

short 0.4 s

Flash code

78

Parameter programming (write EEPROM)

Error location / description of error

76

(in SERDIA)

Error no.

D_F150C.GB.fm. 109-122 01.1203

171

SID 254

SID 254

SID 254

SID 254

SID 254

SID 240

SID 253

SPN

Internal temperature for control unit not in permissible range.

Reference voltage for controller not within permissible range.

Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Check voltage supply. Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Error message (disappears once voltage returns to normal range). Backup value 5 V.

Error message (disappears once temperature returns to normal range).

Error message (disappears once power returns to normal range).

Power supply for controller not within permissible range.

Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Remedial action

Ongoing monitoring of RAM (volatile memory) issues error messages.

Emergency shutdown. Engine cannot be started.

Comments

Note down values of parameters (3895 and 3896). Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Ongoing monitoring of program memory issues error messages (commonly referred to as "Flash test").

Error during parameter programming in controller's hard disk.

Cause

D 110

Program logic

Error group

Stack overflow

Internal error

94

Parameter error (interrogate EEPROM and/ orcheck total incorrect).

Error location / description of error

93

90

(in SERDIA)

Error no.

D_F150C.GB.fm. 110-122 01.1203

10

0.8 s

2

long

short 0.4 s

1

0.4 s

short

Flash code

2

2

2

FMI

SID 254

SID 240

SID 253

SPN

Internal computing error (commonly referred to as "Stack overflow" error).

No data found or check total for data incorrect. (Note: error only occurs during parameter setting / saving and/or reset).

Cause

Emergency shutdown. Engine cannot be started.

Engine cannot be started.

Comments

Note down values of parameters (3897 and 3898). Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Check data for correct setting. Save parameters. Switch ignition off and back on again. Check again. If error occurs, inform DEUTZ service department.

Remedial action

D 111

Functional error, warning

Error group

2

2

2

Oil pressure warning

Coolant temperature warning

Charged air temperature warning

31

32

2

2

Coolant level warning

Speed warning (in coasting mode)

34

35

3

3

3

3

3

0.8 s

30

long

short

6

5

3

2

1

0.4 s

short

Flash code

0.4 s

Error location / description of error

Error no.

(in SERDIA)

D_F150C.GB.fm. 111-122 01.1203

14

1

0

0

1

FMI

SID 190

111

105

110

100

SPN

Check coolant. Check coolant temperature sensor and cable.

Check charged air. Check charged air temperature sensor and cable.

Error message (disappears once coolant temperature has again fallen below recovery threshold). After a delay period has passed - filling limit. Error message (disappears once charged air temperature has again fallen below recovery threshold). After a delay period has passed - filling limit.

Error message.

Refer to section 4.3.3 Overspeed protection.

Coolant temperature has exceeded warning threshold.

Charged air temperature has exceeded warning threshold.

"Coolant level too low" shift input is active.

Speed was/is above (overspeed) speed limit. "Coasting mode" function is active.

Fuel temperature has exceeded warning threshold.

Error message (disappears once fuel temperature has again fallen to below recovery threshold).

Check fuel. Check fuel sensor and cable.

Check PID setting. Check linkage. Check actuator, replace if necessary. Check cable to actuator. Check speed sensor (impulse for incorrect speed). Check number of teeth. Check vehicles for possible coasting mode.

Check parameter (21). Check speed setting.

Check coolant level. Check coolant level sensor and cable.

Check engine (oil level, oil pump). Check oil pressure sensor and cable. Check oil pressure warning characteristics curve.

Remedial action

Error message (disappears once oil pressure returns to above the recovery limit). After a delay period has passed - filling limit.

Comments

Oil pressure below speeddependent warning characteristics curve.

Cause

Problems during paving Problem

Cause

-

change in the material temperature, demixing wrong material composition incorrect operation of the roller incorrectly prepared foundation long standstill times between loads grade control reference line is not suitable grade control jumps to the reference line grade control toggles between up and down (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

Wavy surface ("short waves")

D 112

-

D_F150C.GB.fm. 112-122 01.1203

8.2

Problem

Cause -

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

Cracks in the layer (outer strip)

Marks in the surface -

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

D_F150C.GB.fm. 113-122 01.1203

Screed does not react to corrective measures as expected

-

truck hits too much against the finisher while aligning to the finisher too much play in the mechanical screed link/suspension truck brake is applied vibration is too high while standing on a spot

D 113

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 is obstructed by cold Properly heat the screed bitumen Hydraulic oil level in the tank Top up the oil is too low Tamper or vibration does not operate

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

Oil filter is soiled

Tighten or replace the hose clamps Clean the filter; if necessary, replace the filter

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

Check fuses and cables; replace if necessary

Switch is defective

Replace the switch

One of the pressure limiting Repair or exchange the valves Conveyor or augers run valves is defective too slowly Pump shaft broken Replace the pump Limit switch does not switch Check the switch; replace and or regulate correctly adjust the switch if necessary Pump is defective

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

Oil filter is soiled

Replace the filter

Engine speed is too low

Increase the speed

Leak in the suction line Hopper cannot be swung open

D 114

Tighten the connections

Flow rate regulator defective Replace Leaking seals of the hydrauReplace lic cylinder Control valve is defective

Replace

Power supply interrupted

Check fuse and cables; replace if necessary

D_F150C.GB.fm. 114-122 01.1203

Hydraulic oil level is too low Top up the oil

Malfunction Hoppers lowers inadvertently

Screed cannot be lifted

Cause

Remedy

Control valve is defective

Replace

Leaking seals of the hydraulic cylinder

Replace

Oil pressure too low

Increase the oil pressure

Leaking seal

Replace

Screed relieving or charging is switched on

Switch must be in the centre position

Power supply is interrupted

Check fuse and cables; replace if necessary

Switch on the remote control is set to "auto"

Set the switch to "manual"

Power supply is interrupted

Check fuse and cables; replace if necessary

Switch on the operating Crossbeams cannot panel defective be lifted or lowered Excess pressure valve defective

Replace

Flow rate regulator defective

Replace

Seals defective

Replace

Control valves defective

Replace

Pilot-controlled non-return valves defective

Replace

Seals defective

Replace

D_F150C.GB.fm. 115-122 01.1203

Crossbeams lower inadvertently

Replace

D 115

Malfunction

Traction does not work

Cause

Remedy

Traction drive fuse defective

Replace (fuse panel on the control panel)

Power supply is interrupted

Check potentiometer, cables, connectors; replace if necessary

Traction drive monitoring (type-specific) defective

Replace

Electro-hydraulic servo unit Replace the servo unit of the pump defective Check and adjust if necessary Insufficient supply pressure Check the suction filter; replace the supply pump and the filter if necessary Drive shaft of hydraulic pumps or engines broken

Replace pump or engine

Fuel level too low

Check the fuel level; refill fuel if necessary Replace (fuse panel on control panel) Check potentiometer, cables, connectors; replace if necessary

D_F150C.GB.fm. 116-122 01.1203

Engine speed une- Fuse "engine speed conven, engine stop not trol" defective functioning Defective power supply cables (cables broken or short-circuited)

D 116

8.4

Malfunctions on the emulsion spraying equipment

Malfunction Computer does not count

Cause

Remedy

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 The figures displayed by no longer be the computer are higher controlled than parameter PR2

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

Spraying ramp does Switches "Spraying ramp Check the switch positions not move movement", "compressor", "Spraying ramp", "Feeding" or "emulsion pump" in the wrong position 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 lefthand spraying ramp defective

Check the micro switch and replace it if necessary

D_F150C.GB.fm. 117-122 01.1203

Relays 1, 2 (switch cabinet) Check the relays and replace or 4 (box on the emulsion them if necessary tank) defective Spraying ramp does Switch in the wrong not work 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

D 117

Malfunction Spraying ramp continues spraying even when the movement has stopped

Cause

Remedy

Micro switch for the respec- Check the micro switches; tive lateral movement defec- adjust or correct in longitudinal tive or incorrectly set direction

One nozzle does not Nozzle is clogged Clean the nozzle work Insufficient air pressure in Check the air pressure and the the control lines 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 Switches for the compressed Check the switches in the emulsion air valves defective circuit Filter clogged Clean the filter Filter sucks in air

Check the manual valve for the funnel and close it

D 118

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.

D_F150C.GB.fm. 118-122 01.1203

Correct the position of the filter lid and close it firmly

Malfunction

Cause

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

Metering rate Insufficient emulsion changesbetweentwo temperature work steps Incorrect nozzle size

Bad appearance of the sprayed layer

Remedy

Power supply from the generators: increase the diesel engine speed Check the temperature and correct it if necessary Check the nozzle sizes to determine whether or not they were changed

Insufficient operating pressure in the emulsion circuit

Check the emulsion circuit

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 Check the nozzle sizes; replace the emulsion type or the the nozzles if necessary metering rate

D_F150C.GB.fm. 119-122 01.1203

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 is available.

D 119

9

Emergency device/steering, drive system In case of a male function in the electronic drive system it is possible to override the system by an emergency device. This emergency device is included in the tool set of every crawler machine. To install the emergency device all plugs of the drive pump servo valves have to be replaced by the plugs of the emergency device. (short screw driver is necessary.) The connector for the hydraulic brake valve is replaced by the corresponding connector 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 stud bolt 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 on page D90.

123 122 121

122

D_F150C.GB.fm. 120-122 01.1203

120

D 120

The control unit houses the following functions 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)

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

D_F150C.GB.fm. 121-122 01.1203

- 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

D 121

Pump for right caterpillar drive Pump for left caterpillar drive Servo valve

black gray gray black

24 V Ground/earth

D_F150C.GB.fm. 122-122 01.1203

Steering unit

D 122

E Set-up and modification 1

Special notes on safety

f

Danger to personnel by inadvertent starting of the engine, the traction drive, the conveyor, the auger, the screed or the lifting units. Unless specified otherwise, work may only be performed when the engine is at a standstill! - To protect the paver finisher against inadvertent starting: Set the drive lever to the centre position and set the preselector to zero; if applicable, remove the drive traction fuse from the operating panel; remove the ignition key and the battery main switch. - Secure lifted machine parts (e.g. screed or hopper) against lowering by means of mechanical supports. - Replace parts or have them replaced as stipulated.

f

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

E F150C.GB 1-30 12.03

- 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 under the following conditions: - When paving next to a wall or a similar obstacle. - During transportation on a low-bed trailer.

E1

2

Auger

2.1

Height adjustment

1

The height of the distributor auger (1) should be – measured from its lower edge – be min. 50 mm (2 inches) above the material paving height, depending on the material mixture involved. Example:

Layer height 10 cm Adjustment 15 cm from the ground

An incorrect height adjustment can result in the following problems:

F130_A1.TIF

- Auger too high: Too much material in front of the screed; material overflow. When operating with larger working widths, demixing and traction problems may occur. - Auger too low: Not enough material that can be precompacted by the auger. Irregularities resulting from this cannot be completely compensated for by the screed (wavy surface). In addition, an increased wear on the auger segments occurs. 2.2

Auger crossbeam installed in a fixed position 2 - Lower the screed onto a suitable support (e.g. squared timbers). - Completely extend both levelling cylinders. - Hook lifting chains (2) for lifting the auger crossbeam into the hooks of the F131_A1.TIF crossbeams. - Unfasten retaining screws (3) on the auger crossbeam. - Retract the levelling cylinders until the auger crossbeam has reached the desired height. - Tighten the fixing screws (3) of the auger crossbeam. 3

E F15C.GB 2-30 0300

F129_A1.TIF

E2

2.3

With mechanical adjustment with ratchet (option) - Adjust ratchet driver pin for clockwise or anticlockwise rotation. Turning anticlockwise lowers the auger, turning clockwise lifts the auger. - Set the desired height by alternatingly adjusting the right-hand and the lefthand side. - The current height can be read from the scale in cm or inches (cm = lefthand column, inches = right-hand column). F116_A1.EPS

2.4

With hydraulic adjustment (option) - Define the current setting for the auger crossbeam – left and right sides – on the scale. - Press the switches (4) on the operating panel up or down to extend or retract the hydraulic cylinders.

F117_A1.EPS

m

Actuate both switches simultaneously to avoid warping of the auger crossbeam.

4

- Check whether the heights on the left and on the right are identical.

E F150C.GB 3-30 12.03

6.EPS

E3

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 instructions for the screed): – Screed extension chart, – Auger extension chart.

To attain the desired working width, the respective screed extension parts, side plates, 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 parts on both sides to improve material distribution and to reduce the wear. The diesel engine must be switched off whenever work is performed on the auger. Danger of injuries!

E F15C.GB 4-30 0300

f

E4

2.6

Mounting extension parts

5

- Loosen the clamping screws (6) on the support tube. Then turn in the centre expanding screw (5) to expand the clamping joint.

6

F132_A1.TIF

- Pull the telescopic tube out of the support tube (7). - Mount the required extension parts.

m

7

Observe the guide groove of the spline! Make sure that the shaft end is clean! - Slide in telescopic tube, ensuring that the auger gear is pushed firmly by the stub axle on the auger extension section and that the auger threads are F133_A1.TIF properly aligned. - Remove the expansion screw (5). Then tighten the clamping screws (6). Finally tighten the expansion screw by hand. Before tightening the clamping screws (6) back down, always ensure that the expanding screw (5) is retracted far enough! Failure to do this makes it impossible to secure the telescopic tube properly and the meshing shaft sections may then break.

f

When clamped insufficiently, the telescopic tube can slide out of the support tube. Danger of accidents during transportation!

E F150C.GB 5-30 12.03

m

E5

2.7

Mounting support tube extensions If the working width exceeds 7.50 m, an auger crossbeam extension must be mounted. The support tube extension of the auger crossbeam consists of two halves (8) and is attached to the existing support tube by using a total of 5 screws. After the two halves have been screwed to the support tube, they also must be linked to each other by means of screwed connections.

8 F134_A1.TIF

The telescopic tube is clamped by tightening the screw connections which hold together the carrier tube extension halves (9).

9 F136_A1.TIF

If the working width exceeds 7.50 m the hydraulic hoses (10) for the auger motors must be replaced with longer ones. These long hoses are included in the scope of delivery for this working width.

10

When connecting or disconnecting hydraulic hoses, hydraulic fluid can spurt out at a high pressure. Switch off the finisher and de-pressurise the hydraulic circuit! Protect your eyes!

m

When installing the hoses, make sure that the area around the connections is F0135_A1.TIF clean. Any dirt that enters the hydraulic system can cause malfunctions. E F15C.GB 6-30 0300

f

E6

2.8

Installing tunnel plates To ensure an optimum material flow – especially in the case of large working widths – so-called tunnel plates (11) must be installed. These are located directly above the auger distributor and, working in conjunction with the auger, they form an optimum material transport system. When operating with working widths of more than 3.90 m, two or more combined tunnel plates (13) must be used. In this case, additional stabilising supports (12) must be attached to the telescopic tube.

11

12

13

F0140_A1.TIF

The tunnel plates must be directly screwed to the sockets provided for this purpose (14); they are located on the auger frame sides and can thus be adjusted in height. Refer to the auger extension chart to determine which parts of the conveyor system are required for the desired working width.

A

For an auger extension chart, refer to the Operating instructions for the screed).

14

E F150C.GB 7-30 12.03

F0139_A1.TIF

E7

2.9

Installing additional braces When operating with working widths of more than 7.25 m the augers must be provided with an additional support.

F141_A1.TIF

To do so, attach two braces on both the left-hand and the right-hand side, between the tunnel plate support and the bracket provided on the finisher. The braces are included in the scope of delivery for this working width.

E F15C.GB 8-30 0300

F142_A1.TIF

E8

Pendulum drive system For the following purposes, the entire front section of the vehicle chassis can be raised or lowered by means of a hydraulic cylinder: - Adjust to suit the application depth of the material conveyor or its tyre size - For driving on to the low-bed trailer

f

Danger of crushing! Before actuating the non-return valves, close the hopper. Install the hopper transport guard! Raising the chassis:

3 2

- Close the hopper using the switch / button (1) control and install the hopper transport guard. - Open both non-return valves (A) and press switch / button (1) until the desired height is reached. - Close both non-return valves (B).

Lower the chassis 1

- Close the hopper using the switch / button (1) control and install the hopper transport guard. - Open both non-return valves (A) until the chassis has been lowered to the desired height. - Close both non-return valves (B).

E F150C.GB 9-30 12.03

A

Neutral setting is reached once the notch (2) on the guide frame is level with the upper edge of the guide plate (3).

A

B Pendeltr1.cdr/Pendeltr2.cdr/Pendeltr3.cdr/Pendeltr4.cdr

E9

3

Screed

A

All work involved in installing, setting up and widening the screed are described in the Operating instructions for the screed.

4

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

4.1

Remote controls to socket (15) (on the screed). 15

F171_A1.TIF

4.2

Grade control 16

to socket (16) (on the remote control unit)

17

4.3

Auger limit switches to socket (17) (on the remote control unit) F0119_A1.TIF

4.4

Working lights

18

F124_A1.TIF

E 10

E F15C.GB 10-30 0300

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

5

Operating principle for the spraying system Compared to a conventional emulsion spraying device, spraying from a paver finisher involves 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 normal standard system because the nozzle bores would then have to be so small that they would block all the time. To find a solution, ACMAR has patented the "Alternate Spraying Process". The spraying ramp opens for a brief moment only. Thus it is possible to use nozzle sizes that allow to spray viscous bitumen or emulsions. At the same time, the ramp (consisting of a single part) moves rhythmically across the entire surface. Regardless of the paver finisher speed, the speed of the ramp movement 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 to the right, stops at the turning point for a certain time and returns to the left where it stops again. The stop period of the ramp is negatively proportional to the paver finisher speedy. The higher the paver finisher speed, the shorter are the stop periods of the ramp. A change of the paver finisher speed also causes the spraying ramp frequency to change proportionally in relation to the paver finisher speed.

E F150C.GB 11-30 12.03

This principle makes it possible to maintain continuous and uniform metering of spray action even if the paver speed alters (between 0-15 m/min).

E 11

A switch (19) enables the operator to preselect one of two different spray processes (F, F+R). - F

=

- F+B =

Spraying while the spraying ramp moves from the left to the right (or from the right to the left) Spraying in both directions 19

The ramp sprays in both cases while it moves 20 cm to one side. Then it stops and starts spraying again with the next movement. The two methods result in different metering rates - F for low rates - F+R for increased metering > 500 g/ m² (if the F value is doubled, the metering rate does not alter)

Bild-ure-5a.TIF

See the table on the next page. The nozzle type determines the metering rate: - Model 727: low rate high rate F+R -

from 450 g/m² to 600 g/m² from 600 g/m²

- Model 647: low rate high rate F+R -

from 250 g/m² to 450 g/m² from 450 g/m²

There is another way to alter parameters PR1 and PR2: this is by means of an electronic computer. The gap between two spray processes is defined by means of parameter PR1. PR2=2xPR1. If parameters PR1 and PR2 are increased, this gives rise to reduced metering action. Reducing these parameters increases the metering rate. Adjusting the parameters makes it possible to adapt the metering rate to suit every spray process (F or F+R).

E35.001GB 12-30 12.03

All metering rates can be selected.

E 12

5.1

Selecting the nozzles and the method

Possibility for all nozzles

632.647

Ø 2.2 mm

632.727

Ø 2.8 mm

632.807

Ø 3.6 mm

Working speed

Metering rate [g/m2]

250 300 350 400 450 500 600 700 800 900 1000 500 550 600 650 700 750 800 900 1000 1100 1200 750 800 850 900 950 1000 1050 1100 1200 1300 1400 Metering rate

1

2

3

4

5

6

7

8

E F150C.GB 13-30 12.03

Selection: Recommended nozzles

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

F

F+B

F

F+B

F

F+B

Select between

[g/m2]

250 to 450 500 to 1400

9

- 632.647 - 632.727

632.647

632.727

Operating pressure = 1.3 bar F – forward

Metering rate

Select between

[g/m2]

250 to 700 750 to 1400

- 632.647 - 632.807

632.647

632.807

F + B – forward and backward E 13

5.2

Explanations The emulsion is circulated by means of a pump running at a constant speed. During spraying the backflow line to the tank is closed. The pressure relief valve is constantly operated as the pump capacity is higher than required for spraying. This means that the constant spraying pressure results from the start-up regulation of the pressure relief valve.

m

Never change the setting of the pressure relief valve! Spraying occurs at a constant pressure. To assure a constant flow rate through the spray 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 When filling the tank, the temperature must be 10 °C higher.

E F15C.GB 14-30 0300

m

E 14

6

Programming the computer - Switch on the paver finisher ignition. - Switch (21) 24 V electrical power switch to "On". - Switch (20) spraying ramp: Select "Auto" setting on the fixed Stop-Auto switch. - Pull the computer rack halfway out of its housing. "Pro" then appears on the display screen. R_blanko.tif

20

21

E F150C.GB 15-30 12.03

Bild-5a.TIF

R_01.tif

E 15

- Press the "P1" key. Display: Fct CPt - If a different display appears on screen, select the correct setting using the marked button.

R_02.tif

- Press the "P1" key. Display: MOdE - If a different value is displayed, use the highlighted key to select the correct setting.

R_03.tif

- Press the "P1" key. Display: SPEEd

R_04.tif

E 16

E F15C.GB 16-30 0300

- If a different display appears on screen, select the correct setting using the marked button.

- Press the "P1" key. Display: CYCLE - If a different display appears on screen, select the correct setting using the marked button.

R_05.tif

- Press the "P1" key. Display: Prot - If a different display appears on screen, select the correct setting using the marked button.

R_06.tif

- Press the "P1" key. Display: P1

E F150C.GB 17-30 12.03

- If a different display appears on screen, select the correct setting using the marked button.

R_07.tif

E 17

- Press the "P1" key. Display: P2 - Using the highlighted keys, set the figures for time "t" on either side of the decimal point. Every time a key is pressed, the relevant numeral increases by "1".

A

T must be set to 0.1 s.

R_08.tif

- Press the "P1" key. Display: 0 0 0 0 0 0 - If a different display appears on screen, select the correct setting using the marked button.

R_09.tif

- Press the "P1" key. Display: MEMO

R_10.tif

E 18

E F15C.GB 18-30 0300

- If a different display appears on screen, select the correct setting using the marked button.

- Press the "P1" key. Display: 0 1 . 0 0 0 0 - Using the highlighted keys, set the coefficient values to either side of the decimal point. Every time a key is pressed, the relevant numeral increases by "1".

A

K must be set to 1.0 s. - Press the "P1" key. Display: ProG - Slide the computer rack back into its housing until it locks into position.

R_11.tif

- The display is shown on the right side of the screen. P1 represents parameter PR1 and P2 for parameter PR2. - The parameters for PR1 and PR2 are set using the highlighted keys. Every time a key is pressed, the relevant numeral increases by "1". - Press key "P1" to toggle between parameters PR1 and PR2. The selected parameter flashes on the screen display. - Select parameter PR1 for programming purposes. Enter the impulse value for spraying ramp movement. The basic setting is 700.

R_12.tif

- 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.

E F150C.GB 19-30 12.03

- To complete the programming operation, initiate a reset by pressing the "RST" key.

E 19

6.1

Setting parameters for automatic operation - Set the switch (22) for Ramp Movement to its Semi Auto position. Parameters PR1 and PR2 are important for automatic operation. The basic settings are: - PR1=700 - PR2=1400 Before calculating the parameters: - Prepare and weigh emulsion for three test areas (use scales with a 10 g division). - Spray test areas in front of the paver finisher. - Collect and weigh the test areas. - Determine the area in m² . - Calculate the base value according to the equation below.

22

Bild-5a.tif

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

E F15C.GB 20-30 0300

Base value = 0.40 kg/m²

E 20

Calculating the parameters Parameter equation: PR1 = DOSbase x PR1base / DOS -

PR1 Dosbase PR1base DOS

= = = =

parameter value to be set basic value in kg/m² set value 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 example, the value for PR2 = 700.

A

The smaller the values for parameters PR1 and PR2, the higher the metering rate per m² .

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 parameters PR1 and PR2. - Enter the calculated values as described in section "Programming the computer". The following page contains a "Calculation sheet for the automatic mode" where the relevant values can be entered.

E F150C.GB 21-30 12.03

A

E 21

6.2

Calculation sheet for the automatic mode

CALCULATION SHEET FOR THE AUTOMATIC MODE CUSTOMER: Date: All emulsion spraying systems Type Paver finisher Type Spraying function

PR1 PR2

Pressure

Nozzles

Metering rate

Emulsion type

Remark Base values

Forward

+

Backward

Base values Forward

Backward

E 22

E F15C.GB 22-30 0300

or

6.3

Settings for semi-automatic operation

A

A timer relay (23) replaces the sensor and the electronic computer in the semiautomatic mode. (default setting = 2 secs. This represents a uniform metering rate at an operating speed of approx. 5 m/min.) Completing the calculation sheet

A

Calibration must be performed by a weighing process in order to achieve the basic 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 type 632.727: 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 complete the part of the calculation sheet that refers to - Nozzle type 632.727 - Spraying forward and backward

23

E F150C.GB 23-30 12.03

Bild-5a.TIF, Bild-2.TIF

E 23

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. Calibration for the different nozzle types is the same for the "forward" mode.

E F15C.GB 24-30 0300

A

E 24

6.4

Calculation sheet for the semi-automatic mode (FORWARD + BACKWARD)

CALCULATION SHEET FOR SEMI-AUTOMATIC MODE FORWARD + BACKWARD Metering rate

Working speed - S (m/min)

NozTime T for zle adjustment type

Selection

2

2

3

4

5 Sb

6

7

8

9

10

11

12

13

14

15

16

17 Sb

18

19

20

21

22

23

24

25

Tb

4

Forward 727

6 8 10

+

2 Tb 4 Backward

647

6 8 10

continued... 2

Tb

4 727

6 8 10 2 Tb 4

647

6 8

E F150C.GB 25-30 12.03

10

E 25

6.5

Calculation sheet for the semi-automatic mode (FORWARD only)

CALCULATION SHEET FOR SEMI-AUTOMATIC MODE FORWARD ONLY Metering rate

Working speed - S (m/min)

NozTime T for zle adjustment type

Selection

2

2

3

4

5 Sb

6

7

8

9

10

11

12

13

14

15

16

17 Sb

18

19

20

21

22

23

24

25

Tb

4 727

6 8

Forward

10 2 Tb

Forward

4 647

6 8 10

continued... 2

Tb

4 727

6 8 10 2 Tb 4

647

6 8

E F15C.GB 26-30 0300

10

E 26

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 The calculation sheet only contains 5 figures for time "T". The timer relay uses a potentiometer for setting the time. If the figures on the calculation sheet do not yield an exact DOS value, the following equation can be used to calculate the correct timer relay 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 be reduced. If DOS is being reduced, T needs to be increased.

E F150C.GB 27-30 12.03

A

E 27

7.1

Calculation sheet for spraying nozzles behind the drives

CALCULATION SHEET FOR SPRAYING NOZZLES BEHIND THE DRIVES Metering rate (g/m2)

Working speed (S)

Nozzle type

For pressure = 1.7 bar Nozzle flow rate in 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

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

E F15C.GB 28-30 0300

110 04

E 28

7.2

Explanations for the calculation sheet for the spraying nozzles behind the drives Several nozzle types are available to cover the broadest possible range. Enter the theoretical 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 is 1.7 kg/cm² close to the nozzles. It is however possible with the above formula to calibrate every type of nozzle in order to enter the correct flow rate figure in the corresponding column of the calculation sheet.

A

The calculation sheet shows that it is not possible to run at a metering rate of less than 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, the main spraying ramp must be used. The nozzles behind the tracks must always be adjusted to suit the metering rate of the spraying ramp!

E F150C.GB 29-30 12.03

m

E 29

F Maintenance 1

Notes regarding safety Maintenance work: Maintenance work may only be carried out when the engine is at a standstill. Secure the paver finisher and the attachments against inadvertent starting before beginning 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) against lowering by means of mechanical supports.

m

Unreleased parts or spare parts, unsuitable tools or inexpert installation may cause malfunctions, cause damage to property and be a hazard for persons! Spare parts: Use only approved parts and install them according to the specifications! If in doubt, contact the manufacturer! Re-commissioning: Mount all protective devices before re-commissioning the paver finisher. Cleaning: Cleaning must not be carried out while the engine is running. Do not use any inflammable substances (such as petrol). Avoid directly cleaning electrical parts and insulation material with a steam jet; cover them 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. In addition to these Maintenance Instructions, the Maintenance Instructions of the engine manufacturer must always also be observed. All other maintenance work and intervals noted in these instructions are also binding.

F F150C.GB 1-54 12.03

m

F1

2

Maintenance intervals for the paver finisher

1 2 12 13 17 33 3

36

4

36 5

15 40 14

11 16 10 18

21

22

9

7

8

6

20 19

23

22

21

F F150C.GB 2-54 12.03

Schmier.pic

F2

Oil change

Maintenance point

Check

Item

Lubrication

Daily (or every 10 operating hours)

Number

2.1

Substance

Filling volume

2

Air filter

1

x

3

High 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 oil

see "Filling volumes"

13

Radiator fluid level

1

x

14

Chain tension conveyor

2

x

15

Conveyor deflection roller

2

18

Fuel tank filling level

1

20

Hydraulic oil reservoir filling level

23

x

Grease Grease

5 strokes

x

Diesel fuel

see "Filling volumes"

1

x

Hydraulic oil

see "Filling volumes"

Chain tension conveyor

2

x

35

Filter mats in air intake ducts

3

x

36

Check insulation monitoring function

x

General security check (see section 3.1) Security check 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 after 20 operating hours and replace them where applicable!

F F150C.GB 3-54 12.03

m

F3

1 2 12 13 17 33 3

36

4

36 5

15 40 14

11 16 10 18

21

22

9

7

8

6

20 19

23

22

21

F F150C.GB 4-54 12.03

Schmier.pic

F4

Oil change

Check

Lubrication

2

x

Gear oil 220

see "Filling volumes"

8

Auger bevel gear

2

x

Gear oil 90

see "Filling volumes"

11

Pump distribution gear

1

x

Gear oil 90

see "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

13

Cooling system for engine and hydraulics

1

Oil change

Maintenance point

Substance

Filling volume

Oil change

Item

Check

Every 100 operating hours

Substance

Filling volume

x

Maintenance point

7

Auger centre bearing

33

Engine suspensions

40

Guide for pendulum drive unit

1

x

Check

Every 250 operating hours

Item

F F150C.GB 5-54 12.03

Filling volume

Conveyor gear

Lubrication

2.4

Substance

4

Number

2.3

Maintenance point

Lubrication

Item

Number

Weekly (or every 50 operating hours)

Number

2.2

Grease

5 strokes

Grease

5 strokes

x 4

x

F5

1 2 12 13 17 33 3

36

4

36 5

15 40 14

11 16 10 18

21

22

9

7

8

6

20 19

23

22

21

F F150C.GB 6-54 12.03

Schmier.pic

F6

12

Engine lube oil

1

x

Engine oil

12 A

Oil filter (cup) l

1

x

Maintenance point

Check

Change

Lubrication

Substance

Item

Filling volume

see "Filling volumes"

Maintenance point

Oil change

Item

Check

Yearly (or every 1000 operating hours) Lubrication

2.6

Number

Every 500 operating hours

Number

2.5

Substance

Filling volume

1

V-belt of the engine

x

2

Air filter

x

4

Conveyor gear

2

x

x

Gear oil 220

see "Filling volumes"

8

Auger bevel gear

2

x

x

Gear oil 220

see "Filling volumes"

9

Auger, gear neck bearing

2

Grease

5 strokes

10

Caterpillar drive planetary gear *

2

x

x

Gear oil 90

see "Filling volumes"

11

Pump distribution gear

1

x

x

Gear oil 90

see "Filling volumes"

17

Fuel filter Upstream fuel filter

1

x

34

Hoses and hose clamps

x

x

Diesel engine: Valve clearance Heater plugs

F F150C.GB 7-54 12.03

Have the paver, screed and gas system inspected by a specialist

x

*) First oil change after 1000 hours, then every 1500 hours.

F7

1 2 12 13 17 33 3

36

4

36 5

15 40 14

11 16 10 18

21

22

9

7

8

6

20 19

23

22

21

F F150C.GB 8-54 12.03

Schmier.pic

F8

1

V-belt of the engine

x

2

Air filter

x

13

Water cooler and entire cooling system

1

x

18

Fuel tank and system

3

x

19

Suction/return hydraulic filter *

2

x

20

Hydraulic oil reservoir – entire filling

1

x

Oil change

Maintenance point

Check

Item

Change

Every 2 years (or every 2000 operating hours)

Number

2.7

x

Substance

Filling volume

Cooling fluid

see "Filling volumes"

Hydraulic oil

see "Filling volumes"

F F150C.GB 9-54 12.03

*) Only use filters with a mesh size of 10 µ = 0.01 mm!

F9

3

Maintenance intervals for the emulsion spraying equipment 24 25 26

27

29 31 30

32

27

28

F F150C.GB 10-54 12.03

F151C.wmf

F 10

3.1

Daily (or every 10 operating hours) All intervals given are maximum permissible maintenance intervals. The intervals must be shortened under aggravated conditions of use!

Emulsion pump

4

x

25

Emulsion filter

2

27

Rotary joints of the flexible emulsion hoses

12

28

Spraying ramp

1

x

29

Drain the (condensed) water in the compressed air vessels

2

x

32

Oil level of the compressor

1

Substance

Grease x

x

2 strokes

Diesel fuel Grease

x

Filling volume

3 strokes

Compressor oil

Must be performed in addition to the daily maintenance!

Maintenance point

Clean

A

Oil change

Weekly (every 50 operating hours)

Check

3.2

Lubrication

Only move the flexible emulsion hoses for lubrication when they are hot!

Number

m

Item

F F150C.GB 11-54 12.03

Clean

24

Oil change

Maintenance point

Check

Item

Lubrication

For information on maintenance intervals and works on the screed, please refer to the Screed operating instructions.

Number

A

25

Emulsion filter

2

x

30

Compressor air filter

1

x

31

Compressor oil cooler

1

x

Substance

Filling volume

Score

F 11

24 25 26

27

29 31 30

32

27

28

F F150C.GB 12-54 12.03

F151C.wmf

F 12

32

Air compressor

1

first oil change

x

Substance

Compressor oil

Maintenance point

26

Emulsion pump gear

1

Compressor oil filter

1

Compressor

1

Clean

Item

Oil change

Must be performed in addition to the weekly maintenance!

Check

A

Lubrication

Every 500 operating hours

Number

3.4

32

F F150C.GB 13-54 12.03

Maintenance point

Clean

Item

Oil change

Must be performed in addition to the weekly maintenance!

Check

A

Lubrication

250 operating hours

Number

3.3

x

Substance

x

Compressor oil

A

1)

Clean

Oil change

1

Check

Compressor oil cooler

Lubrication

Must be performed in addition to the weekly maintenance!

Number

A

31

Filling volume

x

Yearly (or every 1000 operating hours)

Maintenance point

4.3 l

Gear oil 90

3.5

Item

Filling volume

Substance

4.3 l

Filling volume

x 1)

Remove prior to cleaning!

F 13

24 25 26

27

29 31 30

32

27

28

F F150C.GB 14-54 12.03

F151C.wmf

F 14

Must be performed in addition to the daily and monthly maintenance!

Maintenance point

Number

26

Emulsion pump gear

1

28

Spraying ramp

1

x

29

Compressed air vessels

2

x

30

Compressor air filter

1

x

Substance

Gear oil 90

Filling volume

3.5 l

x

x

F F150C.GB 15-54 12.03

All screwed connections and adapters

Check

Item

Clean

A

Oil change

Every 2 years (or every 2000 operating hours)

Replace

3.6

F 15

4

Checking, lubricating, oil drain points on the paver finisher

1

2

3

4

5

15

40

16

14

17

12 , 13

11

10

18

19

9

7 , 8

6

20

21 21

22

23

22

A

F 16

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.

F F150C.GB 16-54 12.03

Schmier.pic

4.1

Check points

Pump distributor gear (11) This screw plug (1) can be used for checking the oil level. After unfastening the screw, a little oil should escape. If it does not, top up oil through the filler bore (2).

A

2

Make sure to clean the screw and the vicinity of the drain bore!

1 PVG2.wmf

Caterpillar drive - planetary gear (10) There is a checking plug (34) on the inside of the gear. The oil level is correct if oil escapes from the inspection hole. When screwing out the plug hot oil can spurt out at high pressure. Always check the oil when the gear is cold!

34 F0198_A1.TIF

F F150C.GB 17-54 12.03

f

F 17

Conveyor gear (left/right) (4) 35

The conveyor gears are beneath the footboard of the operator's platform. Checking oil level: only before starting work. The oil level must reach the upper notch of the dipstick (35). Top up oil: after removing the sealing cover (36) through the oil filler neck (37).

A

m

10 cm on the display equal about 0.25 l of oil. The conveyor gears are filled with Optimol Optigear 220 at the factory. Due to the high quality of this oil, it is not necessary to replace the oil at regular intervals. All you need to do is to check the oil level in the gear on a regular basis (refer to section on maintenance intervals).

F151_A1.TIF

36 37

F0152_A1.TIF

The above applies if Optimol Optigear 220 or oil of a similar quality from another manufacturer is used.

Auger bevel gear (left/right) (8) Screw (38) is used for checking the oil level and for topping up oil. Clean the vicinity of the screw plug before unscrewing it. The oil level is correct when a small amount of oil leaks out of the lateral opening.

38

F F150C.GB 18-54 12.03

F0139_A 1.TIF

F 18

Engine lube oil (12)

Oil level check Check the oil level with dipstick (1) every time before work is started. Only check the oil level when the finisher is in a hoizontal position!

1

2

- If necessary, top up the oil level through the filler bore (2).

m

Too high an oil level destroys the seals in the engine while too low an oil level causes the engine to be overheated and destroyed. PVG_115.jpg/Oil115.jpg

Oil change

A

Oil changes should always be carried out at operating temperature. - Unscrew and remove the screw cap from the oil drain point (1) and attach the hose provided for this purpose in the 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 through the aperture in the engine compartment (2). - Start up engine and run at idle speed. - Shut down engine again. Check oil level once again correct if necessary.

F F150C.GB 19-54 12.03

A

1

68

2

At every oil change, you should also replace the filter cartridge (see following section).

PVG_115.jpg/Oil115.jpg

F 19

Engine oil filter (12a)

A

The new filter is installed during the oil change after the old oil has been drained off. 1

- Unfasten lube oil filter cover (1) with a filter belt or key on the hex head and unscrew 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) and guide (4). - Replace rubber gasket (2) and apply a light coating of oil. - Carefully insert a new paper filter cartridge (3) in the guide (4). - Tighten down lube oil filter cover (1) clockwise (25Nm)

A

After installing a new oil filter, check the oil pressure gauge carefully during test operation to ensure that good sealing action is being provided. Check oil level once again.

F F150C.GB 20-54 12.03

Oil115.jpg/Becherfilt.tif

F 20

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 corrosion inhibitor has been added (-25°C). The optimum fill level is 6 cm below the sealing surface of the screw cover.

f

System is pressurised when hot! Danger of scalding when the system is opened!

Hydraulic cooler The paver is equipped as standard with a hydraulic oil cooler. This cooler is essential for the operational safety of the entire hydraulic system.

-

6 cm

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- Kühl115.jpg, Kühl.tif ant wear to gaskets, O-rings, pumps and 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. Only clean the engine while it is cold!

F F150C.GB 21-54 12.03

f

F 21

Fuel tank (18) We recommend to always top up the fuel tank before starting work to prevent the tank from "running dry" which would make it necessary to ventilate the entire fuel system.

F0154_A1.TIF

V-belts and ribbed V-belts (1) - Refer to the Engine operating instructions for inspection and adjustment of belts.

A

1

New V-belts expand and need to be retensioned after approx. 15-20 minutes of operation.

F F150C.GB 22-54 12.03

KeilCom2.tif

F 22

Air filter (2) The amount of dirt in the air filter (1) is determined by the amount of dust in the ambient air. Filter maintenance is essential if the red Service panel (3) is fully visible on the maintenance indicator (2) while the engine is switched off.

1

2

Dust extraction valve

A

- Empty the dust extraction valve (4) by compressing the extractor slots in the direction of the arrow. - Remove any caked dust by compressing the upper section of the valve. Clean the extractor slot from time to time. Filter cartridge:

2

3

- 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. 5 bar), - In emergencies, carefully tap the cartridge to clean it. Avoid damaging the cartridge in this process. - Check cartridge for signs of damage to the filter paper and inspect the gaskets, replacing if necessary.

4

4

8

5

Safety cartridge:

F F150C.GB 23-54 12.03

7

A A

6

- To replace the unit, unfasten the hex nut (8) and pull out the cartridge (7). Lufi115.jpg, Lufineu.tif,Lufi2neu.tif,Lufi3neu.tif - Install a new cartridge, reinstall the hex nut and tighten back down. - Install filter cartridge (6) and close the air filter housing (1). After every air filter maintenance operation, press the reset button on the maintenance indicator (2). Follow the instructions in the engine operating instructions! F 23

High pressure hydraulic filter (3)

m

All filters of the hydraulic system must be checked and replaced where necessary 20 operating hours after repairs have been made!

40

Replace filter cartridges when maintenance indicator (40) turns red. Drain the soiled oil that leaks out after unscrewing the filter cap into a used oil container. Take out the filter cartridge and have it disposed of by specialists (danger of environmental pollution!). Wash out the housing, replace the O-rings and apply a thin layer of oil to them. Mount the filter housing with the filter cartridge again and tighten it properly. The red indicator (40) will then be automatically reset.

F0158_A1.TIF

Suction/return flow hydraulic filter (19) Change filter whenever the maintenance indicator (41) or (42) reaches the red mark. Always replace filters when exchanging the hydraulic oil.

41

Unscrew the lid of the filter housing on the hydraulic oil reservoir and replace the filter cartridge. Never clean and reuse old filters! Always use a new filters.

F0020_A1.TIF

F F150C.GB 24-54 12.03

m

42

F 24

Hydraulic oil reservoir (20) 43

Use dipstick (43) to check the oil level. With retracted cylinders, the oil level must reach the upper mark. Regularly clean the oil reservoir ventilation. Clean the oil cooler surfaces (also refer to the Operating instructions for the engine).

m

Use recommended hydraulic oils only (see the section "Recommended hydraulic oils").

F0020_A1.TIF

Chain tension, conveyor (23)

A

Adjusting screws (44) are located at the front of the crossbeam. The chains should not be too tight or too slack. Too tight a chain can cause the chain to be stopped or to break when material falls into the space between the chain and the sprocket wheel. Too slack a chain can be caught at protruding objects and can thus be destroyed.

m

For the daily visual check, peer horizontally below the bumper. The chain must not hang below the bottom edge of the bumper. If adjustment is required, measure deflection from underside of floor panel to underside of track (see illustration).

44 F0016_A1.TIF

280

280

F0159_A1.TIF

Grease tensioner on conveyor (O)

F F150C.GB 25-54 12.03

A

There is the option of equipping the machine with grease tensioners for the conveyor.

1

The filler valves are located to the left and right sides of the level control cylinders on the pendulum drive. - Fill grease tensioners with grease press through filler valve (1) until the desired track tension is reached. F0016_A1.TIF

F 25

Engine - fuel filter (17) The fuel filter system consists of two filters:

1

- 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 upstream filter which collects the escaping water. Use the drain valve (4) to empty this receiver at regular intervals or whenever the engine control unit issues an error message.

3

5

4

Upstream filter - replacing the filter cartridge

F F150C.GB 26-54 12.03

- Drain off condensate water - Remove connector from water sensor (5) 2 - Unfasten filter cartridge and receiver with a filter wrench or strap and unscrew the unit - Unscrew the receiver (3) from the filter cartridge and clean if necessary. Oelwech.tif - Clean the sealing surface of the filter bracket - Apply light coating of oil to the gasket on the receiver and tighten hand-tight under the 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).

F 26

Main filter - replacing filter cartridge - Unfasten fuel oil filter cover (6) with a filter strap or key on the hex head and unscrew 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 a light coating of oil. - Carefully insert a new paper filter car- Becherfilt.tif tridge (8) in the guide (9). - Tighten down fuel filter cover (6) clockwise (25Nm)

6 7 8 9

A

After installing a new fuel filter, check the oil pressure gauge carefully during test operation 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 been replaced, you need to bleed the fuel system.

2

Entlüft115.jpg

F F150C.GB 27-54 12.03

A

- Unfasten the bleed screw (Allen key) (2) behind and to the right of the filter bracket. - Operating manual pump (1) until fuel emerges from the bleed screw without any air bubbles. - Tighten bleed screw (1) back down. To bleed the fuel system after replacing the main filter, refer to the Engine operating instructions.

1

F 27

Batteries (16) When supplied, the batteries are filled with the correct amount of acid. The acid level should reach the upper mark. If necessary, top up with distilled water! The poles must be free of oxide. Protect them with special pole grease.

Chain tension - caterpillar drive (14)

Batt_150.jpg

The chain tensioner for the caterpillar drive chain is filled via the grease nipple (46) provided on the side of the caterpillar drive.

46

F0200_A1.TIF

approx. 105 mm

The chain tension is correct if the chain sags by approx. 105 mm between the chain plates and the chassis. Move the finisher forward or backward and measure again to check the setting.

F F150C.GB 28-54 12.03

F0199_A1.TIF

F 28

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, dangers or environmental hazards!

Checks by a specialist

A

Have the paver, screed and gas system inspected by a specialist

F F150C.GB 29-54 12.03

- 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.

F 29

4.2

Lube points on paver

Push rollers (22) Lubricate the push rollers on both sides (47).

A

The crossbeam is pivoted at the centre and needs not be lubricated. 47 F0016_A1.TIF

Steel hopper flaps (option) (21) The spring-loaded steel hopper flaps each have a central lube nipple.

21

F0188_A1-TIF

Conveyor deflection rollers (15) The deflection rollers for the conveyor are lubricated with grease nipples (48) located behind the cross beam.

A

48

These centre bearings are lubricated by the external grease nipples.

F F150C.GB 30-54 12.03

F0014_A1.TIF

F 30

Centre auger bearing (7) The centre bearing must be lubricated on the left-hand side of the auger. To do so, the bevel gear unit must be pulled off.

A

7

The centre bearing must be lubricated when in a warm state to force out any bitumen residues. F0015_A1.TIF

Auger external bearing (6) The grease nipples are located on either side above the external auger mounting points. These nipples must be lubricated each time work is finished.

A

The auger outer bearings must be lubricated when in a warm state to force out any bitumen residues.

Auger, gear neck bearing (9) Remove the Allen screw plug from the gear neck and replace the screw located underneath with a 10x1 grease nipple. Using a grease gun, inject 10 strokes into it.

6

Remove the grease nipple and screw both screws back in. The gear bearing is sealed at the underside and is exclusively lubricated with grease.

F F150C.GB 31-54 12.03

A

9 F0139_A1.TIF

F 31

Centre conveyor bearing (5) The grease nipple is located on the righthand side of the rear wall, above the conveyor gear. From this nipple, a lubrication line leads to the bearing. Lubricating the bearing is thus facilitated. 4.3

Oil drain points on the paver finisher

m

Collect used oil and have it disposed of properly.

A

For the filling volumes, see the section "Filling volumes".

5 F0135_A1.TIF

Pump distributor gear (11) Draining the oil:

11

12

- Remove screw cap. - Fit hose (accessories). Route the hose end into a used oil container. - Open the shut-off valve with a suitable wrench and completely drain the oil.

A

Filling with oil: refer to section "Inspection points / pump distributor gear".

Diesel engine (12)

Ablass_150.jpg

- Drain the transmission oil in the same manner as the pump distribution gear (see above). - Replacing the engine oil filter. The filter is located on the right side and can be accessed by removing the sealing cover from the cooling air suction intake.

Caterpillar-drive planetary gear (10)

49 F0113_A1.EPS

F 32

F F150C.GB 32-54 12.03

Screw out the oil drain plug (49) and collect the used oil in a container.

Auger bevel gear (8) To drain the oil, unscrew the lower screw (50). When returning the screw make sure to use a new seal.

m

Make sure to clean the screw and the vicinity of the drain bore!

A

For filling in oil, refer to the section "Check points/pump distribution gear".

50 F0139_A1.TIF

Hydraulic oil reservoir (20) 51

To drain the hydraulic oil, unscrew drain plug (51) and collect the oil in a suitable container using a spout. When returning the screw, make sure to use a new seal.

A

For filling in oil, refer to the section "Check points/hydraulic oil reservoir".

F0164_A1.TIF

Engine mounting (33) Check the engine mounting for any signs of damage, and check that it is securely attached. If necessary, replace any damaged components. Follow the instructions in the Engine operating instructions!

F F150C.GB 33-54 12.03

A

F 33

Hoses and hose connections (34) Carefully check all hoses on the engine and all hydraulic hoses for signs of damage and also check that they are properly secured.

m

Immediately replace any damaged hoses.

f

Ageing hoses become porous and may burst! Danger of accidents!

A

A number stamped on the hydraulic screw connection on these hydraulic hoses provides information on the date of manufacture (1) and the maximum permitted pressure (2) for each hose.

Pump.tif

1

2

Never install hoses on top of one another and always ensure that they are at the correct pressure.

F F150C.GB 34-54 12.03

f

DHH 09/00 225BAR

F 34

Filter mats (35) The filter mats used for cleaning intake air for engine and generator needs to be checked for signs of contamination every day before work starts. There three filter mats, one each:

m

- 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. Immediately replace badly contaminated filter mats because the paver finisher can only operate reliably if the engine and generator have an unobstructed supply of air.

35

F F150C.GB 35-54 12.03

F151C.wmf

F 35

Insulation test (36)

A

The insulation test must be undertaken every day when the machine is running and the sockets are activated. - Activate electrical system using switch (1), telltale (2) lights up. - Press test button (3) - "Insulation error" display must light up. - Press delete button (4) - display for insulation error goes out.

2

1 3

4

f

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

f

Danger from electric voltage Failure to comply with the safety precautions and safety regulations can result in electrical shock injuries from the electrical system. Danger to life! All maintenance and repair work on the screed's electrical system must always be carried out by an electrician.

F F150C.GB 36-54 12.03

f

If the test is completed successfully, work can proceed with the electrical system and external consumers can be used. However if the "Insulation error" indicator lamp displays an error even before the test button is pressed, work cannot proceed with the electrical system or with the external equipment connected up. If an insulation error occurs, the sockets are automatically de-energised (i.e. electriSchalt_230V.wmf/230V.wmf cally isolated). If no errors are displayed during simulation, do not carry out any work on the electrical system.

F 36

5

Checking, lubricating, oil drain points on the emulsion spraying equipment 24 25 26

27

29 31 30

32

27

28

F151C.wmf

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.

F F150C.GB 37-54 12.03

A

F 37

5.1

Emulsion pump (24) The emulsion pump is greased internally and externally (55) by means of 2 pairs of grease nipples.

52

53 54

55 Bild-13.tif

5.2

Emulsion filter (25) There are two steel filter cartridges in the filter housing (54). Clean these cartridges with diesel fuel after every paving job.

56

- Unfasten the cover clamping screw (56) and remove the cover, then rinse in diesel fuel in the cleaning tank to remove all residual traces of emulsion. Use a burner to score the steel filter cartridges once a week.

m

When burning off the steel filter inserts Bild-14.tif ensure that the filter screens (meshes) do not melt or distort. Never place the steel filter cartridges on the ground because this may cause stones to 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 seal the 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 funnel (52). Run the emulsion pump for some seconds. Then add another 3 litres of diesel fuel. Close the manual shut-off valve (53). During operation or when filling with emulsion, the manual shut-off valve must be closed!

F F150C.GB 38-54 12.03

f

F 38

5.3

Emulsion pump gear (26) Oil level check

A

Check the oil level of the emulsion pump gear every 500 operating hours. - Unscrew the inspection plug (60). When the oil level is correct, some oil will leak out. Otherwise, top up with oil. Oil change

A

Change the oil in the emulsion pump gear every two years or after 2000 operating hours.

57 58

- Unscrew the drain plug (59).

A

The transmission oil drains easier when it is warm.

60 58

- Fit the drain plug with a new seal (58) and tighten it firmly. - Fill in the required amount of transmission oil (see the section "Filling volumes") at the filler plug (57).

59

Pumpe.tif

Replace the seals of plugs that were opened.

F F150C.GB 39-54 12.03

A

58

F 39

5.4

Rotary joints of the flexible emulsion hoses (27) - The rotary joints must be greased separately (6 grease nipples on each side (61)).

m

Only move the flexible emulsion hoses when they are hot! 61

Bild-11.tif/Bild-12.tif

5.5

Spraying ramp (28)

A

Check the guide system of the spraying ramp for wear every two years or after 2000 operating hours.

28

F151C.wmf

5.6

Compressed air vessels (29) 62

- Open the manual drain valves (63) of the compressed air vessels (62) to drain the condensed water after work. - Close the manual drain valves (63) before starting work. Check the system for leaks and overall condition every two years or after 2000 operating hours.

63 63 Tanks.tif

F F150C.GB 40-54 12.03

A

62

F 40

5.7

Compressor air filter (30)

A

Clean/replace the air inlet filters every week 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

65 64 66 67 68

Replace the filter if it cannot be cleaned satisfactorily. - Clean the inside of the filter carrier (66) and the filter cap (68). - Mount the filter cartridge (67) on the carrier (66). - Mount the cap (68) and secure it with the screw (64) and the seal (65).

m

Every two years or every 2000 operating hours, install a new filter element (67) and a new gasket (65)!

5.8

Compressor oil cooler (31)

A

Clean the radiator honeycomb every 50 operating hours.

69

- Use compressed air to blow dust deposits off the radiator honeycombs (69). Luft.tif

Remove the compressor every 1000 operating hours or at least once a year and clean it from dust deposits.

F F150C.GB 41-54 12.03

A

F 41

5.9

Compressor (32) Oil level check

A

Check the compressor oil level every day. The sight glass (70) should be half covered.

m

Ensure that the compressor is depressurised. The pressure gauge must register zero. - 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 further until the compressor is no longer under pressure if oil or air leaks occur. 70

71 72

F F150C.GB 42-54 12.03

Kompres.tif

F 42

Oil change

A

Change the oil every 500 operating hours.

f

Danger of burns! We recommend to perform the oil change right after switching off the compressor as warm oil drains more conveniently. Heed all safety regulations pertaining to the handling of hot fluids. Wearappropriate protectiveclothingtopreventburnscaused by hot oil!

71 72

- Ensure that the compressor is depressurised. The pressure gauge must register ZERO.

A

Slowly unscrew the filler plug (71). Do not continue unscrewing the filler plug until the compressor is no longer under pressure if oil or air leaks occur.

73 74 Oelw.tif

F F150C.GB 43-54 12.03

- Unscrew the filler plug (71). Place a suitable oil pan under the filler plug (74) to collect the old oil. Unscrew the drain plug (74). Drain the old oil into the oil pan. - Fit a new seal (73), screw in the drain plug (74) and tighten it.

F 43

Oil filter change

A

Clean the oil filter (75) after having changed the compressor oil. - Slowly remove two Allen screws (78), remove the filter cover (77) and ensure that the O-ring groove is not damaged. - Take out the filter cartridge (79) and wash it with methylated spirit or paraffin. 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 the viewing 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

71 72

70

75

After the test run, the oil level should reach half way up the sight glass! If necessary, top up again with oil!

76 77 78 79 80

F F150C.GB 44-54 12.03

KOMPR2.tif

F 44

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.

Grease

BP

Esso

Multipurpose grease L2

ESSO Multipurpose grease

Total Fina (Total) Total Multis EP 2

Mobil

Renault

Shell

Wisura

Mobilux 2 Mobiplex 47

Multipurpose 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 4.1 Shell Tellus Oil 46 has been filled in at the factory.

Gear oil 90

Gear oil 220

BP Multi EP SAE 90

ESSO GP 90

BP Energol GR-XP 220

ESSO Spartan EP 220

Total EP 90

Total Carter EP 220

MOBIL GX 90

Tranself EP 90

SHELL Spirax G 80 W - 90

MOBIL Mobilgear 630 Mobil-gear SHC 220

Chevron NL Gear Compound 220

SHELL Omala 220

Optimol Optigear 220

Optimol Optigear 220 has been filled in at the factory. Dist. water Diesel fuel Brake oil/ Brake fluid

Ate Disk brake fluid

ELF Total HB F 4

Cooling liquid (anti-freeze and corrosion protection)

F F150C.GB 45-54 12.03

Coolant

BP Blue original Brake fluid

F 45

6.1

Filling volumens for paver finisher Substance

Filling volume

Diesel fuel

210 55.4 46.1

litres US gallons British gallons

Hydraulic oil reservoir

Hydraulic oil

185 48.8 40.6

litres US gallons British gallons

Diesel engine (with oil filter change)

Engine oil

13.0 3.4 2.9

litres US gallons British gallons

Cooling system

Coolant 40% anti-freeze

18.0 4.8 3.9

litres US gallons British gallons

Pump distribution gear

Gear oil 90

4.5 1.2 0.98

litres US gallons British gallons

Caterpillar drive planetary gear *

Gear oil 220

4.0 1.05 0.88

litres US gallons British gallons

Conveyor gear (each side)

Gear oil 220

1.5 0.4 0.32

litres US gallons British gallons

Auger bevel gear (each side)

Gear oil 90

0.6 0.15 0.13

litres US gallons British gallons

Central lubrication unit (option)

Grease

Batteries

Distilled water

F F150C.GB 46-54 12.03

Volume

F 46

7

Electric fuses

7.1

Main fuses (1) (beside the batteries)

1 Flap-l.EPS

1. 7.2

- F3.1 terminal box - F3.2 free

50 A 100 A

Fuses in the terminal box (beside the fuel tank)

1 2 3 4 5 6 7 8

2

9 10 11 12 13 14

QSBFuse.tif

...........

14 QSBFuse2.cdr

F F150C.GB 47-54 12.03

26

F 47

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

F 48

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 F150C.GB 48-54 12.03

F7.1 - F7.7

7.3

Fuses on the operating panel

3

4

! -

+

Element3_sps150C.cdr

Fuse carrier (3)

Fuse1.Tif

2

3

4

5

6

7

8

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

F F150C.GB 49-54 12.03

No.

1

F 49

Fuse carrier (4)

Fuse1.Tif

1

2

3

4

5

6

7

8

No. F2.1 - F 2.8

A

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

F F150C.GB 50-54 12.03

1.

F 50

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 ManufacGrease turer

8.2

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

Transmission oil ManufacTransmission oil turer 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 F150C.GB 51-54 12.03

BP

F 51

8.3

Compressor oil 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

8.4

Filling volumes Substance Emulsion pump gear drives

Gear oil 90

3.5 0.92 0.77

litres US gallons British gallons

Compressor oil

4.3 1.13 0.94

litres US gallons British gallons

F F150C.GB 52-54 12.03

Compressor

Filling volume

F 52

9

Electrical fuses / relays on emulsion spraying equipment

81 82 83 84 85 86

87

88

Bild-2.tif

9.1

Fuses/relays in the spraying system switch cabinet

A

The fuses/relays are located behind the instrument panel. Fuses Item

Protected unit(s)

Rating

81

- Main fuse

10 A

82

- Spraying/ramp movement

3A

83

- Valves for compressed air cleaning

3A

84

- Emulsion pump/compressor

5A

85

- Extendable parts of the spraying ramp

5A

86

- Valves of the spraying nozzles

3A

Relays

F F150C.GB 53-54 12.03

Item

Function

Basic setting

87

- Timer relay for the compressor

approx. 10 s

88

- Timer relay for semi-automatic operation

approx. 2 s

F 53

9.2

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

89

93

91 Ultschall.tif 92

SchaltschrF150_2.cdr/E-Schr_F150.jpg

The fuses are located behind the instrument panel.

f

Caution: High voltage: danger to life!

f

F 54

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 II

35 A (3 units)

Danger from electric voltage Failure to comply with the safety precautions and safety regulations can result in electrical shock injuries from the electrical system. Danger to life! All maintenance and repair work on the screed's electrical system must always be carried out by an electrician.

F F150C.GB 54-54 12.03

A