4812026361en PDF

OPERATION
&
MAINTENANCE
Paver finisher
SD 115 C
SD 135 C
Typ 35
Keep this manual for future reference

Order number for this manual: 4812026362
01-0109
35........................
VALUE
QUALITY
THE ORIGINAL
Your Authorized Dynapac Dealer:

Table of contents
V Preface ..................................................................................... 1
1 General safety instructions ........................................................................ 2
1.1 Acts, directives, accident prevention regulations ....................................... 2
1.2 Warning instructions .................................................................................. 2
1.3 Prohibitive signs ......................................................................................... 4
1.4 Protective gear ........................................................................................... 5
1.5 Environmental protection ........................................................................... 6
1.6 Fire prevention ........................................................................................... 6
1.7 Further instructions .................................................................................... 7
A Correct use and application ................................................... 1
B Vehicle description ................................................................. 1

1 Application ................................................................................................. 1
2 Description of assemblies and functions .................................................... 2
2.1 Vehicle ....................................................................................................... 3
Construction ........................................................................................... 3
3 Danger zones ............................................................................................. 6
4 Safety devices ............................................................................................ 7
4.1 Emergency stop button (1) ......................................................................... 7
4.2 Steering system (2) .................................................................................... 7
4.3 Horn (3) ...................................................................................................... 7
4.4 Ignition key (4) ........................................................................................... 7
4.5 Lights (5) .................................................................................................... 7
4.6 Main switch (10) ........................................................................................ 8
4.7 Hopper transport safeguards (11) ............................................................. 8
4.8 Screed transport safeguards (12) .............................................................. 8
4.9 Latch for protective roof (o) (13) ................................................................ 9
5 Technical data, standard configuration .................................................... 11
5.1 Dimensions (all dimensions in mm) ......................................................... 11
5.2 Allowed angle of rise and slope ............................................................... 12
5.3 Permissible approach angle ..................................................................... 12
5.4 Weights, SD 115 C (all data in t) .............................................................. 13
5.5 Weights, SD 135 C (all data in t) .............................................................. 13
5.6 Performance data for the SD 115 C ......................................................... 14
35_SD115C_SD135C_OMM_PLC_01_GBIVZ.fm
5.7 Performance data for the SD 135 C ......................................................... 15

5.8 Travel drive/traction unit ........................................................................... 16
5.9 Engine SD 115 C ..................................................................................... 16
5.10 Engine SD 135 C ..................................................................................... 16
5.11 Hydraulic system ...................................................................................... 16
5.12 Material compartment (hopper) ................................................................ 17
5.13 Material transfer ....................................................................................... 17
5.14 Material distribution .................................................................................. 17
5.15 Screed lifting device ................................................................................. 18
5.16 Electrical system ...................................................................................... 18
5.17 Permissible temperature ranges .............................................................. 18
1-8
1
6 Location of instruction labels and identification plates ............................. 19
6.1 Identification label for the paver finisher (6) .......................................... 21
7 EN standards ........................................................................................... 22
7.1 Continuous sound pressure level on the SD 115 C, Deutz TCD 2013L0622
7.2 Operating conditions during measurement .............................................. 22
7.3 Measuring point configuration .................................................................. 22
7.5 Operating conditions during measurement .............................................. 23
7.6 Measuring point configuration .................................................................. 23
C1.9 Transport ................................................................................. 1

1 Safety regulations for transportation .......................................................... 1
2 Transportation on low-bed trailers ............................................................. 2
2.1 Preparations ............................................................................................... 2
2.2 Driving onto the low-bed trailer .................................................................. 4
2.3 Secure the paver finisher to the low-bed trailer: ........................................ 4
2.4 After transportation .................................................................................... 5
3 Protective roof (o) ...................................................................................... 6
4 Transportation ............................................................................................ 7
4.1 Preparations ............................................................................................... 7
4.2 Driving mode .............................................................................................. 9
5 Loading by crane ..................................................................................... 10
6 Towing ..................................................................................................... 12
7 Safely parking the vehicle ........................................................................ 15
D1.12 Operation ................................................................................. 1

1 Safety regulations ...................................................................................... 1
2 Controls ...................................................................................................... 2
2.1 Operating panel ........................................................................................ 2
3 Remote control ......................................................................................... 42
35_SD115C_SD135C_OMM_PLC_01_GBIVZ.fm 2-
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2
D2.2 Operation ................................................................................. 1
1 Operation of the input and display terminal ............................................... 1
Key layout on the display ....................................................................... 1
1.1 Menu operation .......................................................................................... 2
Menu structure of the setting and display options ................................. 3
Main menu 00 ........................................................................................ 4
Display and function menu .................................................................... 4
Menu 01 - Diesel speed ......................................................................... 5
Sub-menu 101 - Diesel speed set-up .................................................... 5
Menu 02 - Drive engine measured values ............................................. 6
Sub-menu 103 - Drive engine measured value display ......................... 6
Menu 03 - Distance and fuel display ...................................................... 7
Sub-menu 301 - Display/reset distance travelled, fuel consumption .... 7
Menu 04 - Emergency function / screed stop and tamper start ............. 8
Sub-menu 401 - Emergency function setting ........................................ 8
Menu 05 - Paving thickness ................................................................... 9
Sub-menu 501 - Paving thickness preselection .................................... 9
Sub-menu 502 - Auger speed setting ................................................. 10
Sub-menu 503 - Conveyor speed setting ........................................... 10
Menu 06 - Delayed screed start ........................................................... 11
Sub-menu 102 - Start-up charging setting .......................................... 11
Menu 07 - Screed type ........................................................................ 12
Sub-menu 701 - Screed type setting .................................................. 12
Menu 08 - Operating hour meter ......................................................... 13
Menu 09 - Service ................................................................................ 14
Sub-menu 201 - Password prompt ..................................................... 14
Menu 10 - Error memory ...................................................................... 15
Display error messages: ..................................................................... 16
Error display ......................................................................................... 16
Menu 11 - Programme version ............................................................ 17
Menu 12 - Terminal settings ................................................................ 18
Sub-menu 104 - Terminal settings ...................................................... 18
Menu 13 - Key function test ................................................................. 19
Sub-menu 107 - Key function test ...................................................... 19
1.2 Further displays ....................................................................................... 20
2 Terminal error messages ......................................................................... 21
2.1 Notes on error messages ......................................................................... 29
2.2 Drive engine error codes .......................................................................... 30
2.3 Error codes .............................................................................................. 32
2.4 FMI codes ................................................................................................ 37

2.5 Special functions ...................................................................................... 38
Emergency programme on keyboard failure ........................................ 38
Reversible conveyor ............................................................................ 40
3-8
3
D3.8 Operation ................................................................................. 1
1 Operating elements on the paver finisher .................................................. 1
1.1 Operating elements on the operator's control station ................................ 1
Protective roof (o) .................................................................................. 1
Protective roof (o) .................................................................................. 2
Windscreen wiper (o) ............................................................................. 2
Control panel ........................................................................................ 3
Telescoping seat console (o) ................................................................. 3
Storage compartment ............................................................................ 3
Driver's seat, type I ............................................................................... 4
Driver's seat, type II .............................................................................. 5
Fuse box ................................................................................................ 6
Batteries ................................................................................................. 7
Main battery switch ................................................................................ 7
Hopper transport safeguard ................................................................... 8
Paving thickness indicator .................................................................... 9
Engine compartment lighting ................................................................. 9
Auger height adjustment ratchet (o) .................................................... 10
Auger height indicators (o) .................................................................. 10
Screed transport safeguard ................................................................. 11
Sensor rod / sensor rod extension ....................................................... 12
Separator fluid spraying system (o) ..................................................... 13
230 V system (o) ................................................................................. 14
Conveyor limit switches ....................................................................... 15
Ultrasonic auger limit switches (left and right) ..................................... 16
24 volt / 12 volt sockets (o) (left and right) ........................................... 16
Pressure control valve for screed charging/relieving ........................... 17
Pressure control valve for screed stop with pretensioning .................. 17
Manometer for screed charging/relieving and screed stop
with pretensioning ................................................................................ 17
Central lubrication system (o) .............................................................. 18
Lane clearer (o) ................................................................................... 19
Screed eccentric adjustment (o) .......................................................... 20
Fire extinguisher (o) ............................................................................. 21
Rotary beacon (o) ................................................................................ 21
Auger compartment lighting (o) ........................................................... 22
Fuelling pump (o) ................................................................................. 23
Power moon (o) ................................................................................... 24
8
4
D4.17 Operation ................................................................................. 1
1 Preparing for operation .............................................................................. 1
Required devices and aids .................................................................... 1
Before starting work (in the morning or when starting paving) .............. 1
Check list for the machine operator ....................................................... 2
1.1 Starting the paver finisher .......................................................................... 4
Before starting the paver finisher ........................................................... 4
„Normal“ starting .................................................................................... 5
External starting (starting aid) ................................................................ 6
After starting .......................................................................................... 7
Observe indicator lamps ........................................................................ 8
Oil pressure indicator lamp for the travel drive (79) ............................... 8
Battery charge indicator (70) ................................................................. 9
1.2 Operation in case of transportation .......................................................... 10
Lifting and securing the screed ............................................................ 10
Driving and stopping the paver finisher .............................................. 11
Switching off and securing the paver finisher ...................................... 11
1.3 Preparations for paving ............................................................................ 12
Separator fluid ..................................................................................... 12
Screed heater system .......................................................................... 12
Direction marks .................................................................................... 12
Loading/distributing material ............................................................... 13
1.4 Driving off for laying ................................................................................. 15
1.5 Checks during paving .............................................................................. 17
Paver function ...................................................................................... 17
Quality of the layer ............................................................................... 17
1.6 Paving with screed stop and screed charging/relieving ........................... 18
General ................................................................................................ 18
Screed charging/relieving .................................................................... 18
Screed stop with prestressing .............................................................. 19
Adjusting the pressure (o) .................................................................... 21
Screed stop (with prestressing): .......................................................... 21
For screed charging/relieving: ............................................................. 22
1.7 Interrupting/terminating operation ............................................................ 23
During breaksin paving (e.g. the material supply truck is late) ............ 23
During longer breaks(e.g. lunch break) ............................................... 23
When work is finished .......................................................................... 24
2 Malfunctions ............................................................................................. 26
2.1 Problems during paving ........................................................................... 26
2.2 Malfunctions on the paver finisher or scree ............................................. 28

3 Emergency device/steering, travel drive .................................................. 31
5-8
5
E04 Set-up and modification ......................................................... 1
1 Special notes on safety .............................................................................. 1
2 Distribution auger ....................................................................................... 2
2.1 Height adjustment ...................................................................................... 2
Grain sizes up to 16 mm ........................................................................ 2
Grain sizes > 16 mm .............................................................................. 2
2.2 Mechanical adjustment with ratchet (o) ..................................................... 3
2.3 Hydraulic adjustment (o) ............................................................................ 3
2.4 Height adjustment for large working widths / with brace ............................ 4
3 Auger extension ......................................................................................... 5
3.1 Mounting extension parts ........................................................................... 6
Mounting the material shaft and auger extension .................................. 6
Mounting the outer auger bearing .......................................................... 7
Mounting the auger end bearing ............................................................ 8
3.2 Auger extension chart ................................................................................ 9
Auger upgrading as of 3.14 m ............................................................. 10
3.3 Mounting the auger brace ........................................................................ 17
3.4 Aligning the auger .................................................................................... 19
4 Levelling ................................................................................................... 20
4.1 Slope controller ........................................................................................ 20
4.2 Mounting the sensor arm ......................................................................... 21
4.3 Mounting the grade control system .......................................................... 21
4.4 Setting up the sensor arm ........................................................................ 22
4.5 Big ski 9 m, big ski 13 m ......................................................................... 23
Mounting the big ski bracket on the crossbeam .................................. 25
Mounting the swivel arms .................................................................... 26
Mounting the centre element ............................................................... 27
Extending the big ski ............................................................................ 28
Mounting the sensor bracket ............................................................... 29
Mounting and aligning the sensors ...................................................... 30
Mounting the distributor box ................................................................ 31

Connection diagram ............................................................................. 31
5 Automatic steering unit ............................................................................ 32
5.1 Mounting the automatic steering unit on the paver finisher ..................... 33
Mounting and aligning the sensor ........................................................ 33
Connecting the sensor ......................................................................... 33
Automatic steering unit operating instructions ..................................... 34
6 Limit switch .............................................................................................. 35
6.1 Mounting the auger limit switch ................................................................ 35
7 Screed ...................................................................................................... 36
8 Electrical connections .............................................................................. 36
8.1 Connect remote controls .......................................................................... 36
8.2 Connect grade control .............................................................................. 36
8.3 Connect auger limit switches ................................................................... 36
8
6
F1.0 Maintenance ............................................................................ 1
1 Notes regarding safety ............................................................................... 1
F2.14 Maintenance review ................................................................ 1

1 Maintenance review ................................................................................... 1
F3.6 Maintenance - Conveyor ........................................................ 1

1 Maintenance - Conveyor ............................................................................ 1
1.1 Maintenance intervals ................................................................................ 2
1.2 Points of maintenance ............................................................................... 3
Chain tension, conveyor (1) ................................................................... 3
Conveyor gears (left/right) (2) ................................................................ 5
Conveyor deflectors / conveyor plates (3) ............................................. 6
F4.3 Maintenance - Auger ............................................................... 1

1 Maintenance - Auger .................................................................................. 1
Outer auger bearing (1) ......................................................................... 3
Auger planetary gear (2) ........................................................................ 3
Auger drive chains (3) ............................................................................ 4
Auger box (4) ......................................................................................... 6
Auger blade (5) ...................................................................................... 8
F5.6 Maintenance - Engine ............................................................. 1

1 Maintenance - Engine ................................................................................ 1
Engine fuel tank (1) ............................................................................... 4
Engine lube-oil system (2) .................................................................... 5
Engine fuel system (3) .......................................................................... 7
Engine air filter (4) ................................................................................. 9
Engine cooling system (5) ................................................................... 10
Engine drive belt (6) ............................................................................. 10
F6.3 Maintenance - Hydraulic system ........................................... 1

1 Maintenance - Hydraulic system ................................................................ 1
Hydraulic oil tank (1) .............................................................................. 3
Suction/return flow hydraulic filter (2) .................................................... 4
Bleeding the filter ................................................................................... 5
High-pressure filter (3) ........................................................................... 6
Pump distribution gear (4) ..................................................................... 7
Hydraulic hoses (5) ................................................................................ 8
Auxiliary flow filter (6) ............................................................................. 9
7-8
7
F7.9 Maintenance – Drive units ...................................................... 1
1 Maintenance – Drive units ......................................................................... 1
Chain tension (1) ................................................................................... 4
Bottom plates (2) ................................................................................... 6
Rollers (3) .............................................................................................. 6
Planetary gear (4) .................................................................................. 7
F8.8 Maintenance - Electronic system .......................................... 1

1 Maintenance - Electronic system ............................................................... 1
Batteries (1) ........................................................................................... 5
Alternator (2) .......................................................................................... 6
Electric fuses / relays (3) ..................................................................... 10
Fuses in terminal box (B) .................................................................... 11
Relays in terminal box (C) .................................................................. 13
F9.1 Maintenance - Lubricating points .......................................... 1

1 Maintenance - Lubricating points ............................................................... 1
Central lubrication system (1) ................................................................ 3
Bearing points (2) .................................................................................. 7
F10.0 Checks, decommissioning ..................................................... 1

1 Tests, check-up, cleaning, stopping ........................................................... 1
2 General observation ................................................................................... 3
3 Checks by a specialist ............................................................................... 3
4 Cleaning ..................................................................................................... 4
5 Conservation of paver finisher ................................................................... 5
5.1 Downtime up to 6 months .......................................................................... 5
5.2 Downtime between 6 months and 1 year. .................................................. 5
5.3 Re-commissioning: .................................................................................... 5
F11.5 Lubricants and operating substances .................................. 1

1 Lubricants and operating substances ....................................................... 1
1.1 Hydraulic oils .............................................................................................. 2
1.2 Capacities .................................................................................................. 3
2 Notes on switching from mineral oil to synthetic oil /
synthetic oil to mineral oil ........................................................................... 6
2.1 Drive unit planetary gear ............................................................................ 6
8
8
V Preface
Translation of the original operating instructions.
Safe operation of the machine requires specific knowledge that is imparted by the
present operating instructions. The information is provided in a concise, clearly struc-
tured form. The individual chapters are arranged in alphabetical order and every
chapter starts with page 1. The individual pages are identified by the chapter letter
and the page number.
Example: Page B 2 is the second page of chapter B.
These operating instructions cover various machine options. Make sure that during
operation and maintenance work the description appropriate to the machine option is
used.
Safety instructions and important notes are identified by the following pictograms:
f Precedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
m Precedes notes that must be observed to prevent damage to equipment.
A Precedes general notes and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
In the interest of continued development, the manufacturer reserves the right to make
changes to the machine (which will not, however, change the essential features of the
type of machine described) without updating the present operating instructions at the
same time.
Dynapac GmbH
Wardenburg
Ammerländer Strasse 93
D-26203 Wardenburg / Germany
Telephone: +49 / (0)4407 / 972-0
Fax: +49 / (0)4407 / 972-228
V_01_GB.fm
www.dynapac.com
V1
1 General safety instructions
1.1 Acts, directives, accident prevention regulations
A The locally applicable acts, directives and accident prevention regulations shall be
observed, even if the attention is not specifically directed to these.
The operator himself shall be responsible for the observation and performance of the
related regulations and actions!
A The following alerts, prohibitions and instructions refer to the risks to which people,
machinery and environment are exposed.
A Ignoring these instructions, bans and commands may lead to fatal injuries!
A Furthermore, the Dynapac publication "Directives for the correct and specified appli-
cation of pavers" shall also be observed.
1.2 Warning instructions
Warning pointing to hazardous place or danger!

Not observing the warning instructions may lead to injuries of life
and limb!
Warning: risk of pulling in!
m In this area / with these equipment as a result of rotating or trans-

portation parts, there is a risk of pulling in!
Perform each operation only with equipment swicthed off!
Attention: electric voltage!
m All maintenance and repair work on the screed's electrical system

must always be carried out by an electrician!
Attention: suspended load!
m Never stand under suspended load!
Warning: risk of squeezing!
m Risk of squeezing arises due to the operation of certain parts, use

of some functions and the movement of the machine.
Always make sure that no one stays in the areas exposed to risk!
V_01_GB.fm
V2
Attention: risk of hand injury!
Attention: hot surfaces or hot liquids!
Warning, risk of falling off!
Attention: hazardous batteries!
Attention: materials harmful to health and irritating substances!
Attention: flammable materials!
Attention: gas bottles!

V_01_GB.fm
V3
1.3 Prohibitive signs
It is prohibited to open / step on / reach into / perform / adjust

during operation or when the traction engine is running!
Do not start the engine/drive!

Maintenance and repair works can be carried out only with the Die-
sel engine turned off!
Do not sprinkle with water!
Do not extinguish with water!
Do-it-yourself maintenance is prohibited!

Maintenance can be performed by skilled professionals only!
A Contact the Dynapac service!
Danger of fire: do not use open flame and no smoking!
Do not turn on!

V_01_GB.fm
V4
1.4 Protective gear
A The applicable local regulations may define the use of different protective gear!
Observe these specifications!
Protect your eyes with googles!
Wear appropriate head protection!
Protect your hearing with appropriate ear mufflers!
Protect your feet with safety footwear!
Always wear tight, conforming working coveralls!

Wear visibility vest for good visibility!
In case of polluted air, wear respiratory mask!

V_01_GB.fm
V5
1.5 Environmental protection
A The locally applicable acts, directives and waste disposal regulations shall be ob-
served, even if the attention is not specifically directed to these.
During cleaning, maintenance and repair operation the materials polluting water e.g.:
- lubricants (oils, grease)

- hydraulic oil
- gas oil
- coolant
- detergents
may not enter the soil or the sewer system!
These materials shall be collected, stored, transported in the correct

containers until professional disposal!
Material harmful for the environment!
1.6 Fire prevention
A The applicable local regulations may specify the mounting of appropriate fire extin-
guishers!
Observe these specifications!
Fire fighting device

(optional equipment)
V_01_GB.fm
V6
1.7 Further instructions
m Observe the manufacturer's and other instructions!
A e.g. the maintenance instructions of the engine manufacturer
m Description / figure in case of an electrically heated design!
m Description / figure in case of an electrically heated design!

V_01_GB.fm
V7
A Correct use and application
A The “Guidelines for the Correct Use and Application of Paver finishers” compiled by
Dynapac are included in the scope of delivery for the present machine. The guide-
lines are part of the present operating instructions and must always be heeded. Na-
tional regulations are fully applicable.
The road construction machine described in the present operating instructions is a

paver finisher that is suited for laying mixed materials, roll-down concrete or lean-
mixed concrete, track-laying ballast and unbound mineral aggregates for foundations
for paving.
This machine shall be used, operated and maintained for the purpose of the intended
work as included in the operation manual. Any other use is regarded as improper use
and can cause injury to persons or damage to the paver finisher or other equipment
or property.
Any use going beyond the range of applications described above is regarded as im-
proper use and is expressly forbidden! Especially in those cases where the paver fin-
isher is to be operated on inclines or where it is to be used for special purposes
(construction of dumps, dams), it is absolutely necessary to contact the manufacturer.
Duties of the user: A “user” within the meaning of the present operating instructions
is defined as any natural or legal person who either uses the paver finisher himself,
or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is
considered the person who, in accordance with existing contractual agreements be-
tween the owner and the user of the paver finisher, is charged with the observation
of the operating duties.
The user must ensure that the paver finisher is only used in the stipulated manner and
that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance guide-
lines are observed. The user must also ensure that all persons operating the equip-
ment have read and understood the present operating instructions.
Mounting of attachments: The paver finisher must only be operated in conjunction

with screeds that have been approved by the manufacturer. Mounting or installation
of any attachments that will interfere with or supplement the functions of the paver fin-
isher is permitted only after written approval by the manufacturer has been obtained.
If necessary, the approval of local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
A_01_GB.fm 1-2
A1
B Vehicle description
1 Application
The Dynapac SD 115 C / SD 135 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.
2009_Iso.wmf
B_SD115C_SD135C_01_EN.fm 1-24
B1
2 Description of assemblies and functions
15
16
13 14
19
18
8 4 10 11 12
2
6 7 5 9
2009_ISO.bmp
3 17
Item Designation
1 t Material compartment (hopper)
2 t Truck push rollers
Tube for sensor rod (direction indicator) and holder for levelling
3 t
shoe
4 t Caterpillar drive
5 t Levelling cylinder for paving thickness
6 t Traction roller
7 t Traction arm rail
8 t Paving thickness indicator
9 t Crossbeam
10 t Travel drive of the caterpillar drive
11 t Auger
12 t Screed
B_SD115C_SD135C_01_EN.fm 2-24
13 t Operator’s platform
14 t Operating panel (can be moved to either side)
15 o Protective roof
16 o Working lights
17 o Lane cleaner
18 o Hydraulic front hopper flap
19 o Asphalt fume control system
t = Standard equipment o = Optional equipment

B2
2.1 Vehicle
Construction
The paver finisher has a welded steel frame on which the individual components are
mounted.
The caterpillar drives compensate uneven areas on the ground; the suspension of the
attached screed additionally helps to attain high paving precision.
The continuously adjustable hydrostatic travel drive allows the speed of the paver fin-
isher to be matched to all work conditions.
The operation of the paver finisher is considerably facilitated by the automatic mate-
rial handling system, the independent travel drives and the clearly structured operat-
ing components and controls.
The following extra equipment (option) is available:
o Automatic levelling/slope control system
o Ultrasonic sensors for material transfer (controller)
o Additional cut-off shoe
o Larger working widths
o Automatic central lubrication system for the paver finisher and/or the screed
o Protective roof
o Further equipment and upgrade options on request
Engine: The paver finisher is driven by a water cooled diesel engine. For further de-
tails see the technical data and the engine's instruction manual.
Drive unit: Both caterpillar drives are directly driven by separate drives. They operate
directly, without any drive chains which require maintenance or servicing.
The tension of the caterpillar chains can be readjusted using tensioners.
A swivelling lane cleaner (o), which ensures an even passage during paving, is lo-
cated in front of each of the drive units. Small obstacles lying in the lane are cleared
away to the side.
Hydraulic system: The diesel engine drives the hydraulic pumps for all main paver
B_SD115C_SD135C_01_EN.fm 3-24
finisher drives via the attached distribution gear and its auxiliary drive shafts.
B3
Travel drive: The continuously adjustable travel drive pumps are connected to the
travel drive engines by means of high pressure hydraulic hoses.
These hydraulic motors drive the caterpillar chains via planetary gears that are
mounted directly inside the drive wheels of the caterpillar chains.
Steering system/operator's platform: The independent hydrostatic travel drives al-

low the paver finisher to be turned on the spot.
The electronic synchronisation, controlled from the operating panel, ensures that the
paver 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 crossbar: The push rollers for material trucks are fastened to a crossbar
that is pivoted at its centre.
This crossbar allows different distances to the rear wheels of material trucks to be
compensated. The paver finisher thus deviates less from its course and paving in
curves is made easier.
Material compartment (hopper): The hopper inlet is equipped with a conveyor sys-
tem that empties the hopper and transfers the material to the auger.
The hopper can hold approx. 13.0 t.
To facilitate emptying and to improve material transfer, each of the lateral covers of
the hopper can be hydraulically moved (option).
The hydraulic front hopper flaps (o) ensure that no material remains at the front of
the feeding hoppers.
Material transfer: The paver finisher is equipped with two conveyors driven sepa-
rately that transfer the material from the hopper to the augers.
By scanning the filling height during the paving procedure, the transfer amount or
speed is regulated fully automatically.
Augers: The augers are driven and actuated independently from the conveyors. The
left-hand and the right-hand half of the auger can be controlled separately. The drive
system is fully hydraulic.
The conveying direction can be changed towards the centre or towards the outside.
This ensures that there is always a sufficient supply of material even if an excessive
amount of material is required at one side. The auger speed is continuously controlled
by sensors that monitor the material flow.
Height adjustment and extension of augers: Height adjustment and extension of

augers ensure optimum adaptation to a wide range of paving thicknesses and widths.
The basic configuration allows the height to be adjusted by attaching chains to the
traction crossbeams and by actuating the hydraulic screed lifting device.
B_SD115C_SD135C_01_EN.fm 4-24
When using ratchets for height adjustment (option), barrel nuts at the guide supports
in the rear wall are used to adjust the height.
Another variant allows the height to be regulated at the operating panel by means of
hydraulic cylinders (option).
Auger segments of different lengths can be attached to easily adapt to the different
paving widths.
B4
Levelling/slope control system: The slope control system (option) allows the trac-
tion point to be regulated at the left-hand or the right-hand side with a defined differ-
ence to the opposite side.
To determine the actual value, the two traction crossbeams are linked with a slope
control rod.
The slope control system always operates in conjunction with the screed height ad-
justment of the opposite side.
By adjusting the height of the traction point of the crossbeam (traction roller), the pav-
ing thickness of the material or the laying height of the screed can be controlled.
Actuation occurs electro-hydraulically on both sides and can be controlled manually
by means of toggle switches or automatically by means of an electronic grade control
system.
Screed lifting device: The screed lifting device is used to lift the screed during trans-
portation. Lifting occurs electro-hydraulically on both sides by actuating the hydraulic
cylinders on the crossbeams and is controlled by means of toggle switches on the op-
erating 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 screed remains in floating posi-
tion and relief pressure is applied, thus preventing the screed from sinking while sta-
tionary.
The screed relieving device puts a higher load on the traction unit, thus increasing the
traction.
Activating the screed charging device can improve the compacting result under dif-
ferent paving conditions.
Central lubrication unit (o): The central lubrication pump fitted with a large lubricant
tank supplies grease to the various lubrication circuits through various flow dividers.
They supply lubricant to the service-sensitive points of lubrication (e.g. bearings) at
adjustable intervals.
B_SD115C_SD135C_01_EN.fm 5-24
B5
3 Danger zones
m In these working areas for the machine, there may be a risk of drawing in or crushing
during normal operation caused by rotating and conveying elements, or by compo-
nents in motion.
B_SD115C_SD135C_01_EN.fm 6-24
B6
4 Safety devices
Safe operation is only possible when all operating and control elements are function-
ing correctly and when all safety devices are in position.
A Check the function of these devices at regular intervals. (See chapter D, section 2.1).
5
1
2
Bedienpult2_2009_PLC_C.bmp
4.1 Emergency stop button (1)
- on the operating panel

- on both remote controls
m Pressing the emergency stop button switches the engine, the drives and the steering
system off. Corrective measures that might be necessary (anti-collision manoeuvres,
lifting the screed, etc.) are not possible in this case! Danger of accidents!
4.2 Steering system (2)
4.3 Horn (3)
- On the operating panel

- on both remote controls
B_SD115C_SD135C_01_EN.fm 7-24
4.4 Ignition key (4)
4.5 Lights (5)
B7
4.6 Main switch (10)
10
Batterie2_2009.wmf
4.7 Hopper transport safeguards (11)
11
Hopperlock_2009.wmf
4.8 Screed transport safeguards (12)
A During transportation, when the vehicle

is switched off or in the event of damage,
the screed is held in position via a non-
return valve.
12
B_SD115C_SD135C_01_EN.fm 8-24
Screedvalve.wmf
B8
4.9 Latch for protective roof (o) (13)
13
13
Dach_2009.wmf
B_SD115C_SD135C_01_EN.fm 9-24
B9
21 22
20
25
24
23
635_side_DEM.bmp/Feuerlöscher.bmp
Item Designation
20 Fire extinguisher (o)
21 Engine panels
22 Lateral flaps
23 Walkway
24 Screed coverings
25 Screed hazard flasher
Accessories:
- Wheel chocks
- Warning triangle
- First aid box
B_SD115C_SD135C_01_EN.fm 10-24
B 10
5 Technical data, standard configuration
5.1 Dimensions (all dimensions in mm)
2070
1900
3870
3100
2710
R6
1700
7
490
1140 2840
6200*
6530*
305
1990
B_SD115C_SD135C_01_EN.fm 11-24
2550
3290
3390
*VB 5100
635_side_DEM.bmp,635_front_DEM.bmp
A For screed technical data, refer to the screed operating instructions.
B 11
5.2 Allowed angle of rise and slope
max. 15° max. 15° max. 15°
A Before operating your machine in an inclined position (gradient, slope, lateral inclina-
tion) which is above the specified limit value, please consult the customer service de-
partment for your machine!
5.3 Permissible approach angle
max. 14°
14°
14°
B_SD115C_SD135C_01_EN.fm 12-24
B 12
5.4 Weights, SD 115 C (all data in t)
Paver finisher without screed approx. 16.5

Paver finisher with screed:
- VB 5100 approx. 20.0
With extension parts for max.
approx. 5.5
working width, additionally max.:
With filled hopper
approx. 13.0
Additionally max.
A For the weights of the screed and the screed attachments, see the operating instruc-
tions for the screed.
5.5 Weights, SD 135 C (all data in t)
Paver finisher without screed approx. 16.5

Paver finisher with screed:
- VB 5100 approx. 20.0
With extension parts for max.
approx. 7.2
working width, additionally max.:
With filled hopper
approx. 13.0
Additionally max.
A For the weights of the screed and the screed attachments, see the operating instruc-
tions for the screed.
B_SD115C_SD135C_01_EN.fm 13-24
B 13
5.6 Performance data for the SD 115 C
Continuously hydraulically
Maximum working widths

Minimum paving width
(without cut-off shoes)
(with extension parts)

(with cut-off shoe)
adjustable up to
Screed used
VB 5100 2.55 Basic width 2.00 5.10 8.10 m

VB 6000 3.00 2.45 6.00 8.20 m
VB 805E Plus 2.50 2.00 5.00 8.00 m
Transport speed 0 - 4.5 km/h

Operating speed 0 - 25 m/min
Paving thickness 0 - 300 mm
Max. grain size 40 mm
Theoretical paving performance 750 t/h
B_SD115C_SD135C_01_EN.fm 14-24
B 14
5.7 Performance data for the SD 135 C
Continuously hydraulically
Maximum working widths

Minimum paving width
(without cut-off shoes)
(with extension parts)

(with cut-off shoe)
adjustable up to
Screed used
VB 5100 2.55 Basic width 2.00 5.10 8.80 m

VB 6000 3.00 2.45 6.00 9.0 m
SB 1250 3.00 2.10 - 10.0 m
VB 805E Plus 2.50 2.00 5.00 8.00 m
VB 1105E Plus 3.00 2.50 6.00 9.00 m
Transport speed 0 - 4.5 km/h

Operating speed 0 - 25 m/min
Paving thickness 0 - 300 mm
Max. grain size 40 mm
Theoretical paving performance 750 t/h
B_SD115C_SD135C_01_EN.fm 15-24
B 15
5.8 Travel drive/traction unit
Drive Hydrostatic drive, continuously controllable

Two separately driven caterpillar drives with rub-
drive unit
ber grouser chains
Turning capacity Turning on the spot
Speed See above
5.9 Engine SD 115 C
Make/type Deutz TCD 2013 L06 2V

Version 6-cylinder diesel engine (water-cooled)
Performance 120 kW / 163 hp (at 1800 rpm)
Fuel tank capacity (See chapter F)
5.10 Engine SD 135 C
Make/type Deutz TCD 2013 L06 2V

Version 6-cylinder diesel engine (water-cooled)
Performance 140 kW / 190 hp (at 1800 rpm)
Fuel tank capacity (See chapter F)
5.11 Hydraulic system
Hydraulic pumps via distribution gear

Pressure generation
(directly flanged to the engine)
Hydraulic circuits for:
- Travel drive
- Material transfer and distribution
Pressure distribution - Screed lifting drives for tamper / vibration
- Cylinder actuators for steering, hopper, level-
ling, screed lifting, extending/retracting screed
parts, auger lift (option)
Hydraulic oil reservoir - volume (See chapter F)
B_SD115C_SD135C_01_EN.fm 16-24
B 16
5.12 Material compartment (hopper)
Volume approx. 6.5 m3 = approx. 13.0 t

Minimum inlet height, centre 545 mm
Minimum inlet height, outside 620 mm
5.13 Material transfer
Conveyors Left and right auger separately controllable

Drive Hydrostatic, continuously controllable
Conveying volume controller Fully automatic via configurable switching points
5.14 Material distribution
Augers Left and right auger separately controllable

Hydrostatic central drive, continuously controlla-
ble
Drive independently of the conveyor
Auger halves can be switched to opposite direc-
tions
Conveying volume controller Fully automatic via configurable switching points
- Mechanically
Auger height adjustment
- Hydraulically (o)
Auger extension With extension parts (see auger extension chart)
B_SD115C_SD135C_01_EN.fm 17-24
B 17
5.15 Screed lifting device
At standstill:
- Screed stop
- Screed stop with pretensioning
(max. pressure 50 bar)
Special functions
During paving:
- Screed charging
- Screed relieving
(max. pressure 50 bar)
Mechanical grade control
Levelling system Optional systems with and without
Slope control system
5.16 Electrical system
On-board voltage 24 V
Batteries 2 x 12 V, 100 Ah
20 kVA / 400 V
Alternator (o)
28 kVA / 400 V
Fuses See chapter F, section 5
5.17 Permissible temperature ranges
Operation -5°C / +45°C

Storage -5°C / +45°C
A For the filling volumes of the various lubricants and operating substances, see chap-
ter F. B_SD115C_SD135C_01_EN.fm 18-24
B 18
6 Location of instruction labels and identification plates
12
3 22
20 21
14
9
13
19 1 2
17
8
11
16
7 6
4
18
10
8 18
23
5
B_SD115C_SD135C_01_EN.fm 19-24
15
18
10 (o)
B 19
Item Designation
1 Label „Filler neck for diesel fuel“ *
2 Label „Filler neck for engine oil“ *
3 Label „Operating instructions“*
4 Warning plate „Danger of squeezing!“ **
5 Label „Fixing points for crane transportation“ **
6 Paver finisher identification label
7 Plate „CE + noise level“ (O)
8 Warning plate „Fan danger!“
9 Warning plate „Hot surface!“
10 Label „Spraying with water prohibited“*
11 Label „Heed the operating instructions!“ ***
Label „Vehicle electrical system - danger of high voltage“
- Disconnect batteries and electronics during welding work or when charg-
12
ing the batteries, or use a service watchdog in accordance with the
instruction manual.
Label „Notes on engine starting“
- Let the engine reach operating temperature for 5 minutes at half speed
after cold-starting. Move the traction lever slightly from its central position.
13
At the end of work, allow the engine to idle for at least 5 minutes. Remove
the ignition key after switching off the engine.
Apply the handbrake when the vehicle is stationary (wheeled pavers)
Plate „Crossbeam lock“
- Do not enter or work under screed only secured with screed lock. Danger
14 of accidents!
With mechanical screed lock: Insert only at crown adjustment „zero“.
Screed lock only for transportation purposes.
15 Label „Radiator anti-freeze“ - mixing prohibition*
16 Label „Wear ear mufflers“
17 Label „Risk of hand injury“
18 Label „Lashing point“ - lifting point for transport safeguard**
19 Label „Main battery switch“
20 Label, „Health hazard, environmental hazard“
B_SD115C_SD135C_01_EN.fm 20-24
21 Label „Diesel EN590“

22 Label „First Aid Box“
23 Punched vehicle identification No.
* Labels are located beneath the engine hood / maintenance flap

** Labels are located on both sides of the paver finisher
*** Label is located on the operating panel, above the steering wheel
B 20
6.1 Identification label for the paver finisher (6)
1 2
3
4
5
6
7
8
Fertiger3.tif
Item Designation
1 Paver finisher type
2 Year of construction
3 Serial number of the paver finisher series
4 Max. permissible operating weight, incl. all extension parts, in kg
5 Max. permissible load on the front axle, in kg
6 Max. permissible load on the rear axle, in kg
7 Rated performance in kW
8 Product identification number (PIN)
A The punched vehicle identification number on the paver finisher must match the prod-
uct identification number (8).
B_SD115C_SD135C_01_EN.fm 21-24
B 21
7 EN standards
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 paver finisher was measured under free-field condi-
tions according to the EN 500-6 draft dated March 1997, and ISO 4872.
Sound pressure level at the operator’s position

(at the height of the head): LAF = xxxx dB(A)
Sound capacity level: LWA = xxxx dB(A)
Sound pressure level at the machine
Measuring point 2 4 6 8 10 12
Sound pressure level LAFeq (dB(A)) xxx xxx xxx xxx xxx xxx
7.2 Operating conditions during measurement
The diesel engine was running at maximum speed. The screed was in working posi-
tion, lowered to a rubber mat. Tamper and vibration unit were operated at min. 50%,
while the augers were operated at a minimum of 40% and the conveyors were oper-
ated at a minimum of 10% of their maximum speed.
7.3 Measuring point configuration
Hemispherical measuring surface with a radius of 16 m. The machine was at the cen-
tre. The measuring points had been assigned the following coordinates:
Measuring points 2, 4, 6, 8 Measuring points 10, 12

Co-ordinates X Y Z X Y Z
- 4.32 +10.4 11.36
±11.2 ±11.2 1.5
+4.32 -10.4 11.36 B_SD115C_SD135C_01_EN.fm 22-24
SCHALL.TIF
B 22
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 paver finisher was measured under free-field condi-
tions according to the EN 500-6 draft dated March 1997, and ISO 4872.
Sound pressure level at the operator’s position

(at the height of the head): LAF = 86.5 dB(A)
Sound capacity level: LWA = 105.6 dB(A)
Sound pressure level at the machine
Measuring point 2 4 6 8 10 12
Sound pressure level LAFeq (dB(A)) 73.4 71.2 73.8 72.3 70.0 73.1
7.5 Operating conditions during measurement
The diesel engine was running at maximum speed. The screed was in working posi-
tion, lowered to a rubber mat. Tamper and vibration unit were operated at min. 50%,
while the augers were operated at a minimum of 40% and the conveyors were oper-
ated at a minimum of 10% of their maximum speed.
7.6 Measuring point configuration
Hemispherical measuring surface with a radius of 16 m. The machine was at the cen-
tre. The measuring points had been assigned the following coordinates:
Measuring points 2, 4, 6, 8 Measuring points 10, 12

Co-ordinates X Y Z X Y Z
- 4.32 +10.4 11.36
±11.2 ±11.2 1.5
+4.32 -10.4 11.36
B_SD115C_SD135C_01_EN.fm 23-24
SCHALL.TIF
B 23
C 1.9 Transport
1 Safety regulations for transportation
m Accidents can happen when the paver finisher and the screed are not properly pre-
pared for transportation or when transportation is carried out improperly!
Reduce both the paver finisher and the screed to their basic widths. Remove all pro-
truding parts (such as the automatic levelling system, auger limit switches, aprons,
etc.). When transporting under a special permit, secure these parts!
Close the hopper lids and engage the hopper transport safeguards. Lift the screed
and engage the screed transport safeguards. Convert the protective roof and engage
the latch.
Check that the clamping device for the auger crossbeam is fastened and that the tel-
escopic tube cannot slide out (see chapter E, section 2.5).
Pack all parts that are not permanently fixed to the paver finisher and the screed into
the appropriate boxes and into the hopper.
Close all coverings and check that they are securely seated.
In Germany, gas bottles must not be transported on the paver finisher or on the
screed.
Disconnect the gas bottles from the gas system and protect them with their caps. Use
a separate vehicle to transport them.
When loading via ramps, there is a risk that the machine will slip, tilt or overturn.
Drive carefully! Keep people away from the danger area!
Additional stipulations for transportation on public roads:
m In Germany; caterpillar paver finishers must not be driven as self-propelling vehi-

cles on public roads.
Note that in other countries different regulations may apply.
The operator must be in the possession of a valid permit for vehicles of this type.
The operating panel must be moved to the side of the oncoming traffic and secured
in this position.
The driving lights must be properly adjusted.
Only attachments and 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 pub-
C_1.9_01_EN.fm 1-16
lic roads – especially at road crossings and junctions.
C 1.9 1
2 Transportation on low-bed trailers
m Reduce the paver finisher and the screed to their basic widths; also remove any at-
tached side plates.
The maximum approach angle is indicated in the section entitled „Technical Data“!
m Check the fill level of the operating substances so that these do not escape when driv-
ing on an incline.
m Attachment and loading equipment must meet the conditions of the applicable acci-
dent prevention regulations!
m The weight of the paver finisher must be taken into consideration when selecting the
attachment and loading equipment!
2.1 Preparations
- Prepare the paver finisher for transportation (see chapter D).

- Remove all overlaying or loose parts from paver finisher and screed (see also Op-
erating instructions for the screed). Store these parts in a safe place.
- Move the paver finisher to the uppermost position if necessary.
f 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 the bottle valves.
- Turn off the valves on the bottles and remove the gas
bottles from the screed.
- Transport the gas bottles on a second vehicle; heed all applicable safety regula-
tions.
C_1.9_01_EN.fm 2-16
C 1.9 2
.
Operation Buttons
- Disabling the interlocking of opera-

tion
- Close the hopper lids.
- Engage both hopper transport

safeguards.
- Lift the screed.
- Turn the preselecting regulator to

zero.
- Move the drive lever forward.

Only when remote control
is not connected.
- Extend levelling cylinders

completely.
- Set the drive lever to the centre po-

sition.
A
- Retract the screed parts until the

screed matches the basic width of
the paver finisher.
C_1.9_01_EN.fm 3-16
C 1.9 3
2.2 Driving onto the low-bed trailer
f Make sure that there are no persons in the danger area during loading.
1 2
F0185_A1.TIF
- 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.
- Lower the protective roof (o):
A See section entitled „Protective roof“
2.3 Secure the paver finisher to the low-bed trailer:

- Use only proper and permitted
load fastening devices.
- Use the four securing points provided (1, 2).
For a paver finisher without roof:
- Wait until the exhaust extension pipe has cooled down; then remove it and store it.
C_1.9_01_EN.fm 4-16
C 1.9 4
2.4 After transportation
- Remove the attachment devices.

- Raise the protective roof (o):
For a paver finisher without roof:
- Mount the exhaust extension pipe.
- Lift the screed to the transportation position.

- Start the engine and drive from the trailer at a low engine/traction speed.
- Park the paver finisher in a secure spot, lower the screed and switch off the engine.
- Remove the key and/or cover the operating panel with the protective hood and se-
cure it.
C_1.9_01_EN.fm 5-16
C 1.9 5
3 Protective roof (o)
The protective roof can be raised and

lowered with a manual hydraulic pump.
3
A The exhaust pipe is lowered or raised to-

gether with the roof.
4
- Remove the lower section of the pump
lever (1) from the storage compart- 1
ment, and connect to the upper sec- 2
tion using a pipe (2).
- The locks (3) and (4) on both sides of 5
the roof must be released.
- Set the adjustment lever (5) to the
„Raise“ or „Lower“ position. Dach2_2009.wmf
- Raise the roof: The lever points for-

wards.
- Lower the roof: The lever points backwards.
- Operate the pump lever (1) until the roof has reached the upper or lower limit posi-
tion.
- When the roof is raised, set both locks (3) and (4) on both sides of the roof; when
the roof is lowered, only set one lock (4).
m If the vehicle is equipped with a protective roof, the front window must be swivelled
shut and the engine hood must be closed before lowering the roof
C_1.9_01_EN.fm 6-16
C 1.9 6
4 Transportation
m Reduce the paver finisher and the screed to their basic widths; also remove any at-
tached side plates.
4.1 Preparations
- Prepare the paver finisher for transportation (see chapter D).

- Remove all overlaying or loose parts from paver finisher and screed (see also Op-
erating instructions for the screed). Store these parts in a safe place.
f When the screed is operated with the optional gas heat-

ing system:
- Remove the gas bottles for the screed heating system:

- Close main shut-off valves and bottle valves.
- Turn off the valves on the bottles and remove the gas
bottles from the screed.
- Transport the gas bottles on a second vehicle; heed all applicable safety regula-
tions.
C_1.9_01_EN.fm 7-16
C 1.9 7
.
Operation Buttons
- Disabling the interlocking of opera-

tion
- Close the hopper lids.
- Engage both hopper transport

safeguards.
- Lift the screed.
- Turn the preselecting regulator to

zero.
- Move the drive lever forward.

Only when remote control
is not connected.
- Extend levelling cylinders

completely.
- Set the drive lever to the centre po-

sition.
A
- Retract the screed parts until the

screed matches the basic width of
the paver finisher.
C_1.9_01_EN.fm 8-16
C 1.9 8
4.2 Driving mode
Warning Buttons
- Set the Fast/Slow switch to „Hare“.
- Turn the preselector to maximum.
- Use the drive lever to regulate the speed.
f Press the emergency stop button when a dangerous situation arises!

C_1.9_01_EN.fm 9-16
C 1.9 9
5 Loading by crane
m Use only lifting gear that can bear the load.

(See chapter B for weights and dimensions).
m Attachment and loading equipment must meet the conditions of the applicable acci-
dent prevention regulations!
m The vehicle's centre of gravity is dependent on the screed which is mounted.
1 3 2
2009_side4.bmp/2009_front2.bmp
A Four lifting eyes (1, 2) are provided for loading the vehicle with a crane.
A Depending on the type of screed which is used, the paver finisher's centre of gravity,
with the screed mounted, is located in the area of the drive unit's rear reversing
roller (3).
- Secure vehicle wherever it is parked up.

- Engage the transport safeguards.
- Remove any attachments and extension parts from the paver finisher and the
screed until the basic width has been attained.
- Take off all protruding or loose parts and the gas bottles of the screed heater (see
chapters E and D).
C_1.9_01_EN.fm 10-16
- Lower the protective roof (o):
- Attach lifting gear to the four attachment points (1, 2).
C 1.9 10
m The max. permissible attachment point load is
Attachment point (1): 32.3 kN
Attachment point (2): 85.4 kN
m Make sure that the paver finisher remains in a horizontal position during transport!
C_1.9_01_EN.fm 11-16
C 1.9 11
6 Towing
f Heed all regulations and apply all safety measures applicable for towing heavy con-
struction machines.
m The towing vehicle must be capable of securing the paver finisher, even on slopes.
Use only approved tow bars!

If necessary, remove any attachments and accessories from the paver finisher and
the screed until the basic width has been attained.
A hand pump is located in the engine compartment (left side) 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 vehi-
cle.
- The high-pressure cartridges (4 units)

(1) on the travel drive pumps must all
be unscrewed approx. 3 complete
turns.
1
F0264_A1.TIF
C_1.9_01_EN.fm 12-16
C 1.9 12
- Release lock nut (2), screw threaded
dowel (3) into pump as far as possible
and secure with lock nut. 4
- Actuate lever (4) of hand pump until
sufficient pressure has been built up
and traction system brakes have been
3
released.
- Attach the tow bar to the coupling (5)
located in the bumper. 2
A Now carefully and slowly tow the paver

finisher out of
the construction area.
m Only ever tow the shortest distance to

the means of transport or the next park-
ing possibility.
m The max. permissible towing eye (5)

load is: 188 kN.
X
Pump.eps
C_1.9_01_EN.fm 13-16
C 1.9 13
Following towing, unscrew the threaded
dowel (3) a few turns again and lock with
the lock nut (2).
To make the machine ready for opera-
tion after repair work, the high-pressure
cartridges (1) must be screwed back
firmly into place.
The traction system brakes are now re-
activated and the machine is secured
against rolling.
5 5
2009_Iso.wmf/Hook2009.bmp
C_1.9_01_EN.fm 14-16
C 1.9 14
7 Safely parking the vehicle
m When the paver finisher is parked at a lo-

cation accessible to the public, it must be
secured in such a way that unauthorised
persons or playing children cannot dam-
age the vehicle.
- Pull off the ignition key and the main 1

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

dust cover (2) and lock it.
- Store loose parts and accessories in a
safe place.
IsoPult_2009.bmp/IsoPult3_2009.bmp
A Secure the dust cover (2) during opera-

tion with the lock on the terminal box un-
der the maintenance flap on the right-
hand side!
Dieseltank.eps/Vandalism.bmp
C_1.9_01_EN.fm 15-16
C 1.9 15
D 1.12 Operation
1 Safety regulations
f Starting the engine, the travel drive, the conveyor, the auger, the screed or the lifting
devices can cause injuries or even the death of persons.
Make sure before starting any of these devices that no-one is working at, in or be-
neath the paver finisher or within its danger area!
- Do not start the engine or do not actuate any controls when this is expressly forbid-
den!
Unless otherwise specified, the controls may only be actuated when the engine is
running!
f Never crawl into the auger tunnel or step into the hopper or onto the conveyor. Dan-
ger to life and limb!
- Always make sure during work that no-one is endangered by the machine!
- Ensure that all protective covers and hoods are fitted and secured accordingly!
- Immediately rectify damage which as been ascertained! 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.
- Maintain sufficient safety clearance from overhanging objects, other machines and
points of danger!
- Be careful when travelling on rough terrain to keep the paver finisher from slipping,
tipping or turning over.
f Always be the master over the machine; never try to use it beyond its capacities!
D_1.12_01_EN.fm 1-46
D 1.12 1
2 Controls
2.1 Operating panel
3 4
D_1.12_01_EN.fm 2-46
Isopult6_2009.bmp/Isopult3_2009.bmp
D 1.12 2
m General notes on adherence to CE regulations
All detent switch functions which may pose a risk on starting the diesel engine (auger
and conveyor conveying function) are set to the STOP function in the case of EMER-
GENCY STOP or restarting the control system. If settings are changed when the die-
sel engine is stopped („AUTO“ or „MANUAL“), these are reset to „STOP“ on starting
the diesel engine.
The „Turning on the spot“ function is reset to „Straight-ahead travel“.
Item Designation Brief description
The entire operating panel can be swivelled for operation be-

yond the outer edge of the vehicle.
- Undo the latch corresponding to the swivelling direction and
swivel the operating panel to the desired position.
- Engage the latch in the locating bore again.
Latch swivel oper-
1
ating panel (o) f Only adjust the operating panel position whilst the vehi-
cle is stationary!
A The operating panel can only be swivelled beyond the

outer edge of the vehicle if a telescopic control panel is
fitted!
The entire operating panel can be shifted to the left or right driv-
er's seat.
- Undo the latch corresponding to the swivelling direction and
Latch shift operat-
2 shift the operating panel to the desired driver's position.
ing panel
- Engage the latch in the locating bore again.
f Only adjust the operating panel position whilst the vehi-
cle is stationary!
Vandalism protec- On completion of work, secure the operating panel with the
3
tion facility vandalism protection facility.
To lock the vandalism protection facility.

4 Lock
- Turn the handle to the locking position and lock.
D_1.12_01_EN.fm 3-46
D 1.12 3
10
17 16 15 11 13 14 12
D_1.12_01_EN.fm 4-46
D 1.12 4
In the case of an emergency (danger to persons, possible col-

lision etc.), press in the button!
- Pressing the emergency stop button switches the engine,
the drives and the steering system off.
Making way, lifting the screed or other actions are then no
Emergency stop
10 longer possible! Danger of accidents!
button
- The emergency stop button does not shut off the gas heat-
er system.
Close the main shut-off valve and the valves on the bottles
by hand!
- To restart the engine, the button must be pulled out again.
To activate the ignition voltage by turning the key.

- Switch off by turning the key back to its starting position.
A After activating the ignition voltage, the input and dis-

play terminal requires a few seconds for the booting
process.
11 Ignition lock
A On shutting off the vehicle, first switch off the ignition,
then deactivate the main switch.
A Before the main battery switch is deactivated, a period

of at least 10 seconds must elapse after switching off
the vehicle.
Starting is only possible when the drive lever is in the centre

12 Starter position. All emergency stop buttons (on the operating panel
and the remote controls) must be pulled out.
D_1.12_01_EN.fm 5-46
D 1.12 5
10
17 16 15 11 13 14 12
D_1.12_01_EN.fm 6-46
D 1.12 6
For switching on the paver finisher functions and for continu-

ously regulating the road speed – forward or reverse.
Zero position: Starting is possible; engine at idling speed; no
travel drive;
- To swivel the drive lever out, release by pulling the handle
up.
Depending on the position of the drive lever, the following func-
tions can be activated:
13 Drive lever 1st position:
(traction) - Conveyor and auger on.
2nd position:
14 Horn - Screed motion (tamper/vibration) on; travel
drive on; increase speed until the stop is reached.
A Use the preselector to set the maximum speed.
Horn (14): Press in the event of danger and as an acoustic sig-

nal before the vehicle starts to move!
- The horn can also be used to communicate acousti-
cally with the truck driver for material loading!
D_1.12_01_EN.fm 7-46
D 1.12 7
10
17 16 15 11 13 14 12
D_1.12_01_EN.fm 8-46
D 1.12 8
For setting the maximum speed that can be reached when the
Travel drive prese- drive lever is at its stop.
15
lector The scale roughly matches the speed in m/min (during
A
paving).
The steering wheel movement is transferred electrohydrauli-

cally.
Steering potenti- For precise adjustments (position „0“ = straight-ahead),
16
ometer A
see the straight-ahead travel synchronisation.
For turning on the spot, see switch (Turning on the
spot).
Press in the case of emergencies and to indicate when the ma-

chine starts to move!
17 Horn
A The horn can also be used to communicate acoustically
with the truck driver for material loading!
D_1.12_01_EN.fm 9-46
D 1.12 9
18 19 20 21 22 23
D_1.12_01_EN.fm 10-46
24 25 26 27 28 29
D 1.12 10
Button with detent switch function and LED feedback:

Front working - For switching on the front working lights
18 lights - Switch OFF by pressing the button again
ON / OFF (o)
f Avoid dazzling other road
users!

Rear working - For switching on the rear working lights
19 lights - Switch OFF by pressing the button again
ON / OFF (o)
f Avoid dazzling other road
users!

- For switching on the rotary beacon
Rotary beacon - Switch OFF by pressing the button again
20
ON / OFF (o)
A Switch on for safety on roads and in the construction
site area

Seat heating
21 - For switching on the seat heating
ON / OFF (o)
- Switch OFF by pressing the button again
Filling pump Button with detent switch function and LED feedback:
22 Fuel tank - For switching on the filling pump
ON / OFF (o) - Switch OFF by pressing the button again

Windscreen wiper
23 - For switching on the windscreen wiper
ON / OFF (o)
24 not used
25 not used
26 not used
27 not used
28 not used
29 not used
D_1.12_01_EN.fm 11-46
D 1.12 11
30
31
D_1.12_01_EN.fm 12-46
33
32
D 1.12 12
Pushbutton function:
- To close the left half of the hopper
Close left Separate actuation (o):
30
hopper A
Is required when paving in spaces where there is only
limited space at one side or when obstacles obstruct
truck unloading.
- To close the right half of the hopper
Close right Separate actuation (o):
31
hopper A
Is required when paving in spaces where there is only
limited space at one side or when obstacles obstruct
truck unloading.
- To open the left half of the hopper
Open left
32 If the hoppers are hydraulically actuated at the same
hopper A
time, both the left and the right switch can be used for
actuation.
- To open the right half of the hopper
Open right
33 If the hoppers are hydraulically actuated at the same
hopper A
time, both the left and the right switch can be used for
actuation.
D_1.12_01_EN.fm 13-46
D 1.12 13
34
35
D_1.12_01_EN.fm 14-46
37
36
D 1.12 14
Extend left - To extend the left half of the screed
34
screed This function is not used in vehicle configurations with a
A
screed which cannot be extended.
Extend right - To extend the right half of the screed
35
A
Retract left - To retract the left half of the screed
36
A
Retract right - To retract the right half of the screed
37
A
D_1.12_01_EN.fm 15-46
D 1.12 15
38
39
D_1.12_01_EN.fm 16-46
41
40
D 1.12 16
- To manually trigger the conveying function for the left
half of the auger, conveying direction outwards.
Left auger
„MANUAL“ For manual triggering, the auger function must be
38
conveying direction A
switched to „AUTO“ or „MANUAL“
outwards
A On manual triggering, the automatic function is overrid-

den with full feed capacity.
- To manually trigger the conveying function for the
right half of the auger, conveying direction outwards.
Right auger
39
outwards

- To manually trigger the conveying function for the left
half of the auger, conveying direction inwards.
Left auger
"MANUAL" For manual triggering, the auger function must be
40
inwards

- To manually trigger the conveying function for the
right half of the auger, conveying direction inwards.
Right auger
41
inwards

D_1.12_01_EN.fm 17-46
D 1.12 17
42
43
D_1.12_01_EN.fm 18-46
45
44
D 1.12 18

- The conveying function of the left conveyor is
switched on when the drive lever is swivelled out and
is continuously controlled via the material limit switch-
es in the material tunnel.
Left conveyor
42 - Switch OFF by pressing the button again
„AUTO“
A The function is shut off by pressing the EMERGENCY
STOP button or restarting the vehicle.
A The main function switch locks the conveying function.

- The conveying function of the right conveyor is
Right conveyor
„AUTO“

D_1.12_01_EN.fm 19-46
D 1.12 19
42
43
D_1.12_01_EN.fm 20-46
45
44
D 1.12 20

- The conveying function of the left conveyor is
switched on continuously with full feed capacity, with-
out material control via the limit switches in the mate-
rial tunnel.
Left conveyor
44 To avoid excessive conveying, the system is shut off at
„MANUAL“ A
a defined material height!


- The conveying function of the right conveyor is
out material control via the limit switches in the mate-
rial tunnel.
Right conveyor
45 To avoid excessive conveying, the system is shut off at
„MANUAL“ A
a defined material height!


D_1.12_01_EN.fm 21-46
D 1.12 21
46
47
D_1.12_01_EN.fm 22-46
49
48
D 1.12 22

- The conveying function of the left half of the auger is
es.
Left auger
„AUTO“

- The conveying function of the right half of the auger is
Right auger
„AUTO“

- The conveying function of the left half of the auger is
out material control via the limit switches.
Left auger - Switch OFF by pressing the button again
48
„MANUAL“

- The conveying function of the right half of the auger is
out material control via the limit switches.
Right auger - Switch OFF by pressing the button again
49
„MANUAL“
D_1.12_01_EN.fm 23-46
D 1.12 23
52
50
53
D_1.12_01_EN.fm 24-46
55
51
54
D 1.12 24

- For manual actuation of the levelling cylinders when
the automatic levelling system is switched off.
Levelling A The corresponding switch on the remote control must

50 cylinder adjust- be switched to „Manual“ for this function.
ment
A Levelling cylinder adjustment is carried out with the ad-
justment buttons in the displayed arrow direction.
A This function is also activated when the remote control

is not connected!

- For hydraulic adjustment of the auger height.
- Switch OFF by pressing the button again.
A The height can be read on the scales to the left and the
right of the auger crossbeam support.
Auger Rule of thumb: Paving thickness plus 5 cm (2 inches)
51 equals the auger crossbeam height.
raise/lower (o)
A Actuate both relevant adjustment switches at the same

time as the auger crossbeam otherwise jams!
A Levelling cylinder adjustment is carried out with the ad-

justment buttons in the displayed arrow direction.
D_1.12_01_EN.fm 25-46
D 1.12 25
56
57
D_1.12_01_EN.fm 26-46
D 1.12 26
Adjustment button: Pushbutton function:
Retract on left / - To adjust the selected function in the corresponding
52 raise direction.
+ close front hop- Functions (50) / (51) "OFF" - pushbutton function:
per lid function - To close the front hopper flap.
Retract on right / - To adjust the selected function in the corresponding
53 raise direction.
+ open front hop- Functions (50) / (51) "OFF" - pushbutton function:
per lid function - To open the front hopper flap.
Extend / lower on - To adjust the selected function in the corresponding
54 left direction.
+ close front hop- Functions (50) / (51) "OFF" - pushbutton function:
per lid function - To close the front hopper flap.
Extend on the left / - To adjust the selected function in the corresponding
55 lower direction.
+ open front hop- Functions (50) / (51) "OFF" - pushbutton function:
per lid function - To open the front hopper flap.
D_1.12_01_EN.fm 27-46
D 1.12 27
58
59
D_1.12_01_EN.fm 28-46
D 1.12 28
Detent switch function and LED feedback:
- To lock all functions relevant to paving. Despite
„Auto“ settings in the individual functions, these are
not activated when the drive lever is swivelled out.
56 Main function switch
A The preset vehicle can be relocated and released at
the new paving location. The paving process is con-
tinued on swivelling the drive lever out.
A On restarting, the function is set to „ON“.

Button with detent switch function and LED feedback
A The main function switch must be set to the OFF po-

sition.
- Button function: Keep the button pressed for longer

than 1.5 seconds (LED ON). The screed is lowered
as long as the button is pressed. When the button
is released, the screed is held in the floating posi-
tion. (LED ON).
- Resting function: Press the button briefly (LED ON)
- the screed is lowered. Press the button briefly
Lower screed / again - the screed is stopped.
57 screed
- Screed floating position: Pressing the button
floating position
switches the LED ON and the screed is in readiness
in the „floating position“, which is activated via the
swivelled out drive lever.
- Switch off by pressing the button again or via the
raise screed button.
A During paving, the screed must always be in its float-

ing position. During intermediate stops, the screed is
switched to relieving with pretension.
m Check whether the screed transport safeguard is in-

serted!
D_1.12_01_EN.fm 29-46
D 1.12 29
60 62 64 66 68
D_1.12_01_EN.fm 30-46
61 63 65 67 69
D 1.12 30

- Filling function for the paving process.
The diesel engine's speed is increased to the preselected
nominal speed and all conveying functions set to „Automat-
ic“ (conveyor and auger) are engaged.
Fill vehicle for pav-
58
ing process
A The main function switch must be set to the OFF posi-
tion.
- Switch OFF by pressing the button again or by swiv-

elling the drive lever out to the paving position.

- When the vehicle is stationary, this function enables
all operating functions, which can only be activated
when the drive lever is swivelled out (vehicle driving),
to be started up.
59 Set-up mode
tion.
A The engine speed is increased to the preselected nom-

inal value.
D_1.12_01_EN.fm 31-46
D 1.12 31
60 62 64 66 68
D_1.12_01_EN.fm 32-46
61 63 65 67 69
D 1.12 32

- Tamper ON and OFF function.
- Activation is carried out by swivelling the drive lever
out.
Tamper - Switch OFF by pressing the button again.
60
(screed-specific)
tion.
A The function is preset in conjunction with the „Set-up

mode“ button.

- Vibration ON and OFF function.
- Activation is carried out by swivelling the drive lever
out.
Vibration - Switch OFF by pressing the button again.
61
(screed-specific)
tion.
A The function is preset in conjunction with the „Set-up

mode“ button.
Pushbutton function with LED feedback:

- For raising the screed (LED ON) for switching off the
62 Raise screed „Screed floating position“ function
m Check whether the screed transport safeguard is insert-
ed!
Buttons with detent switch function and LED feedback:

- Increases the engine speed to a higher value without
63 Speed increase swivelling the drive lever out.
D_1.12_01_EN.fm 33-46
D 1.12 33
60 62 64 66 68
D_1.12_01_EN.fm 34-46
61 63 65 67 69
D 1.12 34

- For relieving the screed to influence the traction force
and compaction ratio.
64 Screed relieving - Switch OFF by pressing the button again or switching
between screed relieving and screed charging.
- To preset the hydraulic oil pressure, switch this button and
the „Set-up mode“ button to „ON“.
- For relieving the screed to influence the traction force
and compaction ratio.
65 Screed relieving - Switch OFF by pressing the button again or switching
between screed relieving and screed charging.
- To preset the hydraulic oil pressure, switch this button and
the „Set-up mode“ button to „ON“.
D_1.12_01_EN.fm 35-46
D 1.12 35
70 71 72 73 74 75 76
D_1.12_01_EN.fm 36-46
77 78 79 80 81 82 83
D 1.12 36

Travel drive - To preselect the speed level -
66 fast transport speed
(hare) On restarting, the speed is set to operating speed (tor-
A
toise).

Travel drive - To preselect the speed level -
67 slow operating speed.
(tortoise) On restarting, the buttons are set to operating speed
A
(tortoise).

- Normal position for straight-ahead travel.
A On restarting, the „Straight-ahead travel“ button is set.

Straight-ahead
68
travel If the „Turning on the spot“ function has been inadvert-
A
ently activated (and the steering is set to straight-ahead
travel), the paver finisher does not move. This is often
interpreted as a „malfunction“.

- The vehicle turns on the spot (the caterpillar chains
run in opposite directions) when the steering is set
to „10“.
- Steering turned to the left = vehicle turns to the left
- Steering turned to the right = vehicle turns to the right
69 Turning on the spot A If the „Turning on the spot“ function has been inadvert-
ently activated (and the steering is set to straight-ahead
travel), the paver finisher does not move. This is often
interpreted as a „malfunction“.
f When the vehicle turns, persons and objects next to the

paver finisher are in extreme danger. Monitor the area
where the paver finisher turns!
D_1.12_01_EN.fm 37-46
D 1.12 37
70 71 72 73 74 75 76
D_1.12_01_EN.fm 38-46
77 78 79 80 81 82 83
D 1.12 38
Battery charge in- Must go out after starting when the engine revs up.
70
dicator (red) - If the light does not go out, switch off the engine
Indicates that there is a drive engine fault. Depending on the

type of fault, the vehicle can temporarily continue to be operat-
ed or, in the case of serious faults, should be shut down imme-
diately to prevent further damage from occurring.
Each fault should be rectified as soon as possible!
Error message
71
(yellow) An error code is displayed via the input and display ter-
A
minal!
A Lights up for a few seconds once the ignition has been

switched on for checking purposes.
Lights up when the hydraulic oil temperature is too high.
72
Warning light
hydraulic oil
m Stop the paver finisher when higher temperatures are
encountered (drive lever to the centre position), let the
temperature engine cool down while idling. Determine the cause and
correct it if necessary.
Lights up when the engine temperature is too high.

m The engine performance will be throttled down automat-
ically. (Driving mode remains possible). Stop the paver
finisher (drive lever to the centre position), let the engine
cool down while idling. Determine the cause and rectify
Engine tempera-
73 if necessary (refer to „Malfunctions“ section). After cool-
ture indicator (red)
ing down to normal temperature, the engine will run with
full performance again.
A Indicates the fault together with the „Error message“

lamp.
74 not used
75 not used
76 not used
Lights up if too much water is detected in the water separator
on the fuel system.
„Water in fuel“
m To avoid damaging the drive engine, drain off the sepa-
rated water immediately as described in the mainte-
77
warning lamp (red) nance instructions.
D_1.12_01_EN.fm 39-46
A Indicates the fault together with the „Error message“

lamp.
D 1.12 39
70 71 72 73 74 75 76
D_1.12_01_EN.fm 40-46
77 78 79 80 81 82 83
D 1.12 40
Lights up when a serious error has occurred on the en-
gine. The engine is automatically shut down for safety.
Error message An error code is displayed via the input and dis-
78 with engine stop A
play terminal!
(red)
A Lights up for a few seconds once the ignition has

been switched on for checking purposes.
Must go out right after the engine has been started. Ob-
serve warm running. The hydraulic oil is possibly too
Oil pressure indi- cold and stiff.
79
cator for the hy-
draulic traction
m Do not switch on the traction drive when the lamp
does not go out (see the section „Malfunctions“).
drive (red)
A The lamp goes out when the pressure drops be-
low 2.8 bar = 40 psi.
m Lights up when the oil pressure is too low.

Switch off the engine immediately!
Oil pressure indi- For further possible faults, see Operating instruc-
80 cator lamp for the tions for the engine.
diesel engine (red)
A Indicates the fault together with the „Error mes-
sage“ lamp.
81 not used
82 not used
83 not used
D_1.12_01_EN.fm 41-46
D 1.12 41
3 Remote control
100 102
101
103
104 104
105
106
107
109 108
111 110
113 112
m Attention! Do not disconnect remote controls with emergency stop button (O) during
operation! This causes the paver finisher to be shut down!
D_1.12_01_EN.fm 42-46
D 1.12 42
Function and application as with the emergency stop
Emergency stop button (10) on the operating panel.
100
button (o) Important in the case of dangerous situations which can-
not be seen by the driver.
101 Horn Function as for button (17) on the operating panel.
Manual: Height adjustment possible with buttons (104)
(or the corresponding function on the operat-
Automatic levelling
102 ing panel)
system
Auto: Automatic height adjustment by means of the
grade control system
Button for setting Enables the levelling cylinder on the other side of the
103 the level on the paver finisher to be operated. The display on the other
other side remote control automatically jumps to „Manual“.
Buttons for move-
104 Function as for buttons (52-55) on the operating panel.
ment directions
105 Conveyor Function as for buttons (42-45) on the operating panel.
Conveyor feed ca- Plus/minus buttons for adjusting the feed capacity. Dis-
106 pacity and LED play via LED. Changes are accepted when the button
display (105) is switched to the „Auto“ position.
D_1.12_01_EN.fm 43-46
D 1.12 43
100 102
101
103
104 104
105
106
107
109 108
111 110
113 112
m Attention! Do not disconnect remote controls with emergency stop button (O) during
operation! This causes the paver finisher to be shut down!
D_1.12_01_EN.fm 44-46
D 1.12 44
107 Auger Function as for buttons (46-49) on the operating panel.
Auger conveying For setting the auger conveying direction.
108
direction. - Switch (107) must be set to the „Auto“ position.
Plus/minus buttons for adjusting the feed capacity. Dis-
Auger feed capaci-
109 play via LED. Changes are accepted when the button
ty and LED display
(107) is switched to the „Auto“ position.
Extend/retract Use these buttons to move the screed in the direction in-
110
screed dicated by the arrow.
111 not used
Extend / retract Use these buttons to move the screed in the direction in-
112
screed (o) dicated by the arrow.
For manually actuating the levelling cylinders when au-
Levelling cylinder
113 tomatic levelling is switched off.
left/right (o)
To do this, the function must be switched to „Manual“.
A If the function (102) is switched to „Auto“, it switches to „Manual“ whilst actuating the
buttons (104).
A If the function (107) is switched to „Stop“, it switches to „Auto“ whilst actuating the but-
tons (108).
A Basic auger and conveyor feed capacity for the individual course types (number of
LEDs):
- Surface course: 4
- Binder course: 6
- Base course: 8
D_1.12_01_EN.fm 45-46
D 1.12 45
Lower side
114 116 115

Remote_SPS_neu2.bmp
Socket for auto-

Connect the connection cable for the grade control
114 matic levelling sys-
system here.
tem
Socket for auger

115 Connect the cable for the material limit switch here.
limit switch
Connection cable Connect the plug to the screed.

116
for remote control (See screed operating instructions).
D_1.12_01_EN.fm 46-46
D 1.12 46
D 2.2 Operation
1 Operation of the input and display terminal
A B C D E F G
Terminal_SPS_Kette_2009.wmf/Bild_000.bmp
Key layout on the display
- (A) Encoder (turn and push operation):

- To scroll in the menu
- To select various options within a menu
- To change parameters
- To confirm changed parameters
- (B), (C), (D), (E), (F), (G) keys F1 - F6:

- To select the functions assigned in the display
- To select various options within a menu
- To change parameters
D_2.2_01_EN.fm 1-40
D 2.2 1
1.1 Menu operation
A B C D E F G
Example: Emergency programme (401)
- Turn the encoder (A) until the selection field (1) appears.
- Turn the encoder (A) again until the selection field is positioned over the desired
menu item.
- Press the encoder (A) or key F2 (B) to activate the selected menu item for chang-
ing.
- Set the desired value by turning the encoder (A).
- Press the encoder (A) or key F2 (B) to confirm the set value.
A In various menus, the parameters can be changed directly without having to first con-
firm using the selection field!
D_2.2_01_EN.fm 2-40
D 2.2 2
Menu structure of the setting and display options
The following illustration shows the menu structure and serves to simplify operation
and the procedure in the case of various settings and displays.
D_2.2_01_EN.fm 3-40
D 2.2 3
Main menu 00
Display and function menu

5 1
Displays:
2
- Speed - driving mode (1) 3
- Speed - paving mode (2)
4
- Engine speed (3)
- Distance travelled counter
(4)
9
- Fuel gauge (5)
Selectable functions:
- Drive engine „eco mode“

(F1) Terminal_SPS_Kette_2009.wmf/Bild_000.bmp
- The engine speed is con-

stantly regulated to 1600 rpm
- Automatic steering unit (F2)

- When the automatic steering unit is activated, the steering potentiometer is deac-
tivated. Steering is carried out automatically via ski cable sensing.
- Delayer screed start (F3)

- The screed is blocked for a set time (starting from the start of the paving process)
when one of the screed charging / screed relieving or floating position functions
is activated.
A The functions are activated by pressing the relevant F key.

A frame around the corresponding symbol confirms that the function has been acti-
vated.
Callable function menus:
- Engine speed (F6)
- Open sub-menu (101) - engine speed (9)

D_2.2_01_EN.fm 4-40
D 2.2 4
Menu 01 - Diesel speed
Menu for setting the engine

speed (1)
- Open sub-menu: (F6)

- Return to the main menu:
(F1)
Terminal_SPS_Kette_2009.wmf/Bild_001_2009.bmp
Sub-menu 101 - Diesel

speed set-up
- Save, return to the main

menu: (F6)
- Undo changes, return to
the main menu: (F1)
1
A Adjustment is carried out in
steps of 50; the engine speed
is adapted directly.
A Engine speed display as a

bar chart (1).
D_2.2_01_EN.fm 5-40
D 2.2 5
Menu 02 - Drive engine
measured values
Menu for querying various

drive engine measured val-
ues

(F1)
Sub-menu 103 - Drive en-

gine measured value dis-
play
Display of the following 1

measuring values: 2
- Coolant temperature (1) 3

- Engine oil pressure (2) 4
- Battery voltage (3) 5
- Engine operating hours (4)
- Fuel consumption (5)
- Return to menu 02: (F1)
D_2.2_01_EN.fm 6-40
D 2.2 6
Menu 03 - Distance and fuel
display
Menu for querying various

operating data

(F1)
Sub-menu 301 - Display/re-

set distance travelled, fuel
consumption
Display of the following oper-

ating data:
1
- Distance travelled (1)
- Reset - set value to zero, 2
return to menu 03: (F4)
- Fuel consumption (calcu-
lated value) (2)
- Reset - set value to zero,
return to menu 03: (F3)
D_2.2_01_EN.fm 7-40
D 2.2 7
Menu 04 - Emergency func-
tion / screed stop and
tamper start
In the event that nominal val-

ue specification or actual val-
ue measurement fail (e.g.
sensor defective, remote con-
trol failed), the performance
of various functions can be
set for automatic mode.

(F6)
Sub-menu 401 - Emergency

function setting
Performance adjustment is
possible for the following 1
functions: 2
- Auger (1) 3
- Conveyor (2) 4
- Tamper (3) 5
- Vibration (4)
- Tamper stop (5)
A The current value can be set

from 0 to 100%.
A Settings in these functions

can only be carried out if a
failure has occurred.
- Reset parameters, return to menu 04: (F1)

- Save set parameters, return to menu 04: (F6)
D_2.2_01_EN.fm 8-40
D 2.2 8
Menu 05 - Paving thickness
Menu for setting the type of

course to be laid

(F1)
Sub-menu 501 - Paving

thickness preselection
Preselection of the following

course types:
- Surface course:
Parameter 3
- Binder course: Parameter 2
- Base course: Parameter 1
- Save, open sub-menu: (F6)

menu 05: (F1)
A Directly to the next sub-

menu: (F6)
D_2.2_01_EN.fm 9-40
D 2.2 9
Sub-menu 502 - Auger
speed setting
The speed can be set in 8

stages. The set speed stage
for the relevant auger is
shown in displays (1) and (2).
Basic setting for the individual

course types:
- Surface course: 4 1 2
- Binder course: 6
- Base course: 8
- Save, open sub-menu: (F6)

menu 05: (F1)
A Directly to the next sub-

menu: (F6)
A The remote controls' LED display changes in line with the settings which have been
carried out.
Sub-menu 503 - Conveyor

speed setting
The speed can be set in 8

stages. The set speed stage
for the relevant conveyor is
shown in displays (1) and (2).
Basic setting for the individual

course types:
- Surface course: 4 1 2
- Binder course: 6
- Base course: 8
- Save, return to menu 05:

(F6).
menu 05: (F1). Terminal_SPS_Kette_2009.wmf/Bild_503_2009.bmp
A The remote controls' LED display changes in line with the settings which have been
D_2.2_01_EN.fm 10-40
carried out.
D 2.2 10
Menu 06 - Delayed screed
start
The screed is blocked for a

set time (starting from the
start of the paving process)
when one of the screed
charging / screed relieving or
floating position functions is
activated.

(F1)
Sub-menu 102 - Delayed

screed start setting
Setting the period of time for

start-up charging

(F6)
menu 06: (F1)
D_2.2_01_EN.fm 11-40
D 2.2 11
Menu 07 - Screed type
Menu for setting the screed

type

(F1)
Sub-menu 701 - Screed

type setting
Preselection of the following

screed types:
- VB/EB screed:
Parameter 0
- SB screed:
Parameter 1

(F6)
menu 07: (F1)
D_2.2_01_EN.fm 12-40
D 2.2 12
Menu 08 - Operating hour
meter
Menu for querying the operat-

ing hours

(F1)
D_2.2_01_EN.fm 13-40
D 2.2 13
Menu 09 - Service
Password-protected menu
for various service settings
- Open password prompt:

(F6)
(F1)
Sub-menu 201 - Password

prompt
Password entry:
- Confirm password by
pressing the encoder
D_2.2_01_EN.fm 14-40
D 2.2 14
Menu 10 - Error memory
Menu for querying existing er-

ror messages again
- Display [0]: No error mes-

sages present
- Display [1]: Error messag-
es present
- Call up error messages:

(F6)
(F1)
D_2.2_01_EN.fm 15-40
D 2.2 15
Display error messages:
A If error messages are

present, the display „Atten-
tion“ (600) is always shown
first
- Display error messages:

(F6)
Error display
- Call up the next error: (F6)
A If a further error is present,

the display „Attention“ is
shown again.
A When the last error has been

read out, the system returns
1
to the main menu.
A All error messages can be

identified in the section „Ter-
minal error displays“
A If consultation with Technical

Support is required for your
vehicle, always specify the
number (1) of the error mes-
sage!
Terminal_SPS_Kette_635.wmf/Bild_600_2009.bmp/Bild_638_2009.bmp
D_2.2_01_EN.fm 16-40
D 2.2 16
Menu 11 - Programme ver-
sion
Menu for querying the in-

stalled programme version
A If consultation with Technical

Support is required for your
vehicle, always specify the
programme version!

(F1)
D_2.2_01_EN.fm 17-40
D 2.2 17
Menu 12 - Terminal settings
Menu for various terminal set-

tings

(F1)
Sub-menu 104 - Terminal

settings
4 5
The following setting options

are available:
- Key illumination brightness 1

(1)
- Display brightness (2) 2
- Sensitivity of the encoder 3
(3)
- „Beep“ ON / OFF (6) -
Warning signal with error
messages, until error was
acknowledged.
A The brightness can be set for

both daytime operation (4)
and night time operation (5). Terminal_SPS_Kette_2009.wmf/Bild_107.bmp
A When the working lights are switched on, the system automatically switches to the
night time operation settings.
- Save, return to menu 13: (F6)

- Undo changes, return to menu 13: (F1)
D_2.2_01_EN.fm 18-40
D 2.2 18
Menu 13 - Key function test
Menu for testing the function

of the operating panel keys

(F1)
Sub-menu 107 - Key func-

tion test
On pressing the individual

keys, the relevant key symbol
is shown to confirm the func-
tion. 1
- Save, return to menu 14: 2

(F6)
3
menu 13: (F1)
D_2.2_01_EN.fm 19-40
D 2.2 19
1.2 Further displays
Display No. / meaning Display
Display 646
Emergency stop button actuat-
ed
- Return to the previous
menu: (F6)
Display 647
Set-up mode
Displays: 1
- Engine speed (1) 2
- Distance travelled (2) 3
- Fuel consumption
(calculated value) (3)
- Return to the previous
menu: (F6)
D_2.2_01_EN.fm 20-40
D 2.2 20
2 Terminal error messages
A Every error message is assigned a number. If consultation with Technical Support is

required for your vehicle, specify this number, together with all other visible informa-
tion relating to the error message!
Error No. / meaning Display
Error message 600

General error display
Error message 601

Conductor break
Automatic drive controller trav-
el drive pump
Error message 602

Conductor break
el drive pump
Error message 603

Conductor break
el drive pump
D_2.2_01_EN.fm 21-40
D 2.2 21
Error message 604

Conductor break
el drive pump
Error message 605

- Steering potentiometer de-
fective
Error message 606

- Communication interrupted
Automatic drive controller
drive engine
Error message 607

- Potentiometer for vehicle
speed defective
Error message 608

- Drive lever potentiometer
D_2.2_01_EN.fm 22-40
defective
D 2.2 22
Error message 609

- Battery voltage too low
Error message 610

- „Forwards driving mode“
blocked
Variable:
- Driving/steering direction (1)
Error message 611

- „Backwards driving mode“
blocked
Error message 612

- „Driving mode - left turn“
blocked
Error message 613

- „Driving mode - right turn“
D_2.2_01_EN.fm 23-40
blocked
D 2.2 23
Error message 614

„Forwards / backwards driving
mode“ blocked
Error message 615

- Left drive unit sensor defec-
tive
Error message 616

- Right drive unit sensor de-
fective
Error message 619

- Short-circuit / wiring fault -
drive lever potentiometer /
drive lever microswitch (wir-
ing in opposite direction)
Error message 625

Error engine stop
SPN = affected component
FMI = type of error
D_2.2_01_EN.fm 24-40
OC = frequency of repetition
A See section „Drive en-
gine error codes“!
D 2.2 24
Error message 626

- Drive engine warning mes-
sage
- SPN = affected component
- FMI = type of error
- OC = frequency of repetition
A See section „Drive en-
gine error codes“!
Error message 628

Drive engine master
Error message 629

3
- Slave output conductor
break 2
variable: 1
- Slave No. (1)

- Slave output (2)
- Actuated element (3)
Error message 630 3
- Slave output short-circuit 2

variable: 1
- Slave No. (1)
- Slave output (2)
- Actuated element (3)
Error message 634 1

- Slave failure
variable:
D_2.2_01_EN.fm 25-40
2
- Slave No. (1)
- Fuse (2)
D 2.2 25
Error message 635

- Keyboard failure / keyboard
fuse defective
Error message 636

- Left remote control failure
A Check fuse F250.6
Error message 637

- Right remote control failure
A Check fuse F250.6
Error message 638

Automatic drive controller
master
A Observe section „Notes
on error messages“!
Error message 639

- Conveyor limit switch defec-
tive.
D_2.2_01_EN.fm 26-40
- Left limit switch
D 2.2 26
Error message 640

- Conveyor limit switch defec-
tive.
- Right limit switch
Error message 641

- Auger limit switch defective
- Left limit switch
Error message 642

- Auger limit switch defective
- Right limit switch
Error message 643

- Tamper nominal value po-
tentiometer defective
Error message 644

- Vibration nominal value po-
D_2.2_01_EN.fm 27-40
tentiometer defective
D 2.2 27
Error message 645

display master
D_2.2_01_EN.fm 28-40
D 2.2 28
2.1 Notes on error messages
Terminal_SPS_Kette_2009.bmp/Bedienpult_2009_PLC_C.bmp/Bild_638_2009.bmp
Error message 638
Communication interrupted
Automatic drive controller master.
A First check whether the fuse for the travel drive computer is intact!
If the fuse is not the cause of the interrupted data link, diesel engine emergency start-
ing can be carried out:
- Activate key (1) (LED on).

- Press starting button (2).
D_2.2_01_EN.fm 29-40
D 2.2 29
2.2 Drive engine error codes
If a fault has been detected on the drive

engine, this is indicated by a corre- 1
sponding warning lamp (1) and simulta-
neously appears in code on the display.
Checklight_2009.bmp
The error message simultaneously

shown on the display contains several
numerical codes, which uniquely define
the fault after decoding.
- „ENGINE WARNING!“ display (2) indi-

cates that there is a fault on the drive 2
engine. The vehicle can continue to be
operated on a temporary basis. How-
ever, the fault should be remedied
quickly to prevent further damage.
- „STOP ENGINE!“ display (3) indicates
a serious fault on the drive engine, in
which the engine is stopped or has to
be stopped immediately to prevent fur-
ther damage.
D_2.2_01_EN.fm 30-40
D 2.2 30
Example:
? ?
Deutz_2013L06.tif/Bedienpult_2009_PLC_C.bmp/Bild_635_2009.bmp/Book.tif
Explanation:
Warning light and display signal a serious fault on the drive engine with automatic or
necessary engine shut-down.
Display:
SPN: 157
FMI: 3
OC: 1
Cause: Cable break on sensor for rail pressure.

Effect: Engine shut-down.
Frequency: Fault occurs for the 1st time.
m Notify the customer service of the error number displayed on your paver finisher; the
D_2.2_01_EN.fm 31-40
customer service department will then discuss the further procedure with you.
D 2.2 31
2.3 Error codes
D_2.2_01_EN.fm 32-40
D 2.2 32
D_2.2_01_EN.fm 33-40
D 2.2 33
D 2.2 34
D_2.2_01_EN.fm 34-40
D_2.2_01_EN.fm 35-40
D 2.2 35
D 2.2 36
D_2.2_01_EN.fm 36-40
2.4 FMI codes
D_2.2_01_EN.fm 37-40
D 2.2 37
2.5 Special functions
Emergency programme on keyboard failure
Max rpm
1
3
4
Terminal_SPS_Kette_2009.bmp/Bedienpult_2009_PLC_C.bmp/Bild_638_2009.bmp
To guarantee temporary paver finisher operability in the event that the keyboard fails,
an emergency programme is automatically started.
The following values and functions are activated or set:
- Diesel engine speed to 1800 rpm

D_2.2_01_EN.fm 38-40
- Travel drive (1) to operating speed (tortoise)

- Main function switch (2) to off
- Tamper function (3) engaged
- Vibration function (4) engaged
D 2.2 38
m In the event of keyboard failure, the engaged functions are not confirmed via the rel-
evant LED!
A Tamper and vibration can be switched off via the relevant rotary potentiometers (set
to „zero“).
The tamper and vibration frequency can be read off via the two relevant displays (O).
The remote controls can additionally be

used to activate the following functions:
- By pressing button (1), the hopper is 3

closed.
- By pressing button (2), the hopper is
opened.
- Raise screed:
- Switch off the auger and conveyor 4
(3) bar LEDs by pressing the rele-
vant minus buttons (4).
- Raise the screed continuously by 1
pressing the two minus buttons (4)
together. 2
- Make the screed ready (floating posi- 5
tion):
Remote_SPS_neu1.cdr
- Fully engage the auger and convey-
or (3) bar LEDs by pressing the relevant plus buttons (5).
- Switch the screed to the floating position by pressing the two plus buttons (5) to-
gether.
m The screed is lowered immediately!
A To raise the screed from the floating position, the auger and conveyor bar LEDs first
have to be cleared again.
D_2.2_01_EN.fm 39-40
D 2.2 39
Reversible conveyor
Bedienpult_2009_PLC_C.bmp
The conveyor's direction can be reversed in order to slightly reverse any paving ma-
terial which may be positioned just in front of the auger. This enables e.g. material
losses to be avoided during transportation.
- Switch the main function switch (1) to the „off“ position (LED off).
- Keep one or both buttons (2) depressed for approx. 1 second.
The conveyor moves a distance of approx. 1 metre towards the hopper.
A If necessary, this process can be repeated as often as required to allow the conveyor
to run further in the reverse direction.
D_2.2_01_EN.fm 40-40
D 2.2 40
D 3.8 Operation
1 Operating elements on the paver finisher
1.1 Operating elements on the operator's control station
Protective roof (o)
The protective roof can be raised and

lowered with a manual hydraulic pump.
3
A The exhaust pipe is lowered or raised to-

gether with the roof.
4
- Remove the lower section of the pump
lever (1) from the storage compart- 1
ment, and connect to the upper sec- 2
tion using a pipe (2).
- The locks (3) and (4) on both sides of 5
the roof must be released.
- Set the adjustment lever (5) to the
„Raise“ or „Lower“ position. Dach2_2009.wmf
- Raise the roof: The lever points for-

wards.
- Lower the roof: The lever points backwards.
- Operate the pump lever (1) until the roof has reached the upper or lower limit posi-
tion.
- When the roof is raised, set both locks (3) and (4) on both sides of the roof; when
the roof is lowered, only set one lock (4).
m If the vehicle is equipped with a protective roof, the front window must be swivelled
shut and the engine hood must be closed before lowering the roof!
D_3.8_01_EN.fm 1-26
D 3.8 1
Protective roof (o)
The protective roof is equipped with an

additional front window and two side
windows.
A The front window must be swivelled up

for maintenance work in the tank area.
2
- The front window can be swivelled out
in the direction of travel with the brack- 3
et (1).
1
A If equipped with a telescoping seat con-
sole, the side window must be swivelled
up before telescoping.
WHaus_2009.bmp
- The side windows can be swivelled out to the side with the bracket (2).
Windscreen wiper (o)
- Activate the windscreen wiper (3) on the operating panel if necessary.
D_3.8_01_EN.fm 2-26
D 3.8 2
Control panel
Bedienstand_500_V2.bmp
Telescoping seat console (o)
The seat console can be shifted beyond the outer edge of the vehicle, providing the
driver with a better view of the paving area in this position.
The seat console is additionally equipped with a rotary facility.
Lateral adjustment:
- Pull the locking knob (1)

- Shift the seat console (2) to the desired position
- Engage the locking knob (1).
Rotary facility:
- Pull the locking lever (3)

- Swivel the seat (4) to the desired position
- Engage the locking lever (3).
f After locking the seat console, it must no longer be possible to shift it to another po-
sition!
Storage compartment
D_3.8_01_EN.fm 3-26
A storage compartment (5) is located beneath the driver's seat.

The vehicle documentation or a first aid box can be stored here, for example.
- Open or close the flap by turning the lock.
D 3.8 3
Driver's seat, type I
9
f To avoid damage to health, the individu-
al seat settings should be checked and 10
adjusted before starting the vehicle.
6 7
f After locking the individual elements, it
must no longer be possible to shift then 6
to another position.
3 8
- Weight setting (1): The relevant driv-
er's weight should be set by turning
4 11
the weight adjustment lever when the
driver's seat is unoccupied. 5
- Weight indicator (2): The set driver's
weight can be read off at the viewing 1
window.
2
- Longitudinal adjustment (3): Longi-
seat4.tif
tudinal adjustment is released by actu-
ating the locking lever.
The locking lever must engage in the desired position.
- Seat depth adjustment (4): The seat depth can be individually adjusted. Raise the
button to adjust the seat depth. The desired position is set by simultaneously sliding
the seat surface forwards or backwards.
- Seat inclination adjustment (5): The seat surface's longitudinal inclination can be
individually adjusted. Raise the button to adjust the inclination. The seat surface in-
clines to the desired position by simultaneously loading or relieving it.
- Armrest inclination (6): The armrest's longitudinal inclination can be adjusted by
turning the handwheel. Turning outwards raises the front of the armrest; turning in-
wards lowers it at the front.
In addition, the armrests can be folded up fully.
- Lumbar support (7): Both the height and the extent of the convexity in the backrest
padding can be individually adjusted by turning the handwheel to the left or right.
- Backrest adjustment (8): The backrest is adjusted via the locking lever. The lock-
ing lever must engage in the desired position.
- Back extension (9): By pulling out via perceptible detents, the height can be
individually adjusted up to a limit stop. To remove the back extension, the limit stop
is overcome with a jolt.
- Seat heating ON/OFF (10): The seat heating is switched on and off by actuating
the switch.
- Seat belt (11): The seat belt must be applied before starting up the vehicle.
f The seat belts must be replaced following an accident.

D_3.8_01_EN.fm 4-26
D 3.8 4
Driver's seat, type II
7
f To avoid damage to health, the individu-
al seat settings should be checked and
adjusted before starting the vehicle.
6
f After locking the individual elements, it
must no longer be possible to shift then 6
to another position. 5
3
- Weight setting (1): The relevant driv-
er's weight should be set by turning
8
the weight adjustment lever when the
driver's seat is unoccupied. 4
- Weight indicator (2): The set driver's
weight can be read off at the viewing 1
window.
- Longitudinal adjustment (3): Longi- 2
seat4.tif
tudinal adjustment is released by actu-
ating the locking lever.
The locking lever must engage in the desired position.
- Seat height adjustment (4): The seat height can be individually adjusted. Turn the
handle in the desired direction to adjust the seat height.
- Backrest adjustment (5): The backrest inclination can be continuously adjusted.
Turn the handle in the desired direction to adjust.
- Armrest inclination (6): The armrest's longitudinal inclination can be adjusted by
turning the handwheel. Turning outwards raises the front of the armrest; turning in-
wards lowers it at the front.
In addition, the armrests can be folded up fully.
- Lumbar support (7): Both the height and the extent of the convexity in the backrest
padding can be individually adjusted by turning the handwheel to the left or right.
- Seat belt (8): The seat belt must be applied before starting up the vehicle.
f The seat belts must be replaced following an accident.

D_3.8_01_EN.fm 5-26
D 3.8 5
Fuse box
The terminal box, which contains all fus-

es and relays, etc. is located beneath the
operating panel guide.
1
- The left box (1) contains the electrical
fuses, the right box (2) contains the re-
lays.
- A key for box (1) is included in the ve-

hicle's scope of delivery; box (2) is
equipped with quick-action locks. 2
A An assignment plan for fuses and relays

can be found in chapter F8.
EBox1_2009.wmf
D_3.8_01_EN.fm 6-26
D 3.8 6
Batteries
The batteries (1) for the 24 V system are

located behind the right lateral flap.
A For the specifications, refer to chapter B,

„Technical Data“. For maintenance, see
chapter „F“.
m External starting must only be carried

out according to the instructions (see
section „Starting the paver finisher, ex-
ternal starting (starting aid)“.
1
Main battery switch
The main switch interrupting the circuit

between the battery and the main fuse is
located under the left maintenance flap.
A For the assignment of all fuses, see

chapter F.
- To interrupt the battery's current cir-

cuit, turn the key pin (3) to the left and
pull it out.
A Do not lose the key pin as in this case

3
the paver finisher can no longer be
moved!
Batterie_2009.wmf/Batterie2_2009.wmf/F0077_A1.eps//F0078_A1.eps
D_3.8_01_EN.fm 7-26
D 3.8 7
Hopper transport safeguard
Before transporting or parking the paver

finisher, the hopper halves must be
swung upwards and the transport safe-
guards for the hopper must be inserted.
Position:
1
- (1) - outside on the two hopper halves
or
- (b) - in the hopper (o)
f Do not enter the hopper while the engine

is running! Danger of being caught by
the conveyor! (o)
Without transport safeguards inserted, b
the hopper halves will slowly open; dan-
ger during transportation!
Hopperlock3_2009.bmp/Hopperlock_SK.eps
D_3.8_01_EN.fm 8-26
D 3.8 8
Paving thickness indicator
1
Two scales, on which the currently set
paving thickness can be read off, are lo-
cated on the left and right sides of the
vehicle.
- In the area of the engine hood (1) for

the vehicle driver.
- On the crossbeam guide (2) for the
screed personnel.
- To change the reading position, the
scale (2) can be raised and lowered
again in one of the adjacent locating
bores (3) (front/rear).
2
f To transport the vehicle, the scale (2)
must be raised and lowered again in one
of the outer locating bores (4) (front/
rear).
The pointer (5) must be swivelled by 90° 5
using the locking knob (6). 6
A In normal paving situations, the same

paving thickness should be set on both
3 4
sides of the vehicle!
m Avoid parallax errors!

Scale1_2009.wmf/Scale2_2009.wmf
Engine compartment lighting
A The engine compartment lighting can be

activated when the ignition is switched 1
on.
- On/off switch (1) for the engine com-

partment lighting.
Enginelight_2009.wmf
D_3.8_01_EN.fm 9-26
D 3.8 9
Auger height adjustment ratchet (o)
For mechanical adjustment of the auger

height
- Set the ratchet direction lever (1) to

the clockwise or anti-clockwise direc-
tion. Turning anti-clockwise lowers the
auger, turning clockwise raises the au-
ger.
1
- Actuate the ratchet lever (2)
2
- Set the desired height by alternatingly
actuating the left and right ratchets.
A The current height can be read on both

auger height indicators. Ratsche_2009.wmf
A Observe the notes on adjusting the auger height in the chapter „Set-up and modifica-
tion“!
Auger height indicators (o)
A scale (1), on which the currently set

auger height can be read off, is located
on the left and right sides of the ladder.
3
A Display in cm or inches (o)
2
1
- To adjust the indicator, the bolt (2) can
be released and the pointer (3) can be
shifted to the desired position.
- Tighten the bolt (2) again following ad-
justment.
m When setting the auger height, adjust-

ment must be carried out evenly on both Schnskal.wmf
sides to prevent the auger from jam-

ming!
D_3.8_01_EN.fm 10-26
D 3.8 10
Screed transport safeguard
During transportation, when the vehicle

is switched off or in the event of damage, 1
the screed is held in position via a non-
return valve.
If it is necessary to lower the screed

when the vehicle is deenergised, the
non-return valve on the hydraulic block
can be opened manually.
- Open the non-return valves on both

hydraulic cylinders by screwing the
knurled screw (1) in.
- Open the non-return valve on the hy-
draulic block at the knob (2):
- Press the knob in and engage by
turning anti-clockwise.
A The screed is lowered as long as the

knob on the non-return valve is pressed
in.
2
f Ensure that there is nobody in the dan-
ger area!
P
f For „normal“ operation, unscrew the

knurled screw (1) on both hydraulic cyl-
inders again and set the knob (2) to its
original position.
Screedvalve.wmf/ScreedValve_09.wmf
D_3.8_01_EN.fm 11-26
D 3.8 11
Sensor rod / sensor rod extension
The sensor rod acts as an orientation aid

for the vehicle driver during paving.
Along the defined paving route, the vehi-
cle driver can use the sensor rod to fol-
low a tensioned reference wire or anot-
her marking.
5
The sensor rod runs along the reference
wire or over the marking. Steering devi- 2 2 1
4
ations can therefore be ascertained and
3
corrected by the driver.
m Use of the sensor rod increases the ba-

sic width of the paver finisher. Peil1_2009.wmf
f If the sensor rod is used, ensure that there is no one in the machine's danger area!
A The sensor rod is adjusted when the vehicle is positioned, with its set working width,
on the paving route and the reference marking running parallel to the paving route has
been set up.
Adjusting the sensor rod:
- The sensor rod (1) is located on the face end of the vehicle and can be pulled out
to the left or right after releasing the four clamping levers (2).
A The sensor rod extension is not pulled out in the case of low working widths.
- Once the sensor rod has been set to the desired width, the clamping levers (b) must
be tightened again.
- In the case of larger working widths, the sensor rod extension (3) can be pulled out
from the sensor rod.
- The pulled-out sensor rod extension is secured with a screw (4).
A Depending on the side of the vehicle on which the sensor rod extension is used, the
entire sensor rod may have to be removed and re-inserted on the other side of the
vehicle!
- After releasing the wing nuts (5), the angle and height of the sensor rod extension's
end section can be adjusted.
- Tighten the wing nuts (5) again following adjustment.
D_3.8_01_EN.fm 12-26
D 3.8 12
Separator fluid spraying system (o)
(o)
Used to spray the parts coming into con-
tact with asphalt with a separator emul-
sion.
- Connect the spray hose (1) with quick-

action coupling (2). 2
- Actuate button (3) to activate and de-
activate the pump.
- The indicator lamp (4) lights up when
the emulsion pump is running.
- Actuate the manual valve (5) to spray.
5
m Only switch on the spraying system
when the diesel engine is running; other- 1
wise, the battery will be discharged.
Switch off after use.
A A permanently installed hose package

(6) for the spraying system is available 6
as an option.
- Pull the hose out of the device until a

click is audible. When released, the
hose automatically engages here. The
hose is automatically retracted into the
guide after pulling and discharging
again.
3
f Do not spray onto open flames or hot
surfaces! Danger of explosion!
4
Emu2a.tif/Sprayhose.wmf/Emulsionstank3_2009.wmf
A The spraying system is fed via a canister

(7) behind the left drive unit. (o)
f Refill the canister only while the machine

is stationary! 7
D_3.8_01_EN.fm 13-26
Emulsionstank_2009.wmf
D 3.8 13
230 V system (o)
(o)
A If equipped with a 230 V system, an ad-

ditional switch cabinet is mounted on the
paver finisher.
- An additional 230 V consumer can be

operated at the socket (1). 1
- This is engaged via the relevant fuse
block (2) in the screed heater's switch
cabinet.
A If no consumer is operated at the socket,

the socket should not be engaged!
E-Box2.wmf/Schalt_230V.wmf
D_3.8_01_EN.fm 14-26
D 3.8 14
Conveyor limit switches
The mechanical conveyor limit switches

(1) or the ultrasonic conveyor limit
switches (2) control the material flow on
the relevant half of the conveyor. The
conveyors should stop when the materi-
al has roughly reached the area below
the auger tube.
A This requires that the auger height has

been adjusted correctly (see chapter E). 1
F0114_A1.EPS/Ultra3.EPS
D_3.8_01_EN.fm 15-26
D 3.8 15
Ultrasonic auger limit switches (left
and right)
A The limit switches control the material

flow at the relevant half of the auger
without contact. 1
5
The ultrasonic sensor (1) is secured to 3
the side shield via a bracket (2). To ad-
just, release the clamping lever / stop 2
screw (3) and adjust the sensor's angle.
The connection cables (4) are connect-
ed to the remote controls located at the 4
sides of the screed.
Ultra_Auger.bmp
A The sensors should be adjusted so that

2/3 of the augers are covered with the paving material.
A The paving material must be conveyed over the full working width.
A We recommend adjusting the limit switch positions during material distribution.
A In vehicles with a PLC control system, the deactivation point is set on the remote con-
trol. In vehicles with a conventional control system, the sensor is fitted with a control-
ler (5) for setting the deactivation point.
24 volt / 12 volt sockets (o) (left and

right)
24 V sockets (1) are located beneath the 2

left/right seat consoles.
Additional working lights can be con-
nected here, for example.
(o) A 12 V socket (2) is additionally lo-

cated on the left-hand side 1
of the vehicle.
- Voltage is present when the main

switch is switched on.
A As an option, one socket can be used to

Ratsche_2009.wmf
provide power for an electrically heated
seat.
D_3.8_01_EN.fm 16-26
D 3.8 16
Pressure control valve for screed
charging/relieving
A valve (1) is used to set the pressure for 1

additional screed charging/relieving.
2
- Switching on, see screed charging/re-

lieving 3
(Chapters „Operating panel“, „Opera-
tion“).
- For pressure indication, see manome-
ter (3).
Pressure control valve for screed

stop with pretensioning
1 2
This valve (2) is located beneath the bot-
tom flap of the operator's platform.
It is used to adjust the pressure for

„screed stop with pretensioning“.
- Activation: see „screed charging/re-

lieving device“.
(Chapters „Operating Panel“, „Opera-
tion“).
- For pressure indication, see manome-
ter (3).
3
Manometer for screed charging/re-

lieving and screed stop with preten-
sioning
The manometer (3) indicates the pres- F0184_A1.TIF/Screed_Valve.eps/F0105_A1.TIF
sure for:
- Screed stop with pretensioning when the drive lever is set to the neutral position
(pressure setting with valve (2));
Screed charging/relieving when the drive lever is in the third position (pressure setting
with valve (1)).
D_3.8_01_EN.fm 17-26
D 3.8 17
Central lubrication system (o)
The central lubrication system is activat-

ed in automatic mode as soon as the
drive engine is started.
- Pumping time: 12 min

- Pause time: 2 h
1
m It is prohibited to change the factory-set
durations of pumping and break without
consulting the technical customer serv-
ice!
A Changing the duration of lubrication and

breaks may be necessary when laying
mineral or cement bound material mix.
Manual start of lubrication (pumping 2

time):
Lincoln3.jpg/Lincoln9.jpg
- Remove the screw cap (1).
- Keep the starting button (2) depressed for at least 2 sec.
- Replace the screw cap (1).
A Observe the instructions in section „Maintenance“!
D_3.8_01_EN.fm 18-26
D 3.8 18
Lane clearer (o)
A swivelling lane clearer (1), which de-

flects small obstacles away to one side,
is located in front of both drive units.
A The lane clearers should only be swiv-

elled down during paving.
1 2
Swivelling the lane clearers:
- Swivel the lane clearer (1) up and se-

cure in the uppermost position with a
shackle (2). 4
- To lower the lane clearer, it must be 3
raised a little and the shackle (2) must 5 mm
be swivelled back.
LW_2009A.bmp
m To avoid collisions, the lane clearer must

be adjusted so that a few mm are available between the ground and the blade (3).
A The blade's level above the ground is adjusted with a bolt (4).
D_3.8_01_EN.fm 19-26
D 3.8 19
Screed eccentric adjustment (o)
(o)
3
To pave thicker layers of material, if the
piston rods in the levelling cylinder are
operating close to their limit position and
if the desired paving thickness cannot be
reached, it is possible to alter the ap- III II
proach angle of the screed by adjusting I
the eccentric.
- Pos. I: Paving thickness up

to approx. 7 cm
2
- Pos. II Paving thickness of approx.
7 cm to approx. 14 cm
1
- Pos. III Paving thickness above
approx. 14 cm Wetterhaus.eps
- The spindle (1) is not adjusted.

- Unfasten locks (2) for eccentric adjustment.
- Swivel screed to the desired position using the lever (3), and engage the locking
knob again.
A If the levelling unit is connected to a height controller, this has the function of balanc-
ing out any rapid rise in the screed position: The levelling cylinders are extended until
the correct height is reached.
- The change in approach angle can only take place slowly and uniformly on both
sides at once during paving operation, and involves the use of eccentric adjust-
ments. Failing this, any rapid response in the screed could easily cause waves to
appear on the road surface.
The setting process should therefore take place before work starts!
D_3.8_01_EN.fm 20-26
D 3.8 20
Fire extinguisher (o)
(o)
A The suitable fire extinguisher version
must be selected by the vehicle operator
depending on the type of operation.
A The paver finisher personnel must be fa-

miliarised with fire extinguisher opera-
tion.
A Observe the inspection intervals for the

fire extinguisher!
Feuerlösch_2009.wmf
Rotary beacon (o)

(o)
m The function of the rotary beacon must

be checked daily before starting work.
2
- Place the rotary beacon onto the plug- 1
in contact and secure with a wing bolt
(1).
- Raise the bracket (2), swivel to the
outer position and allow to engage
there. 4
- Slide the rotary beacon with tube (3) to
the desired height and secure with the
3
clamping bolt (4).
- Activate the function on the operating
Rundum_2009.wmf
panel as necessary.
A The rotary beacon is easy to remove and should be stored securely at the end of
work.
D_3.8_01_EN.fm 21-26
D 3.8 21
Auger compartment lighting (o)
(o)
Two working lights are located on the left
and right on the roof console for illumi-
nating the auger compartment.
A These are activated together with the

other working lights on the operating
panel!
Lamp_2009..wmf
D_3.8_01_EN.fm 22-26
D 3.8 22
Fuelling pump (o)
(o)
m The fuelling pump must only be used to

pump diesel fuel.
m Foreign bodies which are larger than the

mesh size of the intake cage (1) lead to
damage. An intake cage must therefore
always be used.
4
m Each time fuelling is carried out, the in-
take cage (1) must be checked for dam-
age, and must be replaced if damaged. 1
Do not work without it under any circum-
stances, as the fuelling pump is not oth- 2 3
erwise protected against foreign bodies. Fuelpump_2009.wmf
- Insert the suction hose (2) into the container which is to be emptied.
A To enable the container to be emptied completely, the suction hose must reach down
to the floor of the container.
- Activate the function on the operating panel as necessary.
m The fuelling pump does not shut off automatically. Therefore, never leave the pump
unattended when fuelling!
m Never operate the pump without pumping a fluid. The risk of damaging your diesel
pump is run if it runs dry.
- To end fuelling, switch the function „off“ on the operating panel.

- Place the end of the hose, with the intake cage, into its cup (3) so that no diesel is
able to escape into the environment.
- Gather up the hose and place it over the bracket (4).
D_3.8_01_EN.fm 23-26
D 3.8 23
Power moon (o)
The power moon is a special, illuminated 2

balloon with shadow-reducing and anti- 1
dazzle light.
f Use of the power moon increases the

height of the paver finisher.
f Note the passage height of bridges and

tunnels.
f The power moon must not be used in the

vicinity of highly flammable materials
(e.g. petrol and gas); a safety distance of
at least 1 metre must be maintained from
combustible materials.
f A safety distance of at least 50 m must

be maintained from high-voltage lines,
and at least 2.5 m from railway track volt-
age lines.
f The power moon must not be operated if

the electric supply cables or connectors
are damaged.
- Hold the handle (1) tightly and pull the

detent pin (2) out.
- Press the handle down until the detent
pin engages.
m Before starting up, check whether the

Velcro seal around the power moon is
closed. If the skin is damaged, it must be
repaired or replaced. The bulbs must be
checked for firm seating and damage.
Powerm1.wmf/Powerm2.wmf
D_3.8_01_EN.fm 24-26
D 3.8 24
- Secure the lower part of the tripod (3)
to the preassembled bracket (5) using
the relevant assembly parts (4). 8
- Connect the tripod sections (6) and
secure with stop screws (7).
- Place the power moon's journal (8)
onto the top part of the tripod and se-
cure with the stop screws (9).
9
- Finally, place the assembled tripod
sections, together with the power
moon, onto the lower part of the tripod 6
(3) and secure with the stop screws
(10).
- When the power moon has been fully 7
assembled and secured, the power
moon connector (11) can be connect-
ed to its current supply. 6
- The power moon is switched off by re-
moving the power connector (11) from 10
the socket. 5
3
11
4
Powermoon_2009.bmp
D_3.8_01_EN.fm 25-26
D 3.8 25
D 4.17 Operation
1 Preparing for operation
Required devices and aids
To avoid delays on site, check before starting work whether or not the following de-
vices and aids are present:
- Wheel loader for transporting heavy extension parts

- Diesel fuel
- Engine oil and hydraulic oil, lubricants
- Separator fluids (emulsion) and manual injector
- Two filled propane gas bottles (o)
- Shovel and broom
- Scraper (spatula) for cleaning the auger and the hopper infeed area
- Parts that may become necessary for extending the auger
- Parts that may become necessary for extending the screed
- Percentage spirit level + levelling rail, 4 m long
- Levelling wire
- Protective clothing, signal vest, gloves, ear protection
Before starting work

(in the morning or when starting paving)
- Heed the safety instructions.

- Check the personal protective equipment.
- Take an inspection walk around the paver finisher and check for leaks and damag-
es.
- Install parts removed for transportation or for the night.
- When screed is operated with the optional gas heating system, open the closing
valves and the main shut-off valve.
- Perform the check according to the „Checklist for the machine operator“ given be-
low.
D_4.17_01_EN.fm 1-34
D 4.17 1
Check list for the machine operator
Check! How?
Emergency stop button Push in the button.
- on the operating panel The diesel engine and all running drives
- on both remote control units o must stop immediately.
The paver finisher must immediately fol-
low every steering wheel movement in a
Steering
precise manner. Check straight ahead
travel.
Horn
Briefly press the horn button.
- on the operating panel
Horn signal must sound.
- on both remote control units o
Switch on with the ignition key, walk
Lights around the paver finisher to check and
switch off again.
With the ignition switched on, press the
Screed hazard flasher switches for extending/retracting the
(with vario screeds) screed parts.
The rear lights must flash.
Gas heater system (o): Check:
- Bottle holders - Secure seat
- Bottle valves - Cleanliness and tightness
- Pressure reducer - Working pressure 1.5 bar
- Hose break safety devices - Function
- Shut-off valves - Function
- Main shut-off valve - Function
- Connections - Tightness
- Indicator lamps of the switch box - All indicator lamps must light up when
the system is switched on
D_4.17_01_EN.fm 2-34
D 4.17 2
Check! How?
For larger working widths, the walkway
Auger coverings plates must be extended and the auger
tunnels must be covered.
For larger working widths, the walkway
plates must be extended.
Hinged walkway plates must be swung
Screed covers and walkways down.
Check that the side shields, the side
plates and the covers are securely seat-
ed.
When the hopper is closed, it must be
possible to push the locking bolts on
Hopper transport safeguard
both halves of the hopper into the
relevant locating bores.
The screed must be held in its relevant
Screed transport safeguard position by the hydraulic non-return
valves.
Both locking bolts must be in the provid-
Protective roof
ed bore hole.
Miscellaneous:
Check that the hoods and flaps are se-
- Engine panels
curely seated.
- Lateral flaps
Accessories:
- Wheel chocks The accessories must be in the provided
- Warning triangle holders.
- First aid box
D_4.17_01_EN.fm 3-34
D 4.17 3
1.1 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 mainte-
nance work (e.g. monthly or annual maintenance) must be performed.
- Check the safety devices and protective devices.
D_4.17_01_EN.fm 4-34
D 4.17 4
„Normal“ starting
10
12
15 11 13
- Set the drive lever (13) to the centre position and the travel drive preselector (15) to
minimum.
- Insert the ignition key (11) in position „0“.
m The lights should be switched off during starting to reduce the current drain on the
battery.
A It is impossible to start the machine, if the drive lever is not in the central position or
if one of the emergency stop buttons (10) is depressed.
(„STOP“ is seen on the LC display)
- Press the starter button (12) to start the engine. Do not let the starter run perma-
nently for more than 20 seconds; allow for a break of 1 minute after every attempt!
D_4.17_01_EN.fm 5-34
D 4.17 5
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:
10
12
15 11 13
- Switch on the ignition (11), set the drive lever (13) to the centre position and the
travel drive preselector (15) to minimum.
- Use appropriate cables to connect the external power source.
m Observe the polarity! Always connect the negative cable last and disconnect it first!
A It is impossible to start the machine, if the drive lever is not in the central position or
if one of the emergency stop buttons (10) is depressed.
(“STOP“ is seen on the LC display)
- Press the starter button (12) to start the engine. Do not let the starter run perma-
D_4.17_01_EN.fm 6-34
nently for more than 20 seconds; allow for a break of 1 minute after every attempt!
When the engine is running:
- Disconnect the power source.
D 4.17 6
After starting
59
13
To increase the engine speed:
- Set the drive lever (13) to position 1 (slightly off the centre position).
- Press button (59) to increase engine speed.
A The engine speed is increased to the preset value.
m Let the paver finisher warm up for approx. 5 minutes if the engine is cold.
D_4.17_01_EN.fm 7-34
D 4.17 7
Observe indicator lamps
The following indicator lamps must be observed under all circumstances:
For further possible faults, refer to the Operating instructions for the engine.
Oil pressure indicator lamp for the travel drive (79)
59
48 49
44 45
79
13
- Must go out after starting.
m If the lamp does not go out:

Do not switch on the traction drive! Otherwise, the entire hydraulic system could be
damaged.
When the hydraulic oil is cold:
- Set the conveyor switch (44)/(45) to „manual“ and the auger switch (48)/(49)
to „manual“.
- The remote control must be connected and the auger functions must be set
to „auto“.
- Set the drive lever (13) to position 1.
- Press switch (59) to increase engine speed. Conveyor and auger start to operate.
- Let the hydraulics warm up until the indicator lamp goes out.
A The lamp goes out when the pressure drops below 2.8 bar = 40 psi.
D_4.17_01_EN.fm 8-34
For further possible malfunctions, refer to section „Malfunctions“.
D 4.17 8
Battery charge indicator (70)
70
Must go out after starting when the engine revs up.
m If the lamp does not go out or lights up during operation: Briefly rev up the engine.
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_4.17_01_EN.fm 9-34
D 4.17 9
1.2 Operation in case of transportation
Lifting and securing the screed

62 65
56
52
50
51
53
- Switch (56) must be switched off

- Switch off the switch (65) and raise the screed using switch (62).
- Extend the levelling cylinders completely using the switches (50)/(52)/(53).
A The remote control must be connected and this function must be set to „Manual“.
- Raise the auger crossbeam using the switches (51)/(52)/(53).

A The screed is hydraulically secured in the raised position.
D_4.17_01_EN.fm 10-34
D 4.17 10
Driving and stopping the paver finisher
66
10
15 11 13
- Set the Fast/Slow switch (66) to „Hare“.

- Set the preselector (15) to mark 10.
- For driving, carefully tilt the drive lever (13) forward or backward according to the
drive direction desired.
f In case of an emergency, press the emergency stop button ((10)!
- To stop the vehicle, move the drive lever (13) into its centre position.
Switching off and securing the paver finisher
- Turn the ignition key (11) to the „0“ position and pull it out to switch off the engine.
m The battery may be exhausted if the paver finisher stands still for longer periods of
time with the ignition switched on.
- Lower the screed.

D_4.17_01_EN.fm 11-34
D 4.17 11
1.3 Preparations for paving
Separator fluid
Spray the parts coming into contact with

asphalt (hopper, screed, auger, push
roller) with a separator fluid.
m Do not use diesel fuel as it dissolves the

bitumen (prohibited in Germany!).
F0147_A1.TIF
Screed heater system
Switch on the screed heater approx. 15–30 minutes (depending on the ambient tem-
perature) before paving begins. Warming up prevents the material from sticking to the
screed plates.
Direction marks
To ensure straight paving, a direction

mark must be present or established
(road edge, chalk lines or similar).
- Slide the operating panel to the de-

sired side and secure it.
- Pull the direction indicator out of the
bumper (arrow) and adjust it accord-
ingly.
Peil1_2009.wmf
D_4.17_01_EN.fm 12-34
D 4.17 12
Loading/distributing material
58
56
48 49
44 45
32 33
- Button (56) has to be switched off.

- Use switch (32)/(33) to open the hopper.
Instruct the truck driver to dump the material.
- Set the switches for the auger (48)/(49) and the conveyor (44)/(45) to „Auto“.
- Activate function (58) to fill the vehicle for the paving process.
D_4.17_01_EN.fm 13-34
D 4.17 13
- Switch the conveyors on.
The limit switches for the conveyors
(89) or (89ao must switch off when
the material has reached the area be-
neath the auger crossbeam.
- Check that the material is transferred
properly.
Manually switch on or off the conveyor
if the material is not conveyed properly
until a sufficient amount of material
lies in front of the screed.
89
89a
F0114_A1.EPS/Ultra3.EPS
D_4.17_01_EN.fm 14-34
D 4.17 14
1.4 Driving off for laying
61 60 67
57
46 47
42 43
15 13
102
A 105
107
D_4.17_01_EN.fm 15-34
Bedienpult2_2009_PLC_C.bmp/Remote_SPS_neu1cdr
D 4.17 15
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 Travelling direction Position

67 Traction drive fast/slow Tortoise-operating speed
15 Travel drive preselector Mark 6-7
Preparation for screed floating posi-
57 LED ON
tion
61 Vibration LED ON
60 Tamper LED ON
42/43
Auger left/right auto
107
46/47
Conveyor left/right auto
105
102 Levelling auto
A Speed regulator, vibration approx.40-60
B Speed control for the tamper approx.40-60
- Push the drive lever (13) all the way to the front and start driving.
- Observe the distribution of the material and adjust the limit switches if necessary.
- Set the compacting elements (tamper / vibration) according to the required com-
paction ratio.
- Let the paving master check the paving thickness after 5–6 meters and correct if
necessary.
Carry out the check in the area of the caterpillar chains or drive wheels as the screed
tends to level an uneven ground. The reference points for the layer thickness are the
caterpillar chains or drive wheels.
The basic setting of the screed must be corrected when the actual layer thickness de-
viates significantly from the values indicated by the scales (see the operating instruc-
tions for the screed).
A The basic setting is for asphalt material.

D_4.17_01_EN.fm 16-34
D 4.17 16
1.5 Checks during paving
The following points must be constantly observed during paving:
Paver function
- Screed heater system

- Tamper and vibration
- Engine oil and hydraulic oil temperature
- The screed parts must be retracted and extended in time when obstacles are in the
way
- Uniform material transport and distribution or supply to the screed; may require cor-
rections to settings of the material switches for conveyor and auger.
A See the section „Malfunctions“ when paver finisher functions fail.
Quality of the layer
- Paving thickness
- Slope
- Evenness in the driving direction and at right angles to it (check with 4 m levelling
rod)
- Surface structure/texture behind the screed.
A See section „Malfunctions, problems during paving“ if the paving quality is poor.
D_4.17_01_EN.fm 17-34
D 4.17 17
1.6 Paving with screed stop and screed charging/relieving
General
The screed hydraulics can be influenced in two ways to attain optimum paving re-
sults:
- Screed stop with prestressing

with the paver finisher halted,
- Screed charging or relieving
with the paver finisher driving.
A Relieving reduces the screed weight and increases the traction force.
Charging increases the screed weight, reduces the traction force, but increases the
compaction ratio. (To be used with light-weight screeds in exceptional cases.)
Screed charging/relieving
This function charges or relieves the screed regardless of its own dead weight.
64
65
Function (64) Relieving (screed „lighter“)

Function (65) Charging (screed „heavier“)
The „Screed charging and relieving“ functions are only effective when the paver fin-
D_4.17_01_EN.fm 18-34
isher moves. When the paver finisher stops, „Screed stop“ is automatically selected.
D 4.17 18
Screed stop with prestressing
Via „Screed stop“, the screed is held by the relieving pressure and the
counter pressure of the material to prevent the screed from sinking in when the paver
finisher stops during paving.
62
57
- Automatic screed stop when the drive lever is in the centre position
- To raise the screed press switch (62).
- To lower the screed:
- Resting function: Keep button (57) pressed for longer than 1.5 seconds. The
screed is lowered as long as the button is pressed. When the button is released,
the screed is stopped again.
- Button function: Press button (57) briefly - the screed is lowered. Press the button
briefly again - the screed is stopped.
As in the case of screed charging and relieving, a pressure of 2-50 bar is separately
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 support-
ing the screed stop function, especially in situations where the screed relieving func-
tion 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.
D_4.17_01_EN.fm 19-34
A pressure greater than 10-15 bar neutralises the screed weight, thus preventing the
screed from sinking into the material.
D 4.17 19
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.
D_4.17_01_EN.fm 20-34
D 4.17 20
Adjusting the pressure (o)
64
62
65
56
57
59
15 13
Pressure adjustments can only be made while the diesel engine is running. There-
fore:
- Start the diesel engine and turn the traction controller (15) back to zero (precaution
against inadvertent advancing).
- Activate the „floating position“ using switch (57).
Screed stop (with prestressing):
- Set the drive lever (13) to the centre position.

- Set switch (56) to position (LED OFF) and switch (59) to position (LED OFF).
- Use control valve (93a) (below the bottom plate of the operator's platform) to adjust
the pressure and read it off at the manometer (93c).
(Basic setting: 20 bar)
D_4.17_01_EN.fm 21-34
D 4.17 21
For screed charging/relieving:
93c
- Set the drive lever (13) to the centre
position.
- Set switch (56) to position (LED OFF)
and switch (59) to position (LED ON).
- Select the desired function (LED ON):
- (Relieving (64))
- (Charging (65))
- Use control valve (93b) (below the
bottom plate of the operator's plat-
form) to adjust the pressure and read 93b
it off at the manometer (93c).
93a
A When screed charging/relieving is nec-

essary 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 correct-

ed during paving. (max. 50 bar)
F0103_A1.EPS/Screedvalve.eps
D_4.17_01_EN.fm 22-34
D 4.17 22
1.7 Interrupting/terminating operation
During breaksin paving (e.g. the material supply truck is late)
15 13
- Determine the approximate duration.

- When cooling down of the material below the minimum paving temperature must
be expected, run the paver finisher empty and create an edge like the end of a lay-
er.
- Set the drive lever (13) to the centre position.
During longer breaks(e.g. lunch break)
- Drive lever (13) into centre position, RPM speed adjustment (15) to minimum posi-
tion.
- Switch off the ignition.
- Switch the screed heater system off.
- When screed is operated with the optional gas heating system, close the valves of
the bottles.
A The screed must be heated up to the correct paving temperature before paving may
be restarted.
D_4.17_01_EN.fm 23-34
D 4.17 23
When work is finished
62
15 11 13
- Run the paver finisher empty and stop it.

- Lift the screed by using switch (62).
- Retract the screed parts to the basic screed width and lift the auger. Where appli-
cable, completely extend the levelling cylinders.
A The screed is hydraulically secured in the raised position.
- While operating the tampers at a low speed, let any material residues drop out.
- Set the drive lever (13) to the centre position and the speed adjuster (15) to mini-
mum.
- Switch off the ignition (11).
- Switch the screed heater system off.
- 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.
D_4.17_01_EN.fm 24-34
D 4.17 24
- Read and check the oper-
ating hour meter to deter-
mine whether maintenance
work must be performed
(see chapter F).
- Cover and lock the operat-
ing panel.
- Remove material residues
from the screed and the
paver finisher and spray all
parts with separator fluid.
D_4.17_01_EN.fm 25-34
D 4.17 25
2 Malfunctions
2.1 Problems during paving
Problem Reason
- change in the material temperature, demixing
- wrong material composition
- incorrect operation of the roller
- incorrectly prepared foundation
- long standstill times between loads
- grade control reference line is not suitable
- grade control jumps to the reference line
- grade control toggles between up and down
Wavy surface
(inertia setting is too high)
(„short waves“)
- bottom plates of the screed are loose
- bottom plates of the screed are warped or not uniformly
worn
- screed is not operated in the floating position
- too much play in the mechanical screed link/suspension
- paver finisher speed is too high
- augers are overloaded
- changing material pressure against the screed
- change in the material temperature
- demixing
- roller has stopped on the hot material
- roller has turned or roller speed has been changed too fast
- incorrect operation of the roller
- truck brake is applied too tight
- long standstill times between loads
Wavy surface
- grade control reference line is not suitable
(“long waves”)
- incorrect installation of the grade control
- limit switch is not correctly set
- screed is empty
- screed has not been switched to the floating position
- too much play in the mechanical screed link
- auger is set too deep
- auger is overloaded
- material temperature is too low
- moisture on the foundation
Cracks in the layer - demixing
(over the entire - wrong material composition
width) - wrong layer height for maximum grain size
- cold screed
- bottom plates of the screed are worn or warped
D_4.17_01_EN.fm 26-34

- material temperature
Cracks in the layer - cold screed
(centre strip) - bottom plates are worn or warped
- wrong crowning
D 4.17 26
Problem Reason
- screed extendable parts are incorrectly installed
Cracks in the layer - limit switch is not correctly set
(outer strip) - cold screed
- bottom plates are worn or warped
- moisture on the foundation
- demixing
- wrong material composition
- wrong layer height for maximum grain size
Layer composition is - long standstill times between loads
not uniform - vibration is too slow
- screed extendable parts are incorrectly installed
- cold screed
- bottom plates are worn or warped
- screed is not operated in the floating position
- auger is overloaded
- truck hits too much against the finisher while aligning to the
finisher
Marks in the surface - too much play in the mechanical screed link/suspension
- truck brake is applied
- vibration is too high while standing on a spot
Screed does not re- - wrong layer height for maximum grain size
act to corrective - incorrect installation of the grade control
measures as expect- - vibration is too slow
ed - screed is not operated in the floating position
- too much play in the mechanical screed link
D_4.17_01_EN.fm 27-34
D 4.17 27
2.2 Malfunctions on the paver finisher or scree
Malfunction Reason Remedy

See operating instructions for the
At the diesel engine Diverse
engine
See „External starting“ (start as-
Diesel engine does Batteries empty
sistance)
not start
Diverse see „Towing“
Tamper is obstructed by
Properly heat the screed
cold bitumen
Hydraulic oil level in the tank
Top up the oil
is too low
Pressure limiting valve is Replace the valve; if necessary,
Tamper or vibration
defective repair and adjust the valve
is not functioning
Seal or replace the connections
Leak in the suction line of
Tighten or replace the hose
the pump
clamps
Clean the filter; if necessary, re-
Oil filter is soiled
place the filter
Hydraulic oil level in the tank
Top up the oil
is too low
Check fuses and cables; replace
Power supply interrupted
if necessary
Switch is defective Replace the switch
One of the pressure limiting
Repair or exchange the valves
Conveyor or augers valves is defective
run too slowly Pump shaft broken Replace the pump
Limit switch does not switch Check the switch; replace and
or regulate correctly adjust the switch if necessary
Check the high pressure filter for
Pump is defective dirt particles; replace if neces-
sary
Oil filter is soiled Replace the filter
Engine speed is too low Increase the speed
Hydraulic oil level is too low Top up the oil
Leak in the suction line Tighten the connections
Flow rate regulator defec-
Replace
Hopper cannot be tive
swung open Leaking seals of the hydrau-
Replace
lic cylinder
Control valve is defective Replace
Check fuse and cables; replace if
necessary
D_4.17_01_EN.fm 28-34
D 4.17 28
Control valve is defective Replace
Hoppers lowers inad-
Leaking seals of the hydrau-
vertently Replace
lic cylinder
Oil pressure too low Increase the oil pressure
Leaking seal Replace
Screed cannot be lift- Screed relieving or charging Switch must be in the centre po-
ed is switched on sition
necessary
Switch on the remote con-
Set the switch to „Manual“
trol is set to „Auto“
necessary
Switch on the operating
Crossbeams cannot Replace
panel defective
be lifted or lowered
Excess pressure valve de-
Replace
fective
Flow rate regulator defec-
Replace
tive
Seals defective Replace
Control valves defective Replace
Crossbeams lower Pilot-controlled non-return
Replace
inadvertently valves defective
Seals defective Replace
D_4.17_01_EN.fm 29-34
D 4.17 29
Replace (Fuse strip on the oper-
Traction drive fuse defective
ating panel)
Check potentiometer, cables,
connectors; replace if necessary
Travel drive monitoring
Replace
(type-specific) defective
Traction does not Electro-hydraulic servo unit
Replace the servo unit
work of the pump defective
Check and adjust if necessary
Insufficient supply pressure Check the suction filter; replace
the supply pump and the filter if
necessary
Drive shaft of hydraulic
Replace pump or engine
pumps or engines broken
Check the fuel level; refill fuel if
Fuel level too low
Irregular engine necessary
speed, engine stop Fuse „engine speed control“ Replace (fuse strip on the oper-
function does not defective ating panel)
work Electrical power defect Check potentiometer, cables,
(line break or short circuit) connectors; replace if necessary
D_4.17_01_EN.fm 30-34
D 4.17 30
3 Emergency device/steering, travel drive
In case of a malfunction 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 caterpillar machine.
To install the emergency device all plugs of the travel drive pump servo valves have
to be replaced by the plugs of the emergency device. (A short screw driver is neces-
sary for unscrewing the plugs.)
The plug of the hydraulic brake valve is replaced by the corresponding plug of the
emergency device.
Electrical power is provided via one of the 24V sockets.
The current power supply is connected to the operating panel.
To connect the plugs follow the wiring diagram on the next page.
2 3
Following functions are located in the control unit:
Item Designation
1 Switch for preselection of the zero position and forward reverse movement
2 Adjustment knob for speed control (Replace speed preselector)
3 Steering knob
4 Switch to turn the paver on the spot
D_4.17_01_EN.fm 31-34
D 4.17 31
Function
If the emergency device is connected all functions like engine speed, conveyor, au-
ger, tamper and vibration have to be controlled by the drive lever.
Driving off for laying
- Preselect the speed with turning knob (2)

- Push switch (1) in laying direction
- Engage drive lever like under normal conditions
- All other functions (3, 4) have to be in the position described in the instruction man-
ual
Transport
- Adjust turning knob (2) to a low speed

- Push switch (1) to the recommended direction
- Engage the drive lever to forward direction.
If the recommended direction is reverse, the drive lever should still be moved to for-
ward direction
- Adjust the driving speed with turning knob (2)
- All other functions have to be in the position described in the instruction manual.
f Whenever the engine is started, switch (1) must be in neutral position because the
machine would otherwise set off immediately! Danger of accidents!
D_4.17_01_EN.fm 32-34
D 4.17 32
GREY
Wiring harness
for the
BLACK drive pump
on the left drive unit
marked YELLOW!
24 V / earth/ground
D_4.17_01_EN.fm 33-34
control unit
D 4.17 33
E 04 Set-up and modification
1 Special notes on safety
f Danger to personnel by inadvertent starting of the engine, travel drive, conveyor, au-
ger, screed or screed lifting devices.
Unless otherwise specified, 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 applica-
ble, remove the travel drive fuse from the operating panel; pull out the ignition key
and the main battery switch.
- Protect raised machine parts (e.g. screed or hopper) against lowering by means of
mechanical safeguards.
- Replace parts or have them replaced as stipulated.
f When connecting or disconnecting hydraulic hoses and when working on the hydrau-
lic system, hot hydraulic fluid may spurt out at high pressure.
Switch off the engine and depressurise the hydraulic system! Protect your eyes!
- Mount all protective devices before re-commissioning the paver finisher.

- The walkway must always reach over the entire working width of the screed.
The hinged walkway (option for all variable screeds) may only be swung up under
the following circumstances:
- When paving next to a wall or a similar obstacle.
- During transportation on a low-bed trailer.
E_04_EN.fm. 1-36
E 04 1
2 Distribution auger
2.1 Height adjustment

1
Depending on the mix of materials, the
set height of the distribution auger (1) –
measured from its bottom edge – should
lie above the material layer height.
Grain sizes up to 16 mm
Example:
Paving thickness 10 cm F0130_A1.TIF
Min. height setting 15 cm
from the ground
Grain sizes > 16 mm
Example:
Paving thickness 10 cm
Min. height setting 18 cm
from the ground
A An incorrect height setting can result in the following problems during paving:
- 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 by the screed (wavy surface).
In addition, increased auger segment wear occurs.
E_04_EN.fm. 2-36
E 04 2
2.2 Mechanical adjustment with ratchet
(o)
- Set the ratchet direction lever (1) to

the clockwise or anti-clockwise direc-
tion. Turning anti-clockwise lowers the
auger, turning clockwise raises the au-
ger.
- Set the desired height by alternatingly 1
adjusting the right-hand and the left-
hand side.
- The current height can be read at the
scale (2).
2.3 Hydraulic adjustment (o)
- Determine the currently set height of

the auger crossbeam - left and right on
the scale (2).
m Actuate both of the corresponding func-

tion buttons on the operating panel
evenly to prevent the auger crossbeam
from jamming.
2
- Check whether the heights on the left
and on the right are identical.
Ratsche_2009.wmf / Schnskal.wmf
E_04_EN.fm. 3-36
E 04 3
2.4 Height adjustment for large working widths / with brace
1 2
3
5
4
Abstreb0_2009.wmf
Auger height adjustment for large working widths can be carried out with a hinged
brace:
m Only adjust the height of the auger with the slewing bracket retaining pins removed!
- Remove the slewing bracket (3) split pin (1) and retaining pin (2) on both sides of
the vehicle.
- Push the slewing brackets with braces from the attaching point on the material
shaft.
- Carry out height adjustment.
- Push the slewing brackets with braces onto the attaching point on the material
shaft.
- Install the split pin (1) and retaining pin (2) again.
A If the retaining pins (2) cannot be inserted in the new position, the braces must be
extended or shortened by rotating the adjustment rods until a continuous bore ena-
bles the retaining pin (2) to be inserted.
- Loosen lock nuts (4).
A The adjustment rods (5) are each equipped with a bore. A suitable drift can be used
to adjust the length of the adjustment rod here.
- Extend or shorten the braces by rotating the adjustment rods (5) until the retaining
pins can be inserted.
- Retighten the lock nuts (4).
- Install the split pin (1) and retaining pin (2).
m Each time the height is adjusted, the auger must be realigned via the braces!
E_04_EN.fm. 4-36
A See section „Aligning the auger“!
E 04 4
3 Auger extension
Auger_DEM.bmp
Depending on the type of screed, the most diversified working widths can be reached.
A Auger and screed extension must match.

Refer to the appropriate chapter „Set-up and modification“ in the Operating instruc-
tions for the screed:
– screed extension chart
To attain the desired working width, the respective screed extensions, side plates, au-
gers, tunnel plates or cut-off shoes must be mounted.
For 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.
f The diesel engine must be switched off whenever work is performed on the auger.
Danger of injuries!
A If the operating conditions on the construction site permit an auger extension to be

fitted, or render this necessary, always additionally fit the outer auger bearings.
For auger width extensions with an outer auger bearing on the basic unit, fit the short-
er auger blade to the bearing. Otherwise, destruction between the auger blade and
bearing may occur.
E_04_EN.fm. 5-36
E 04 5
3.1 Mounting extension parts
Mounting the material shaft and auger extension
1
4
Augerparts1_DEM.wmf/Augerparts2_DEM.wmf
- Secure the additional material shaft (1) to the basic unit or the adjacent material
shaft with the relevant assembly parts (2) (bolts, washers, nuts).
- Remove plug (3).
- Remove the assembly parts (4) of the adjacent auger blade; insert the auger shaft
extension into the auger shaft.
- Reinstall the previously removed assembly parts (4) and simultaneously tighten the
auger shaft bolts.
- Insert the plug (3) at the end of the auger.
A Depending on the operating width, the outer auger bearing and/or auger end bearing
must be installed:
E_04_EN.fm. 6-36
E 04 6
Mounting the outer auger bearing
1
2
3
6
5
Augerparts5_DEM.wmf
- Remove plug (1).

- Remove the assembly parts (2) of the adjacent auger blade; insert the outer auger
bearing (3) into the auger extension.
- Secure the outer auger bearing to the brace shaft with the relevant assembly parts
(4) (bolts, washers, pins).
- Reinstall the previously removed assembly parts (2) and simultaneously tighten the
auger shaft and bearing shaft bolts.
- Mount the auger half (5) on the outer side of the bearing with the relevant assembly
parts (6) (bolts, washers, nuts).
E_04_EN.fm. 7-36
E 04 7
Mounting the auger end bearing
4
2
1
7
6
5
3
Augerparts3_DEM.wmf/Augerparts4_DEM.wmf
- The auger end bearing must first be pre-assembled:

- Mount the auger end bearing (1) together with the fitted plate (2) on the interme-
diate plate (4) with the relevant assembly parts (3) (bolt, washer).
- Remove plug (5).
- Remove the assembly parts (6) of the adjacent auger blade; insert the auger end
bearing (7) into the auger extension.
- Secure the auger end bearing to the material shaft with the relevant assembly parts
(8) (bolts, washers, nuts).
- Reinstall the previously removed assembly parts (6) of the auger blade and simul-
taneously tighten the auger shaft and bearing shaft bolts.
E_04_EN.fm. 8-36
E 04 8
3.2 Auger extension chart
Symbol Meaning
- (160L) - Auger blade 160 mm left
160L 160R - (160R) - Auger blade 160 mm right
- Auger extension part 320 mm

- (320L)
left
320L 320R - Auger extension part 320 mm
- (320R)
right
- (640L)
right
- (640R)
right
- (960L)
left
- (960R)
right
- (320) - Material shaft 320 mm
320
640

960
- Material shaft 960 mm with

- (960BL)
brace left
960BL 960BR
- Material shaft 960 mm with
- (960BR)
brace right
Outer auger bearing

E_04_EN.fm. 9-36
Auger end bearing
E 04 9
Auger upgrading as of 3.14 m
320 320
320 L 320 R
640 640
640 L 640 R
Auger upgrading as of 4.42 m E_04_EN.fm. 10-36
320 640 640 320
320 L 640 L 640 R 320 R
E 04 10
320 960 960 320
320 L 960 L 960 R 320 R
640 960 960 640
640 L 960 L 960 R 640 R

E_04_EN.fm. 11-36
E 04 11
E 04 12
m m
960BL 960 960 960BR
160L 160R
640 L 960 L 960 R 640 R
E_04_EN.fm. 12-36
E_04_EN.fm. 13-36
m m
320 640 960 960 640 320
160L 160R
320 L 640 L 960 L 960 R 640 R 320 R
E 04 13
E 04 14
m m
640 960BL 960 960 960BR 640
160L 160R
640 L 640 L 960 L 960 R 640 R 640 R
E_04_EN.fm. 14-36
E_04_EN.fm. 15-36
m m
320 640 960BL 960 960 960BR 640 320
160L 160R
320 L 640 L 640 L 960 L 960 R 640 R 640 R 320 R
E 04 15
E 04 16
m m
640 640 960BL 960 960 960BR 640 640
160L 160R
640 L 640 L 640 L 960 L 960 R 640 R 640 R 640 R
E_04_EN.fm. 16-36
E_04_EN.fm. 17-36
3.3
2
1
25
1
23
3
4
24
5
7 6 23
Mounting the auger brace
15
20 21 26 22
11
8
26
19 14
17
27
13
18
18 10
12
9 16
E 04 17
A Before mounting the auger brace, the required auger height should already have
been set on the basic auger!
Note the section „Height adjustment for large operating widths / with brace“!
- Mount the left/right guide plates (1) on the vehicle frame shackles with the relevant
assembly parts (2).
A The guide plates must be mounted on the front side of the shackles.
- Slide the support shackle (3) over the guide plate and secure in the groove with a
pin (4) and split pin (5).
- Slide the lower support shackle (3) over the attaching point of the material shaft and
secure with a pin (6) and split pin (7).
- Mount the brace bracket (8) on the drive unit with the assembly parts (9).
A The inclination on the bracket must point in the direction of travel!
- Insert the fulcrum bracket (10) into the brace bracket (8) and secure with the retain-
ing pin (11).
- Secure the retaining pin (11) with a split pin (12).
A The first brace set must be set in the rear bore. If the operating width necessitates a
second brace, the front bore must be used!
- Mount the slewing bracket (14) at the brace shaft (13) with retaining pins (15).
- Secure the retaining pins (15) with a split pin (16).
- Mount the braces (17) on the fulcrum bracket (10) with the assembly parts (18).
A The braces must be mounted on the outer side of the fulcrum bracket (10)!
- Remove the spring cotter pin (19) and retaining pin (20), pull out the adjustment rod
(21) until the brace can be mounted on the slewing bracket (14) together with the
corresponding assembly parts (22).
- Secure the adjustment rod (21) in an appropriate bore with a retaining pin (20) and
spring cotter pin (19).
- Mount the vertical brace (23) in the same way.

- In this case, secure the vertical brace at the outer auger bearing (24) and the low-
er support bore (25).
A At the support (3) mounting point, the brace must be secured at the rear side in each
case!
E_04_EN.fm. 18-36
E 04 18
3.4 Aligning the auger
- Loosen lock nuts (26).
A Note the left-hand thread (L) and right-hand thread (R) mark on the brace!
- Extend or shorten the braces (17) by rotating both adjustment rods (21) until all
mounted material shafts align with the auger.
A The adjustment rod (21) is equipped with a bore (27) on the left and right. A suitable
drift can be used to adjust the length of the adjustment rod here. The rotational direc-
tion for extending or shortening the adjustment rod is determined by the left-hand
thread (L) or right-hand thread (R).
A A cord, which aligns with the screed or the rear wall of the vehicle, can be tensioned
e.g. to provide assistance during alignment!
- Extend the upper and lower adjustment rods until the material shafts are aligned
vertically.
- Retighten the lock nuts (26).

- Align the auger height in the same way by adjusting the vertical brace (23).
A Check the horizontal alignment with a spirit level!

E_04_EN.fm. 19-36
E 04 19
4 Levelling
4.1 Slope controller
m During operation, no work may be car-

ried out on the slope control linkage or
the slope controller!
- Mount the slope control linkage (1) in

the intended position between the two
crossbeams.
- Mount the slope controller (2) on the 2
slope control linkage's retaining plate
(3).
1
A Four securing holes are provided for
mounting on the sensor's retaining plate.
3
Querneig.wmf
A The digital slope controller must be
mounted in such a way that the marking
arrow on the housing points in the direction of travel.
A The analogue slope controller must be mounted in such a way that the displays for
the operator visibly point backwards.
- Connect the left or right connection cable to the intended handset or vehicle socket.
A Exhaustive operating instructions can be found in the documentation for the corre-
sponding levelling system.
E_04_EN.fm. 20-36
E 04 20
4.2 Mounting the sensor arm
- Position the sensor arm mounting (1)

on the corresponding journal of the
screed side board.
- Tighten the pin (2) so that the sensor
arm is just still able to swivel.
2
A The sensor arm can be secured on the
side board with the lock (3).
3
1
Tastarm.wmf
4.3 Mounting the grade control system
Insert the grade control system into the 2

clamp bracket (1) and secure with the
clamping bolt (2) to prevent rotation.
1
F0258_A1.TIF/
E_04_EN.fm. 21-36
E 04 21
4.4 Setting up the sensor arm
6
Before starting paving, the sensor arm 5
must be set, with the grade control sys-
tem, to its reference (cable, kerb, etc.). 4
2
A Sensing should be carried out in the
area of the auger.
3
- Swivel the sensor arm (2) over the ref-
erence.
- Use the following options to adjust the
sensor arm precisely: Tastarm.wmf
- After loosening the clamping bolts (3), the sensor arm length can be set up.
- The sensing height can be set by loosening the clamping bolts (4).
- Adjustment of the lateral sensing angle is possible at the lock (5).
- Height adjustment for analogue grade sensors is carried out by means of a crank
(6). To lock it, the crank is inserted into one of the available notches following the
adjustment work.
A All assembly parts and clamping points must be tightened properly to ensure safe and
precise sensor arm operation!
- Connect the left or right grade control system connection cable to the intended
handset or vehicle socket.
A If the vehicle is to be operated with automatic grade sensing on both sides, the above
described adjustment process must be repeated on the second side.
A Exhaustive operating instructions can be found in the documentation for the corre-
sponding levelling system.
E_04_EN.fm. 22-36
E 04 22
4.5 Big ski 9 m, big ski 13 m
5
3
6 8
4 2
3
7 1
2
8
MBS6.bmp
The big ski is used for contactless sensing over a particularly large reference length.
A A total max. ski length of approx. 9.30 m can be achieved with the combination of 1
centre element and 2 module elements together with the sensor arm extensions. A
total max. ski length of approx. 13.50 m can be achieved with the combination of 1
centre element and 4 module elements together with the sensor arm extensions.
A The big ski enables the alignment of the individual sensors at the front and rear to be
shifted over the reference. The sonic ski can actually be positioned in front of and be-
hind the vehicle in order to guarantee safe reference sensing even on cornering.
A Before starting paving, the big ski must be set, with the grade control system mount-
ed, to its reference (cable, kerb, etc.).
The big ski essentially consists of the following components:
- Centre element (1)

- Extension modules (2)
- Crossbeam bracket (3)
- Front swivel arm (4)
- Rear swivel arm (5)
- Sensor bracket (6)
E_04_EN.fm. 23-36
- Sensor bracket, extendable (7)

- Arm extension (8)
A Assembly of the short version is described in the following, as the longer variant is
achieved simply by adding further module elements.
E 04 23
MBS11.bmp
The distances between the sensors are ideally identical (X1 = X2).
A The centre sensor is mounted in the usual individual sensor position so that, if nec-
essary, work can be carried out with just one sensor by switching over on the MOBA-
matic (e.g. at the start of paving, road junctions, etc…)
A Depending on application, the mechanism can be mounted at the side next to the
screed or also above the screed. This is dependent on the paving width required in
each case.
A The procedure for mounting the big ski is the same in both cases.
A So that the big ski can be operated as parallel to the ground as possible during pav-
ing, it must be attached according to the subsequent paving conditions. To do this,
the screed should be lowered to the desired course thickness and the traction point
should be set appropriately.
m When mounting the two crossbeam brackets, it is vital to ensure that these do not
hamper the free movement of either the crossbeam or the screed construction! Clear-
ance must be guaranteed throughout the entire working range!
E_04_EN.fm. 24-36
E 04 24
Mounting the big ski bracket on the crossbeam
A The entire big ski construction is mount-

ed laterally on the crossbeams. To do
so, the two crossbeam brackets must
first be mounted. The crossbeam brack-
et design differs slightly depending on
the paver finisher which is used. 1
During assembly, it is possible either to
bolt the bracket directly at the existing
bores or, as described in the following, to
secure it to the crossbeam using clamp-
ing plates. 4
3
The front bracket is mounted directly be- 2
A
hind the traction point; the rear bracket is
mounted at approximately the height of
the auger. MBS5.bmp
- Place both brackets (1) over the crossbeam at the corresponding point and mount
with bolts (2) and sleeves (3).
A For different crossbeam thicknesses, use the mounting's corresponding bores.
- The mounting tube is aligned via the two bolts (4).
A Align the bracket vertically.

E_04_EN.fm. 25-36
E 04 25
Mounting the swivel arms
- Slide a fixing ring (1) over the tube of

the big ski bracket (2).
A The fixing ring's 45° chamfer must point

upwards.
- Then slide the two swivel arms (3)

onto the tube of the big ski bracket.
1 3
A The rear swivel arm is positioned, rotat-
ed by 180°, on the big ski bracket.
- Slide a fixing ring (4) (flat version) onto

the front swivel arm and secure with 2
the relevant star handle bolt.
MBS3a.bmp/MBS3c.bmp
E_04_EN.fm. 26-36
E 04 26
Mounting the centre element
MBS6b.bmp
A During assembly, it must be ensured that the round lug (1) for attaching the subse-
quent modules points upwards.
A The centre element (2) is already fitted in the factory with 2 pre-assembled sliding
parts (3) / (4), which are pushed over the two round mounting journals of the swivel
arms.
- First slide the rear sliding part (3) onto the rear swivel arm from below. Then raise
the centre element, together with the rear swivel arm, until the front sliding part (4)
can be pushed onto the front swivel arm from above.
- Then secure the rear sliding part with a fixing ring (5) and the relevant star handle
bolt.
A Once the first part of the beam has been assembled, it is initially aligned:
- The centre element is now aligned horizontally using the fixing rings on the swivel
arms, and also with the fixing rings on the big ski brackets if necessary.
- Next, the centre element is aligned by rotating the swivel arms parallel to the paver
finisher.
- Finally tighten all securing bolts.
E_04_EN.fm. 27-36
E 04 27
Extending the big ski
A The big ski can be extended to both the

9 m and 13 m versions.
A Structure of the 9 m version: One exten-

sion part at the front/rear each.
Structure of the 13 m version:
Two extension parts at the front/rear 2
each.
1
- Place the extension module (1) onto
the centre element (2) and secure with
a bolt (3).
3
MBS1.bmp
E_04_EN.fm. 28-36
E 04 28
Mounting the sensor bracket
A A sensing system with 3 sensors is pro-

vided over the entire length of the big ski.
One sensor each on the centre element,
2 1
and the front and rear end elements.
A The centre sensor should be mounted

on the ski in precisely the location in
which it would be found during normal
operation (approx. the height of the au-
ger).
The two other sensors should be mount-
ed the same distance away from it.
A Extendable sensor brackets (1) are

mounted in the two outer positions; the
normal sensor bracket (2) is mounted in 6
the centre.
5
- Place the sliding bracket (3) over the
corresponding big ski element from
the inner side.
- Insert the sensor bracket (4) into the
sliding bracket (5) from below and se-
cure with the relevant star handle 4
bolts.
- Place the clamping ring (6) onto the
sensor bracket tube and secure with 6
7
the relevant star handle bolt.
- In the case of the extendable sensor

brackets, slide in the arm extension MBS2.bmp/MBS12.bmp
(7) and secure in position with the rel-

evant star handle bolt.
E_04_EN.fm. 29-36
E 04 29
Mounting and aligning the sensors
- Insert the sensor mounting (1) into the

bracket (2).
- Align the sensor and secure with the
relevant star handle bolts.
- The sensing height can be adjusted 4
3
by loosening the star handle bolts
(3).
A At the two outer sensor brackets, the 5

sensor can also be mounted on the swiv-
elling sensor extension arm (4).
2
This therefore enables the two outer
sensors to be swivelled during paving for 1
diverse requirements, e.g. cornering.
- By loosening the star handle bolts MBS8.bmp

(5), the length of the extension arm
can be adjusted.
- The sensor bracket with extension arm can be swivelled by loosening the star
handle bolts (3).
A If a sensor extension arm is swivelled to the side, it must be ensured that the attached
sensor is subsequently aligned in the direction of travel.
A All assembly parts must be mounted and tightened properly to ensure safe and pre-
cise operation of the big ski!
E_04_EN.fm. 30-36
E 04 30
Mounting the distributor box
A The distributor box should be mounted

in such a way that simple wiring to the
controller and the sensors is possible.
4
m The connections for the sensors should
always point down to prevent water from
3
2
entering the distributor box. Inlets which
are not required must be sealed with
dust caps.
- Allen head bolts are used to initially

mount the distributor box (1) on the
mounting plate (2). 1
A The input connector always points in the

direction of travel. MBS10.bmp
- Then mount the mounting plate on one of the two sliding brackets (4) on the centre
element using a star handle bolt (3).
m Mounting the big ski on the right-hand side of the vehicle:

To meet the requirement that the input connector always points in the direction of
travel, the sliding bracket, on which the distributor box is to be mounted, must be
pushed onto the big ski from the inside to the outside here.
Connection diagram
A The three sensors are connected to the

distributor box and the distributor to the
manual unit according to the following 5
scheme.
- Sensors
- Front (1) 4
- Centre (2)
- Rear (3)
- Distributor box (4)
- Manual unit (5)
E_04_EN.fm. 31-36
1 2 3
MBS9bmp
E 04 31
5 Automatic steering unit
2 1
15
12
10
13 9
6 11
7
14
3
E_04_EN.fm. 32-36
4 5
Lenk_2009.wmf/Peil_2009.wmf
E 04 32
5.1 Mounting the automatic steering unit on the paver finisher
m During operation, no work may be carried out on the automatic steering unit!
A Depending on the desired sensing side on the vehicle, the sensor rod tube may have
to be removed and re-inserted on the other side of the vehicle!
- Pull the sensor rod tube (1) at the front of the vehicle out to the desired length and
secure with the clamping levers (2).
- Insert the automatic steering unit tube (3) into the sensor rod tube (1) and secure
with bolts (4) and lock nuts (5).
- Swivel the extension arm (6) to the desired angle and secure by tightening the bolt
(7).
Mounting and aligning the sensor
- Insert the sensor mounting (8) into the bracket (9) and secure with a wing nut (10).
- Align the angle between the sensor and reference and secure with the relevant star
handle bolt (11).
A The sensor and reference must be at right angles to each other!
- The sensing height can be set by loosening the fixing screw (12).
A The reference should run centrally along the sensor.
- The sensor's distance from the reference can be set by loosening the fixing
screw (13).
A The distance between the sensor and reference (cable) should be 350 mm.
A All assembly parts must be mounted and tightened properly to ensure safe and pre-
cise operation of the automatic steering unit!
Connecting the sensor
A A sensor for connecting the sensing system to the vehicle's control system is located
on the left and right sides of the vehicle on the inner side of the bumper.
- Connect the relevant connection cable (14) to the socket (15) and sensor (8).
m Route the connection cable so that it cannot be damaged during operation.
m Secure unused sockets with the relevant protective caps.

E_04_EN.fm. 33-36
E 04 33
Automatic steering unit operating in-
structions
- When the automatic steering unit is

activated, the steering potentiometer
is deactivated. Steering is carried out
automatically via ski cable sensing.
- Activate the function on the operating
panel as necessary. 2
- The automatic steering unit can be 1
overridden by actuating the steering
potentiometer.
- The switch (1) is used to set the sens-

ing side:
- Right: Automatic steering unit on the Lenkski.wmf
right side of the vehicle.
- Left: Automatic steering unit on the left side of the vehicle.
- The LEDs (2) indicate the distance from the reference.

- LED + / - : Distance from the reference too high / too low.
- Centre LED: Distance correct.
E_04_EN.fm. 34-36
E 04 34
6 Limit switch
6.1 Mounting the auger limit switch
The auger's ultrasonic limit switch is

mounted on both sides on the side
board's handrail. 3
2
- Place the sensor bracket (1) onto the

handrail, align it and tighten with a
wing bolt (2).
1
- Align the sensor (3) and secure with a
clamping lever (4). 4
- Connect the left or right sensor's con-
nection cable (5) to the intended re- 5
mote control socket.
Sonic.wmf
E_04_EN.fm. 35-36
E 04 35
7 Screed
The Operating instructions for the screed cover all work required for mounting, setting
up and extending the screed.
8 Electrical connections
Establish the following connections when the mechanical components have been
mounted and set up:
8.1 Connect remote controls
to socket (1) (on the screed).

1
Socket.bmp
8.2 Connect grade control
to socket (2) (on the remote control unit)
8.3 Connect auger limit switches
to socket (3) (on the remote control unit)
2 3
F0119_A1.TIF
E_04_EN.fm. 36-36
E 04 36
F 1.0 Maintenance
1 Notes regarding safety
f Maintenance work: Maintenance work may only be carried out when the engine is
at a standstill.
Secure the paver finisher and the attachments against inadvertent starting before be-
ginning any maintenance work:
- Set the drive lever to the center position and the speed preselector to zero.
- Remove the ignition key and the battery main switch.
f Lifting and jacking up: Secure lifted machine parts (e.g. screed or hopper) against
lowering by means of mechanical supports.
m Spare parts: Use only approved parts and install them according to the specifica-
tions! If in doubt, contact the manufacturer!
f Re-commissioning: Mount all protective devices before re-commissioning the paver

finisher.
f Cleaning: Cleaning must not be carried out while the engine is running.
Do not use any inflammable substances (such as petrol).
Avoid directly cleaning electrical parts and insulation material with a steam jet; cover
them up beforehand.
f Working in closed environments: Exhaust fumes must be led into the open. Pro-
pane gas bottles must not be stored in closed rooms.
m In addition to these Maintenance Instructions, the Maintenance Instructions of the en-

gine manufacturer must always also be observed. All other maintenance work and in-
tervals noted in these instructions are also binding.
A The instructions for the maintenance of the optional equipment are included in the
sub-chapters of this chapter.
F_1.0_01_GB.fm 1-2
F 1.0 1
F 2.14 Maintenance review
1 Maintenance review
6.3 8.8 9 10
3.6 5.6
4.3
7.9
F_2.14_01_EN.fm 1-2
F 2.14 1
Maintenance required after the
following service hours
2000 / every 2 years

1000 / annually
If necessary
Assembly Chapter
20000
5000
100
250
500
10
50
Conveyor F3.6 q q q q q
Auger F4.3 q q q q q
Engine F5.6 q q q q q q
Hydraulics F6.3 q q q q q q
Drive units F7.9 q q q q
Electronics F8.8 q q q q q q q
Lubrication points F9 q q q q
Checking/stopping F10 q q q
Maintenance required q
A In this overview, you will find the maintenance intervals for optional machine equip-
ment!
F_2.14_01_EN.fm 2-2
F 2.14 2
F 3.6 Maintenance - Conveyor
1 Maintenance - Conveyor
F_3.6_01_EN.fm 1-6
F 3.6 1
1.1 Maintenance intervals
Interval

1000 / annually
If necessary
Item
Maintenance point Note

100
250
500
10
50
- Conveyor chain -
q
Check tightness
- Conveyor chain -
q
Adjust tightness
1
- Conveyor chain -
q
Check chain
- Conveyor chain -
q
Replace chain
- Conveyor gear
q
Check oil level
- Conveyor gear
2 q
Top up oil
- Conveyor gear
q
Change oil
- Check conveyor deflectors, con-
q
veyor plates
3
- Replace conveyor deflectors, con-
q
veyor plates
Maintenance q
Maintenance during the running-in period g
F_3.6_01_EN.fm 2-6
F 3.6 2
1.2 Points of maintenance
Chain tension, conveyor (1)
Check chain tension:
For the daily visual check, peer horizon-

tally below the bumper. The chain must
not hang below the bottom edge of the bumper.
Should readjustment be necessary, measure the slack in unladen condition from the
lower edge of the bottom plate to the lower edge of the chain (see figure).
m The conveyor chains should not be too

tight or too slack. An excessively taut
chain can cause the chain to be stopped
280 280
or to break when material falls into the
space between the chain and the F0159_A1.TIF
sprocket.
An excessively slack chain may catch on protruding objects and be destroyed.
Adjustment of chain tension:

x
A The chain tension can be adjusted with
grease press. The filling connections (A)
are located behind the bumper on the
left and right sides.
Conveyor_set_2009.wmf
F_3.6_01_EN.fm 3-6
F 3.6 3
Check / replace chain:
A At the latest, the conveyor chains (A)

must be replaced when their elongation
has progressed so far that they can no
longer be re-tensioned.
m Chain links must not be removed to

shorten the chain!
Incorrectly dividing the chains would
lead to the destruction of the drive
wheels! A
m If components have to be replaced as a

result of wear, the following components
should always be replaced in sets:
- Conveyor chain
- Conveyor deflectors
- Conveyor plates
- Conveyor chain reversing rollers
- Conveyor gear drive wheels Convey_2009.bmp
A Your Dynapac customer service will be happy to provide support during maintenance,
repair and the replacement of wearing parts!
F_3.6_01_EN.fm 4-6
F 3.6 4
Conveyor gears (left/right) (2)
The conveyor gears are located under

the footplate of the operator's platform.
Checking the oil level: Only before
starting work. The oil level must reach
the upper notch of the dipstick (A).
Filling in oil: After removing screw cap (B) through the oil filler neck (C).
F0151_A1.TIF/F0152_A1.TIF
F_3.6_01_EN.fm 5-6
F 3.6 5
Conveyor deflectors / conveyor
plates (3)
A At the latest, the conveyor deflectors (A)

must be replaced when their lower edg-
es are worn or reveal holes.
m The conveyor chain is not offered pro-

tection by worn conveyor deflectors!
- Remove conveyor deflector bolts.

A
- Remove the conveyor deflectors from
the material tunnel.
- Install new conveyor deflectors with
new bolts.
A At the latest, the conveyor plates (B)

must be replaced when the wear limit of
5 mm in the rear area beneath the chain B
has been reached.
m If components have to be replaced as a

result of wear, the following components Convey_2009.bmp
should always be replaced in sets:
- Conveyor chain
- Conveyor deflectors
- Conveyor plates
- Conveyor chain reversing rollers
- Conveyor gear drive wheels
F_3.6_01_EN.fm 6-6
F 3.6 6
F 4.3 Maintenance - Auger
1 Maintenance - Auger
F_4.3_01_EN.fm 1-8
F 4.3 1
Interval

1000 / annually
If necessary
Item

100
250
500
10
50
- Outer auger bearing -

1 q
Lubricate
- Auger planetary gear -
q
Check oil level
2 q
Top up oil
q
Change oil
- Auger drive chains -
q
Check tension
3
- Auger drive chains -
q
Adjust tension
- Auger box -
q
Check oil level
- Auger box -
4 q
Top up oil
- Auger box -
q
Change oil
- Auger blade -
q
Check wear
5
- Auger blade -
q
Replace auger blade
Maintenance q
Maintenance during running-in period g
F_4.3_01_EN.fm 2-8
F 4.3 2
Outer auger bearing (1)
The grease nipples are located on each

side at the top of the outer auger bear-
ings.
These nipples must be lubricated at the

end of work to force out any bitumen re- 6x
sidues which may have entered and to
supply the bearings with fresh grease
when warm.
A If the auger is extended, the outer rings

should be loosened slightly when initially
greasing the outer bearing points in or-
der to improve ventilation on greasing.
The outer rings must be properly se-
cured again after greasing.
A New bearings must be filled with 60

strokes of grease using a grease gun.
Schneckaula.tif
Auger planetary gear (2)
- To check oil level, unscrew and re-

move the inspection screw (A).
A When oil level is correct, the oil comes

up to the lower edge of the inspection
bore or a small amount of oil escapes
through the aperture.
F_4.3_01_EN.fm 3-8
F 4.3 3
To top up oil:
B
- Unscrew inspection screw (A) and fill-
er screw (B).
- Fill in the specified oil into the filler
bore at (B) until the oil level has
reached the lower edge of the inspec- A
tion bore (A).
- Screw the filler (B) and inspection
screws (A) back in.
To change oil: c
A The oil should be changed when at oper-

ating temperature.
- Unscrew the filler screw (B) and drain

plug (C).
- Drain the oil.
- Screw the drain plug (C) back in.
- Unscrew the inspection screw (A).
- Fill the specified oil into the filler bore
at (B) until the oil level has reached the Augerdrive_gear_DEM.bmp
lower edge of the inspection bore (A).
- Screw the filler (B) and inspection screws (A) back in.
Auger drive chains (3)
To check the chain tension:
- Manually turn both augers to the right

and left. In this case, movement clear-
ance (C) at the augers' outer circumference should be 13-15 mm.
F_4.3_01_EN.fm 4-8
F 4.3 4
To re-tension the chains
- Release the mounting screws (A).

- Set the chain tension correctly using
the threaded pins (B):
- Tighten the threaded pins to 20 Nm A
using a torque wrench.
- Subsequently loosen the threaded
pins again by one full revolution.
- Retighten the bolts (A).
C
Augerdrive_chain_DEM.bmp/Schnecksp.tif
F_4.3_01_EN.fm 5-8
F 4.3 5
Auger box (4)
Check oil level
A In case of correct oil level, the oil is be-

tween the two notches of the dipstick
(A).
F_4.3_01_EN.fm 6-8
F 4.3 6
To top up oil:
- Unscrew screws (B) from the top cov-

er of the auger box.
A
- Take off the cover (C).
- Fill up oil to the correct level.
- Reinstall the cover.
- Use the dipstick to check the fill level
again.
Change oil

ating temperature.
- Place a suitable collecting container

under the auger box.
- Loosen bolts (D) from the circumfer-
ence of the worm shaft flange.
A The oil runs out between the flange and

auger box.
B D
- Drain out all oil.
- Correctly retighten flange bolts (D) di- C
agonally.
- Pour the specified oil in through the
open top cover (C) of the auger box
until the oil level has reached the cor-
rect level on the dipstick (A).
- Correctly reinstall the cover (C) and
screws (B).
Augerdrive_dip_DEM.bmp/augerdrive_chain_DEM.bmp
F_4.3_01_EN.fm 7-8
F 4.3 7
Auger blade (5)
A If the surface of the auger blade (A) be-

comes sharp-edged, the diameter of the
auger is reduced and the blades (B)
have to be replaced.
- Remove the bolts (C), washers (D),

nuts (E) and auger blade (B).
f Risk of injury due to sharp-edged parts!
A
m Auger blades must be installed play-
free; the contact surfaces must be dirt-
free!
- Install the new auger blade (B); re-

place the bolts (C), washers (D) and
nuts (E) if necessary.
D
E
Schneckaula.tif / DEMAuger_rep1.bmp
F_4.3_01_EN.fm 8-8
F 4.3 8
F 5.6 Maintenance - Engine
1 Maintenance - Engine
F_5.6_01_EN.fm 1-10
m In addition to these maintenance instructions, the maintenance instructions issued by

the engine manufacturer must be adhered to under all circumstances. All mainte-
nance work and service intervals itemised here are binding in nature.
F 5.6 1
Interval

1000 / annually
500 / annually
If necessary
Item

100
250
10
50
- Fuel tank
q
Check filling level
- Fuel tank
1 q
Refill with fuel
- Fuel tank
q
Clean the tank and system
- Engine lube-oil system
q
Check oil level
q
Top up oil
2
q
Change oil
q
Change oil filter
- Engine fuel system
q Fuel filter (drain the water separa-
tor)
q
3 Replace fuel pre-filter
q
Replace fuel filter
q
Bleed fuel system
Maintenance q
F_5.6_01_EN.fm 2-10
F 5.6 2
Interval

1000 / annually
500 / annually
If necessary
Item

100
250
10
50
- Engine air filter

q
Check air filter
- Engine air filter
q Dust collector
4
Emptying
- Engine air filter
q q Air filter cartridge
Clean / replace
- Engine cooling system
q
Check radiator fins
q
Clean radiator fins
q
Check level of the coolant
5 - Engine cooling system
q
Top up coolant
q
Change coolant
q Check coolant
(additive concentration)
- Engine drive belt
q
Check drive belt
- Engine drive belt
6 q
Re-tighten drive belt
- Engine drive belt
q
Replace drive belt
F_5.6_01_EN.fm 3-10
Maintenance q
F 5.6 3
Engine fuel tank (1)
- Check the filling level on the gauge

on the operating panel.
A Fill the fuel tank each time before start-

ing work so that the fuel system cannot
„run dry“ and time-consuming venting
(bleeding) can therefore be avoided.
For filling in the fuel:
- Unscrew cap (A) (under the tank cov-

er).
- Fill in fuel through the filling port until
the required fill lever is achieved.
- Replace the cap (A). A
Clean the tank and system:
- Unscrew the drain plug (B) at the bot-

tom of the tank and drain into a collec-
tion pan about 1 l fuel.
- When returning the screw, make sure
to use a new seal.
m If necessary, the batteries must be cov-

ered or removed!
KTank_2009.wmf/Batterie_2009.wmf
F_5.6_01_EN.fm 4-10
F 5.6 4
Engine lube-oil system (2)
Check oil level
A In case of correct oil level, the oil is be-

tween the two notches of the dipstick
(A).
A Check the oil level when the paver finish-

er is in a horizontal position!
m Too much oil in engine damages gas-

kets; too little oil results in overheating
and engine destruction.
For filling in the oil:
- Remove cap (B).

- Fill up oil to correct level.
- Return cap (B). A
- Use dipstick to check level again.
D B
Oil change:
A Change the oil when the engine is at op-

erating temperature.
Motor_2009.wmf
- Place the end of the oil drain port hose
(C) in the collection container.
- Remove the screw cap with a wrench
and allow the oil to drain completely.
- Replace the screw cap and tighten
properly. C
- Fill in the specified quality of oil
through the filling port (B) on the en-
gine until the oil level rises to the cor-
rect mark on the dipstick (A).
Drain_2009.wmf
F_5.6_01_EN.fm 5-10
F 5.6 5
Changing the oil filter:
A The new filter is inserted during an oil change once the used oil has been drained out.
- Unscrew the filter (D) and clean its contact surface.

- Apply light coating of oil to the gasket on the new filter and fill filter with oil before
installing it.
- Tighten filter by hand.
A After installing the oil filter, attention must be paid to the oil pressure display and good
sealing during the test run. Check oil level again.
F_5.6_01_EN.fm 6-10
F 5.6 6
Engine fuel system (3)
A The fuel filter system consists of three fil-

ters:
- Prefilter (A) with water separator

- Two main filters (B)
A Depending on the machine, the prefilter

is in the engine compartment or under
the tank lid!
Prefilter - draining of water
A Drain the collecting vessel at regular in-

tervals, or in response to an error mes-
sage from the engine control unit.
- Drain off surplus water at cock (C) and collect in a container, then close the cock
again.
Changing the prefilter:
- Drain off surplus water at cock (C) and A

collect in a container, then close the
cock again. E
A
- Pull down the connection of the water
detector (D). C
- Use a filter wrench or filter belt to loos- D
en the filter cartridge (A) and tank and
unscrew
- Unscrew the tank (E) from the filter F
cartridge and clean if necessary.
- Clean sealing surface of filter bracket.
- Oil collector seal slightly and screw
hand-tight under the new filter car-
tridge
- Oil filter cartridge gasket slightly and
screw hand-tight under the bracket.
- Replace the connection of the water
detector (D).
B B
F_5.6_01_EN.fm 7-10
Motor_2009.wmf
F 5.6 7
Replacing the main filter:
- Unscrew the filter (B) and clean its contact surface.

- Apply light coating of oil to new filter gasket
- Tighten filter by hand.
A After fitting the filter, ensure good sealing action during the test run.
Venting the filter:
- Release the manual fuel pump's (F) bayonet lock by pressing and simultaneously
turning counter-clockwise.
- The pump plunger is now pressed out via the spring.
- Pump until a very high resistance is perceptible and pumping can only be carried
out very slowly.
- Now continue pumping a few more times. (The return line must be filled).
- Start the engine and operate for approx. 5 minutes at idle speed or low load.
- Check the prefilter for leaks whilst doing this.
- Lock the manual fuel pump's (F) bayonet lock by pressing and simultaneously turn-
ing clockwise.
F_5.6_01_EN.fm 8-10
F 5.6 8
Engine air filter (4)
Empty dust collector
- Empty the dust removal valve (B) on

the air cleaner housing (A) by pressing
the discharge port in the direction of
the arrow.
- Remove any dust deflectors by press-
ing together the upper valve section.
A Clean outfeed slot occasionally.

E
Cleaning / replacing the air filter car-
tridge
D B
A Pollution of the combustion air filter de-

pends on the dust content of the air and A
the mesh size of the filter selected.
A Filter maintenance becomes necessary

if:
- The maintenance indicator (O) red F

servicing field (C) is fully visible when
the engine is stopped. C
- Engine electronics service indicator
- ?Open the air filter lid.
- Pull out the filter cartridge (D) and the
safety cartridge (E). Motor_2009.wmf
A Clean the filter cartridge (D) and replace after one year at the latest.
- Blow out with dry pressure air (max. 5 bar) from inside out or tap it (in case of emer-
gency only).
A Do not damage cartridge when doing so.
- Check the soundness of the filter papers of the filter cartridge (by exposing to light)
and the soundness of the seals. Replace them as required.
A Replace the safety cartridge (E) after the filter has been serviced 5 times, but after
2 years at the latest (never clean it!).
After completing the maintenance work:

F_5.6_01_EN.fm 9-10
- Press the reset button (F) of the maintenance indicator (O). The maintenance indi-
cator is ready for operation once again.
F 5.6 9
Engine cooling system (5)
Checking / topping up coolant
The cooling water level must be checked

when the system is cold. Make sure that
the anti-freeze and anti-corrosive liquid
us sufficient (-25 °C).
f When hot, the system is under pressure.

When it is opened, there is danger of
scalding!
- If necessary fill in a sufficient amount

of coolant through the open port (A) of
the compensating tank.
Change coolant
Observe engine operating instructions! A

A
Checking and cleaning the radiator

fins
- If necessary, remove leaves, dust or

sand from the radiator.
Motor_2009.wmf
Engine drive belt (6)
Check / replace the drive belt
A Observe engine's operating instructions!
F_5.6_01_EN.fm 10-10
F 5.6 10
F 6.3 Maintenance - Hydraulic system
1 Maintenance - Hydraulic system
F_6.3_01_EN.fm 1-10
F 6.3 1
Interval

1000 / annually
If necessary
Item

100
250
500
10
50
- Hydraulic oil tank -

q
Check fill level
1 q
Top up with oil
q
Change oil and clean
q
Check maintenance indicator
2 - Hydraulic oil tank -
q q Intake / return
hydraulic filter; change, vent
- High pressure filter -
q
Check maintenance indicator
3
- High pressure filter -
q
Replace filter element
- Pump distribution gear -
q
Check oil level
4 q
Top up oil
q
Change oil
- Hydraulic hoses -
q
Visual inspection
5
- Hydraulic hoses -
q q
Replace hoses
- Auxiliary flow filter-
6 q q (o)
Replace filter element
F_6.3_01_EN.fm 2-10
Maintenance q
F 6.3 2
Hydraulic oil tank (1)
- Oil level check on dipstick (A).
A With retracted cylinders, the oil level

must reach the upper mark.
- Remove cap (B).

- Fill in oil through the filling port until the
required filling level is achieved on the
dipstick (A). A
- Screw cap (B) on again.
A Regularly remove dust and pollution

from the vent port of the oil tank. Clean
the surfaces of the oil cooler. B
m Use only the recommended hydraulic

oils - see section „Recommended hy-
draulic oils“.
To change oil:
- To drain the hydraulic oil unscrew the

drain plug (C) at the bottom of the
tank.
- Collect the oil in a container using a
funnel.
- After draining, reinstall the screw us-
ing a new seal.

ating temperature.
m When changing the hydraulic oil also

change the filter.
HTank1_2009.wmf/H_Tank2_2009.wmf
F_6.3_01_EN.fm 3-10
F 6.3 3
Suction/return flow hydraulic filter (2)
Carry out filter replacement according

to the interval or when the maintenance
indicator (A) reaches the red mark at a
hydraulic oil temperature of more than
80°C.
A The hydraulic oil temperature is read off

on the hydraulic oil temperature indica-
tor (O) on the operator's platform.
m When changing the hydraulic oil also

change the filter.
B
- Remove cover securing screws (B)
and lift off cover.
- Disassemble the removed unit into:
- Cover (C)
- Separating plate (D) A
- Filter (E) H
- Dirt trap (F)
- Clean the filter housing, cover, sepa-
rating plate and dirt trap.
- Check the O-rings (G), replace if nec- G
essary.
- Coat the sealing surfaces and O-rings
with clean operating fluid.
F E D C
HTank_2009.wmf/Montage2.eps/Hydtank_V2a.eps
F_6.3_01_EN.fm 4-10
F 6.3 4
Bleeding the filter
- Fill the opened filter housing with hydraulic oil up to approx. 2 cm below the top
edge.
- If the oil level drops, replenish oil again.
A Slow oil level reduction of approx. 1 cm / min. is normal!
- If the oil level remains stable, slowly insert the assembled unit with new filter ele-
ment into the housing and tighten the cover securing screws (B).
- Open the bleed screw (H).
- Place a transparent hose (I) onto the bleed screw, ending in a suitable container.
- Start the up drive motor at idle speed.
- Close the bleed screw (H) as soon as the oil forced through the hose is clear and
therefore free of air bubbles.
A The process from assembling the filter cover to starting the drive engine should take
place in less than 3 minutes, as the oil level in the filter housing otherwise falls too far.
m Ensure seal integrity is good after changing the filter.

F_6.3_01_EN.fm 5-10
F 6.3 5
High-pressure filter (3)
The filter elements must be replaced

when the maintenance indicator (A)
turns red.
- Unscrew filter housing (B).

- Remove the filter cartridge.
- Clean the filter housing.
- Insert the new filter cartridge.

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

mark in the maintenance indicator (A)
automatically reverts to green.
HDD_2009.wmf
F_6.3_01_EN.fm 6-10
F 6.3 6
Pump distribution gear (4)
- Check oil level on the viewing glass

(A) (at the side of the distribution box).
A The oil level must be up to the centre of

the viewing glass.

B
- Unscrew the filler screw (B).
- Fill in oil through the filling port until the
required filling level is achieved on the
viewing glass (A).
- Screw in the filler screw (B) again.
m Make sure to clean the screw and the vi-

cinity of the drain bore!
Oil change:
Change the oil when the engine is at op-

erating temperature.
- Place the end of the oil drain port hose

(C) in the collection container.
- Remove the screw cap with a wrench
and allow the oil to drain completely.
A
- Replace the screw cap and tighten
properly.
- Fill in the oil of specified quality
through the filling port on the gearbox
(B) until the oil level rises to the centre
of the viewing glass (A).
C
F_6.3_01_EN.fm 7-10
PVG2.wmf/PVG_Glas.wmf/Drain_2009.wmf
F 6.3 7
Hydraulic hoses (5)
- Specifically check the condition of the

hydraulic hoses.
- Immediately replace any damaged
hoses.
f Ageing hoses become porous and may

burst! Danger of accidents!
A A number stamped onto the threaded

connection provides information about
the date of manufacture (A) and the
maximum pressure permitted for this
hose (B).
m Never install hoses on top of one anoth-

er and always ensure that they are at the
correct pressure.
A B
PVG2.wmf
DHH 09/00 225 BAR
F_6.3_01_EN.fm 8-10
F 6.3 8
Auxiliary flow filter (6)
A The hydraulic oil change is omitted on

use of an auxiliary flow filter!
The quality of the oil must be checked
regularly.
The oil level must be topped up if neces-
sary!
Replacing filter element:
- Release the threaded cover connection (A) then open the non-return valve briefly
to lower the oil level in the filter, then close the non-return valve again.
- Replace filter element (B) and sealing
ring (C): A
- Turn filter element clockwise with the
help of carrier straps and, at the
same time, raise it slightly.
- Wait for a moment until the oil has
escaped downwards, then remove C
the filter element.
- Check inlet and outlet in filter housing
(D). B
- As required, top up hydraulic oil level
in filter housing then screw down the
cover. D
- Bleed the fuel system
m Do not remove the cardboard sleeve

from the filter element! This is part of the
filter!
Nebenstrohm.wmf
F_6.3_01_EN.fm 9-10
F 6.3 9
F 7.9 Maintenance – Drive units
1 Maintenance – Drive units
635_ISO_Dyn.bmp/LW_DEM_inter.bmp
F_7.9_01_EN.fm 1-8
F 7.9 1
Interval

1000 / annually
If necessary
Item

100
250
500
10
50
- Chain tension -
q
Check
- Chain tension -
1 q
Adjust
- Chains-
q
Relieve
- Bottom plates -
q
Check wear
2
- Bottom plates -
q
Replace
- Rollers -
q
Check for leaks
- Rollers -
3 q
Check wear
- Rollers -
q
Replace
- Planetary gear -
q
Check oil level
- Planetary gear -
4 q
Top up oil
- Planetary gear -
q
Change oil
Maintenance q
F_7.9_01_EN.fm 2-8
F 7.9 2
f Any work on the pretensioned spring element must only be carried out by trained,
specialist personnel!
f The spring elements must only be removed by a specialist workshop! The following
applies to all spring elements in the event of a necessary repair: replace the complete
unit only!
f Repairing the spring elements involves significant safety measures and should only
be carried out by a specialist workshop!
F_7.9_01_EN.fm 3-8
F 7.9 3
Chain tension (1)
m If the chains/tracks are not tensioned

sufficiently, they can slip out of their
guide formed by rollers, drive gear and
idler wheel, thereby increasing wear lev-
els.
m If the chains/tracks are tensioned too tightly, this increases wear on the idler wheel
and drive unit mounting, and also increases wear on track bolts and bushes.
Checking / adjusting chain tension:

x A
- The chain tension is adjusted with
grease tensioners. The filling ports are
located on the left and right in the track
chassis.
- Unscrew the screws (A). B
- Remove cap (B).
- Screw head section for flat nipple
(toolbox) onto the grease gun.
LW_DEM2.bmp
A Over a length (L) of 1-1.5 m, slack (F) of

2-3 cm must be present. This applies in
linear fashion if the free length (L) is less L
than or equal to 1-1.5 m (at least 4 track
links). F
The slack is determined using a measur-
ing rule. This involves the dimension (F) B
being measured from the edge of the
bottom plate to the measuring rule (at
the centre point of the slack in the track).
- Use the grease gun to press grease

into the chain tensioning cylinder until Spann_LWDEM.bmp
the correct tension is set.
A On completion of the tensioning process, the grease gun is removed. Now the trac-
tion unit should be moved backwards and forwards approx. 1 complete turn of the
drive wheel. Check the position of tracks on idler wheel and drive wheel.
A Repeat this procedure on both drive units!

F_7.9_01_EN.fm 4-8
- Reinstall cover (B).
F 7.9 4
Tensioning the chain:
A
- Unscrew the lubricating nipple on the
grease tensioner using a tool until the
grease is able to emerge from the nip-
ple's lateral hole.
B
f The grease in the tensioning element is
under pressure. Carefully and slowly un-
screw the filling valve, but not too far.
A The idler wheel moves back independ-

ently or must be reset manually. LW_DEM2.bmp
F_7.9_01_EN.fm 5-8
F 7.9 5
Bottom plates (2)
E
m Always use new bolts and nuts when in-
stalling new bottom plates!
- After removing the worn bottom

plates, the adhesions must be cleaned C
from the contact surfaces of the chain
links and the nut seats.
- Place the bottom plate with the front A
edge (A) over the chain links' bolt eye
(B).
- Lubricate the threads and the contact
surfaces beneath the bolt heads with a
B D
thin film of oil or grease.
Bodenplatte.bmp
- Insert the bolts (C) into the holes and
screw them into the nuts (D) a few
turns.
- Tighten the bolts without applying significant torque.
- Tighten the bolts diagonally to the required torque (E).
Rollers (3)
m Rollers with damaged surfaces or which

are leaking should be replaced immedi-
ately!
- Relieving the caterpillar chain:

- Raise the track chassis using suitable
lifting equipment and remove adhering
dirt.
f Observe the safety measures when rais-

ing and securing loads!
- Remove the defective roller.

- Install the new roller using new as- Laufrolle.bmp
sembly parts.
- Lower the track chassis and tension the caterpillar track properly.
F_7.9_01_EN.fm 6-8
F 7.9 6
Planetary gear (4)
- For oil level check unscrew and re-

move the inspection bolt (A).
A When oil level is correct, the oil comes

up to the lower edge of the inspection
bore or a small amount of oil escapes
through the aperture.
- Unscrew the filler screw (A).

- Fill in the specified oil into the filler
bore at (A) until the oil level has
reached the lower edge of the filler
bore.
- Tighten the filler screw (A) back in. A
Oil change:
B
ating temperature.
m Ensure that no dirt or foreign bodies are

able to enter the gear.
- Turn conveyor chain sprocket until „oil Gear_OK.bmp

max“ mark is horizontal and drain plug
(B) is at the bottom.
- Unscrew and remove the drain plug (B) and filler screw (A) and drain off oil.
- Check gaskets on both screws and replace if necessary.
- Tighten the drain plug (B) back in.
- Fill new oil through the filler bore until the „oil max“ mark is reached.
- Tighten the filler screw (A).
F_7.9_01_EN.fm 7-8
F 7.9 7
F 8.8 Maintenance - Electronic system
1 Maintenance - Electronic system
F_8.8_01_EN.fm 1-14
F 8.8 1
Interval

1000 / annually
If necessary
Item

100
250
500
10
50
Filling level of
q
battery electrolyte - check
1
q Top up with distilled water
q Apply grease to battery terminals
Maintenance q
F_8.8_01_EN.fm 2-14
F 8.8 2
Interval
If necessary
Item
20000
1000
5000
100
250
10
50
- Alternator Also see

Electrical system insulation moni- screed op-
q
toring erating in-
Check function structions
- Alternator
Visual check for pollution or dam-
age
q (o)
- Check the cooling air openings for
pollution or clogging, clean if nec-
essary.
- Alternator
Check the ball bearings „by listen-
q (o)
2 ing“ and replace them if neces-
sary.
- Alternator
q q (o)
Replace ball bearings
- Alternator
q Check the drive belts for damage, (o)
replace if necessary
- Alternator
q Drive belts - check tension, adjust (o)
if necessary.
- Alternator
q (o)
Replace drive belts
Maintenance q
F_8.8_01_EN.fm 3-14
F 8.8 3
Interval

1000 / annually
If necessary
Item

100
250
500
10
50
3 q Electric fuses
Maintenance q
F_8.8_01_EN.fm 4-14
F 8.8 4
Batteries (1)
Maintenance of batteries
A The batteries are factory-filled with the

correct quantity of acid. The fluid level
should come up to the top mark. If re-
quired, top up the battery, but only use
distilled water to do so!
m The battery terminal clips must be free of

corrosion (oxide) and protected with a
special grade of terminal grease.
m When removing the batteries, always

first remove the negative terminal, en-
suring that the battery terminals cannot
be short circuited.
Batterie_2009.wmf
F_8.8_01_EN.fm 5-14
F 8.8 5
Alternator (2)
Electrical system insulation monitoring
A Check insulation daily with operating

machine and switched on connection
sockets.
- Turn on the electrical equipment with

switch (1), indicator lamp (2) comes
on.
- Press test button (3) and the inscrip-
tion „Insulation fault“ must light up. 2 1
- Press the clear button (4) and the in-
sulation fault inscription goes off. 3 4
f If the test is completed successfully,

work can proceed with the electrical sys-
tem and external consumers can be
used.
If the „Insulation fault“ control light indi-
cates a fault already before pressing the
control button, then work cannot pro-
ceed with the electrical system and the
external consumers. In the case of an in-
sulation fault the sockets are automati- Schalt_230V.wmf/230V.wmf
cally turned off.
Work with the electric system cannot proceed if the simulation does not indicate a fail-
ure.
f In the event of malfunctions, the electrical system must be checked and repaired by
a specialist electrician. Work with these devices and the operating equipment can be
resumed after this.
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.
Lethal hazard!
All maintenance and repair work on the electrical system must always be car-
ried out by an electrician!
F_8.8_01_EN.fm 6-14
F 8.8 6
Check ball bearings / replace ball
bearings
A Report the displayed fault code to the

customer service of the paver finisher
and they will discuss with you the steps
to be taken.
F_8.8_01_EN.fm 7-14
F 8.8 7
Drive belt (V-belt)
Checking belt tension
The tension of each belt must be in-

spected with a pretension checking in-
strument.
Specified tension:
- In case of initial assembly: 550 N

- After the run-in period / maintenance
interval: 400 N Riemensp.tif
A Instructions for checking tightness in the

pretention measuring instrument instructions.
A A pretention measuring instrument can be ordered under article No. 532.000.45!
F_8.8_01_EN.fm 8-14
F 8.8 8
Adjusting belt tension
D
- Loosen the clamping bolts (A) on both
sides of the guide.
- Loosen lock nuts (B) for the adjusting
A C B
screws.
- Using the adjusting screws (C), raise
C
or lower the alternator until the re-
quired belt tension is set.
- Tighten lock nuts (B) and clamping
bolts (A) again.
B
m During adjustment work, it must be en-
sured that the alternator bracket is A
raised evenly!
The distance (D) must be checked and
must be equal on both sides of the
bracket!
Replacing belt
- Reduce the belt tension on the adjust-

ing device so that the belt can be re-
moved from the pulley.
- Mount the new belt and adjust tension
again.
A Always replace the belts in sets.

D
Generator1_2009.bmp/Generator1_2009.bmp
F_8.8_01_EN.fm 9-14
F 8.8 9
Electric fuses / relays (3)
Fuses_635_konv.eps
A Main fuses
B Fuses in terminal box
C Relays in terminal box
Main fuses (A)
F A
F1.1 Main fuse 50
F_8.8_01_EN.fm 10-14
F 8.8 10
Fuses in terminal box (B)
27
!
F A
F2 Display 2
F3 Fan control 5
F4 Engine start 10
F5 Emergency stop 7,5
F6 Terminal 15 7,5
F7 Main computer 7,5
F8 Main computer 5
F9 Engine control 25
F10 Travel drive computer 15
F11 Travel drive computer 1
F12 Display 2
F13 Keyboard 2
F14 Module A51 5
F15 Module A52 5
F16 Module A53 5
F17 Module A54 5
F18 Module A55 5
F19 Module A56 5
F20 Horn 5
F_8.8_01_EN.fm 11-14
F21 Front lighting 10

F22 Rear lighting 10
F23 Auger lighting 10
F24 24V socket on left 10
F25 24V socket on right 10
F 8.8 11
F. A
F26 Travel drive computer interface 1
F27 Engine sensors 3
F28 Screed 5
F29 Screed 10
F30 Rotary beacon 5
F31 Seat heating 5
F32 Diesel fuelling system 5
F33 Windscreen wiper 5
F34 Reverse buzzer 3
F35 12-volt system 15
F36 Emulsion / diesel spraying system 5
F37 Engine diagnosis 3
F38 Electric heating 5
F_8.8_01_EN.fm 12-14
F 8.8 12
Relays in terminal box (C)
K5
!
1 Starter lock
2 Starting lock
3 Terminal 15 current supply
4 Engine control
5 Travel drive computer
6 Horn
7 Front lighting
8 Rear lighting
9 Auger lighting
10 Loader emergency stop
11 Rotary beacon
12 Seat heating
13 Diesel fuelling system

F_8.8_01_EN.fm 13-14
14 Windscreen wiper
15 Reverse buzzer
F 8.8 13
F 9.1 Maintenance - Lubricating points
1 Maintenance - Lubricating points
A The information on the lubricating points for the various assemblies is assigned to the
F_9.1_01_EN.fm 1-8
specific maintenance descriptions and must be read there!
A Due to the use of a central lubrication system (o), the number of lubricating points
may deviate from the description.
F 9.1 1
Interval

1000 / annually
If necessary
Item

100
250
500
10
50
q - Check lubricant tank fill level (o)
q - Top up lubricant tank (o)
q - Bleed central lubrication system (o)

1
q - Check pressure limiting valve (o)
- Check flow of lubricant at the

q (o)
consumer
2 q - Bearing points
Maintenance q
F_9.1_01_EN.fm 2-8
F 9.1 2
Central lubrication system (1)
Danger of injuries!
f Do not reach into the tank when the

pump is running!
f The central lubrication system must only

be operated with the safety valve in-
stalled!
Handverl.jpg/Gefahr.jpg
f Do not undertake any work on the pres-

sure relief valve during operation!
f Risk of injury due to escaping lubricant, as the system operates at high pressures!
f Ensure that the diesel engine cannot be started when working on the system!
f Observe safety regulations for handling hydraulic systems!
m Ensure maximum cleanliness when working on the central lubrication system!
The following assemblies' lubricating

points can be automatically supplied
with grease by the central lubrication
system:
- Conveyor
- Auger
- Steering, axles (wheeled pavers)
Lincoln3.jpg
F_9.1_01_EN.fm 3-8
F 9.1 3
Central lubrication system Check fill-
ing level
A The lubricant tank should always be

filled sufficiently to ensure that the sys-
tem
does not "run dry", that adequate lubri- a
cating point supply is ensured and that
time-consuming bleeding does not be-
come necessary.
- Always maintain a fill level above the

"MIN" mark (a) on the tank.
Lincoln3.jpg/Lincoln4.jpg
Top up lubricant tank
Lincoln3.jpg/Grease2.wmf/Greasegun.wmf
b
- A lubricating nipple (b) is located on the lubricant tank (a) for filling purposes.
- Connect the grease gun (c) enclosed on delivery to the filling nipple (b) and fill the
lubricant tank (a) up to the MAX mark.
A When the lubricant tank is completely empty, the pump may have to run for up to 10
minutes until the full delivery rate is achieved after filling.
F_9.1_01_EN.fm 4-8
F 9.1 4
Bleed central lubrication system
Bleeding the lubrication system is nec- c

essary if the central lubrication system
has been operated with an empty lubri-
cant tank. a
- Release the main lubrication line (a)

at the distributor (b). d
- Start up the central lubrication sys-
tem with the filled lubricant tank (c).
- Allow the pump to run until lubricant
emerges from the previously re- d
leased main line (a).
- Reconnect the main line (a) to the b
distributor. Lincoln3.jpg/Lincoln4.jpg
- Release all distribution lines (d) from

the distributor.
- Reconnect all distribution lines as soon as lubricant has emerged.
- Check all connections and lines for leaks.
Check pressure limiting valve
m If lubricant emerges at the pressure lim-

iting valve (a), this indicates a malfunc-
tion in the system.
The consumers are no longer adequate-
ly supplied with lubricant.
- Release all distribution lines (b)

leading from the distributor (c) to the
consumers in succession.
- If lubricant emerges from one of the
released distribution lines (b) under
pressure, search in this lubrication a
circuit for the cause of the blockage
which has triggered the pressure
limiting valve. b
- After rectifying the malfunction and
reconnecting all lines, again check
the pressure limiting valve (a) for lu- b
bricant emergence.
- Check all connections and lines for
leaks. c
Lincoln3.jpg/Lincoln4.jpg/Lincoln5.jpg
F_9.1_01_EN.fm 5-8
F 9.1 5
Check the flow of lubricant at the con-
sumers
a
Each lubrication channel at the consum-
ers must be checked as regards clear-
ance.
- Remove the lubrication line (a) and

install a normal lubricating nipple (b).
- Connect the grease gun (c) en-
closed on delivery to the lubricating
nipple (b).
- Operate the grease gun until the lu- b
c
bricant visibly emerges.
- Rectify any faults in the flow of lubri-
cant.
- Reinstall the lubrication lines. Lincoln6.jpg/Lincoln8.jpg/Greasegun.wmf
- Check all connections and lines for
leaks.
F_9.1_01_EN.fm 6-8
F 9.1 6
Bearing points (2)
2x
A One lubricating nipple (a) is located at
each hydraulic cylinder bearing point
(top and bottom).
Zylinder.bmp
A A lubricating nipple (b) is located on both

sides at the mounting of the hydraulic 2x
front hopper (o).
Conveyor_set_2009.wmf
F_9.1_01_EN.fm 7-8
F 9.1 7
F 10.0 Checks, decommissioning
1 Tests, check-up, cleaning, stopping
F_10.0_01_GB.fm. 1-6
F 10.0 1
Interval
2000 / 2 years
1000 / year
as required
No.
Points of maintenance Remark
100
250
500
10
50
1 q - General observation
2 q q - Checks by a specialist
3 q - Cleaning
4 q - Conservation of paver finisher
Maintenance q
Maintenance during run-in period g
F_10.0_01_GB.fm. 2-6
F 10.0 2
2 General observation
The daily practice includes the walk around the machine with checking the following
items:
- Are there injuries on the parts or control elements?

- Are there leaks on the engine, the hydraulics, the gear box, etc.?
- Are all the locking points secure (conveyor, auger, screed)?
m Repair the detected faults immediately in order to avoid risks of accidents and envi-
ronmental pollution!
3 Checks by a specialist
A Subject the paver finisher, the screed and the optional gas or electric operated equip-
ment to checks by a specialist
- as required (according to the circumstances of application and operating condi-

tions),
- however, minimum once a year, so that the machine retains its reliable operating
condition.
F_10.0_01_GB.fm. 3-6
F 10.0 3
4 Cleaning
- Clean all parts which come into contact with the material to be laid.
- Spray the polluted parts with the separating agent spray equipment (o).
m Before cleaning with high pressure jet, lubricate all the bearings with grease as spec-
ified.
- Clean the machine with water after laying mineral mixes, lean concrete etc.
m Do not spray water on the bearings,

electric or electronic parts.
- Remove the residue of the material

laid.
m After cleaning with high pressure jet, lubricate all the bearings with grease as speci-
fied.
f Risk of slipping! Take care of the clean-

liness of the walkways and steps, make
sure that they are free of grease and oil.
F_10.0_01_GB.fm. 4-6
F 10.0 4
5 Conservation of paver finisher
5.1 Downtime up to 6 months
- Stop the machine in a place protected from intensive sunshine, wind, moisture and
frost.
- Lubricate all the lubrication points with grease as specified, use the optional central
lubrication unit as appropriate.
- Change the oil in the Diesel engine
- Tightly seal the muffler of the exhaust pipe.
- Remove the batteries, charge and store them at room temperature in well ventilat-
ed premises.
m Recharge the dismounted batteries every 2nd month.
- Protect all shiny metal surfaces, e.g. piston rods of the hydraulic cylinder against
corrosion using an appropriate agent.
- If the machine cannot be halted in a closed hall or under a shed, it must be covered
with an appropriate canvas. In each case all the air inlets and outlets shall be tightly
sealed using plastic film and adhesive tape.
5.2 Downtime between 6 months and 1 year.
- Perform all operations described for „Downtime up to 6 months“.

- After draining the engine oil, fill the engine with conservation oil permitted by the
manufacturer of the engine.
5.3 Re-commissioning:
- Perform the operations opposite to what were described in the section „Downtime“.
F_10.0_01_GB.fm. 5-6
F 10.0 5
F 11.5 Lubricants and operating substances
1 Lubricants and operating substances
m 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 oil or fuel.
A Pay attention to the correct filling volumes (see the section „Capacities“).
m Incorrect oil or lubricant levels increase the wear and cause the paver finisher to fail.
m Never mix synthetic oils with mineral oils!
Total Fina
BP Esso Mobil Renault Shell Wisura
(Total)
SHELL
BP Multi-pur- ESSO Multi-
Total Mobilux 2 Alvania
Grease pose grease Multi-purpose purpose Retinax A
Multis EP 2 Mobiplex 47 Grease EP
L2 grease grease
(LF) 2
See Operating instructions for the engine.

Engine oil
Shell Remula Super-FE 10 W 40 has been filled at the factory.
See (see section 1.1)

Hydraulic oils
Shell Tellus Oil T46 has been factory-filled.
SHELL
Transmission BP Multi ESSO MOBIL Tranself
Total EP 90 Spirax G
oil 90 EP SAE 90 GP 90 GX 90 EP 90
80 W - 90
MOBIL Chevron
BP ESSO Optimol
Total Carter Mobilgear 630 NL Gear SHELL
Transmission Energol Spartan Optigear
EP 220 Mobil-gear Compound Omala 220
oil 220 GR-XP 220 EP 220 220
SHC 220 220
Optimol Optigear 220 has been filled in at the factory.
Shell
Synthetic trans- Tivela
mission oil 220 220
Shell Tivela 220 is filled in the factory.
Dist. water
Diesel fuel
BP ATE
Brake oil,
Blue original Disc brake Total HB F 4 ELF
brake fluid
brake fluid fluid
Cooling liquid (anti-freeze and corrosion protection)

Cooling liquid
AGIP Antifreeze Spezial 956.99.58.15
F_11.5_01_EN.fm 1-6
F 11.5 1
1.1 Hydraulic oils
Preferred hydraulic oils:
a) Synthetic hydraulic liquids based on ester, HEES
Manufacturer ISO viscosity class VG 46
Shell Natural HF-E46
Panolin HLP SYNTH 46
Esso HE 46
Total Fina Elf Total Biohydran SE 46
b) Mineral oil pressure fluids
Manufacturer ISO viscosity class VG 46
Shell Tellus Oil 46
Total Fina Elf Total Azolla ZS 46
m When changing from mineral oil pressurised fluids to biodegradable pressure fluids,
please contact our factory advisory service!
A Only use containers which are clean on inside and outside for filling oil or fuel.
F_11.5_01_EN.fm 2-6
F 11.5 2
1.2 Capacities
Substance Volume
Fuel tank Diesel fuel 370 litres
Hydraulic oil reservoir Hydraulic oils 190 litres
Pump distribution gear Transmission oil 90 4.5 litres
Transmission oil 220

Planetary gear - drive unit 2.5 litres
(synthetic)
Conveyor gear (on each side) Transmission oil 90 1.5 litres
Central lubrication system

Grease
(option)
Batteries Distilled water

F_11.5_01_EN.fm 3-6
F 11.5 3
Engine type Deutz TCD 2013 L06 2V
Deutz_2013L06
Substance Volume
Diesel engine
Engine oil 10W40 20.0 litres
(with oil filter change)
Engine cooling system Cooling liquid 20.0 litres
Engine type Deutz TCD 2012 L06 2V
Deutz_2013L06
Substance Volume
Diesel engine
Engine oil 10W40 21.5 litres
(with oil filter change)
F_11.5_01_EN.fm 4-6
Engine cooling system Cooling liquid 20.0 litres
F 11.5 4
Auger
Auger_DEM.bmp
Substance Volume
Planetary gear -
Transmission oil 90 0.5 litres
augers (on each side)
Auger box Transmission oil 460 2.5 litres
Outer auger bearing

Hot bearing grease 115 grammes
(per bearing)**
** for new installation

F_11.5_01_EN.fm 5-6
F 11.5 5
2 Notes on switching from mineral oil to synthetic oil / synthetic oil to mineral oil
2.1 Drive unit planetary gear
m Never mix synthetic oils with mineral oils!
- Always drain used oil completely.

ating temperature.
- Flush out assembly with the new

grade of oil to be used.
- Operate drive unit for 10 minutes for
flushing purposes.
- Top up correct grade of oil in accord-
ance with the relevant maintenance
instructions.
F_11.5_01_EN.fm 6-6
F 11.5 6
TRAINING/EDU-
CATION
We offer our Customers various
training programmes on DYNAPAC
equipment in our specialised training
centre in our factory. We hold train-
ing sessions also for special arrange-
ments in addition to courses and
programs held on fixed dates
SERVICE
In case of operational failures and questions
related to parts, please, contact one of our au-
thorised service representations. Our skilled
specialists will arrange for the fast and pro-
fessional repair.
OPERATING ADVICE
Anytime when our dealers cannot help you,
please, feel free to contact us directly. The
team of our "Technical Advisors" is at your
disposal.
Don’t hesitate to contact
your local dealer for:
service
spare parts
documentation
accessories
and
information
about the complete
Dynapac
paving and planing
range

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OPERATION

Keep this manual for future reference

Your Authorized Dynapac Dealer:

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

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

5.7 Performance data for the SD 135 C ......................................................... 15

C1.9 Transport ................................................................................. 1

D1.12 Operation ................................................................................. 1

2.4 FMI codes ................................................................................................ 37

2.2 Malfunctions on the paver finisher or scree ............................................. 28

Mounting the distributor box ................................................................ 31

F2.14 Maintenance review ................................................................ 1

F3.6 Maintenance - Conveyor ........................................................ 1

F4.3 Maintenance - Auger ............................................................... 1

F5.6 Maintenance - Engine ............................................................. 1

F6.3 Maintenance - Hydraulic system ........................................... 1

F8.8 Maintenance - Electronic system .......................................... 1

F9.1 Maintenance - Lubricating points .......................................... 1

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

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

F11.5 Lubricants and operating substances .................................. 1

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.

1.1 Acts, directives, accident prevention regulations

1.2 Warning instructions

Warning pointing to hazardous place or danger!

Warning: risk of pulling in!

m In this area / with these equipment as a result of rotating or trans-

Attention: electric voltage!

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

Attention: suspended load!

m Never stand under suspended load!

Warning: risk of squeezing!

m Risk of squeezing arises due to the operation of certain parts, use

Attention: hot surfaces or hot liquids!

Warning, risk of falling off!

Attention: hazardous batteries!

Attention: materials harmful to health and irritating substances!

Attention: flammable materials!

Attention: gas bottles!

It is prohibited to open / step on / reach into / perform / adjust

Do not start the engine/drive!

Do not sprinkle with water!

Do not extinguish with water!

Do-it-yourself maintenance is prohibited!

A Contact the Dynapac service!

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

Do not turn on!

Protect your eyes with googles!

Wear appropriate head protection!

Protect your hearing with appropriate ear mufflers!

Protect your feet with safety footwear!

Always wear tight, conforming working coveralls!

In case of polluted air, wear respiratory mask!

- lubricants (oils, grease)

may not enter the soil or the sewer system!

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