Atlas Copco DYNAPAC Svedala Demag DF 115 C - F2.3 Maintenance Overview; Maintenance Review

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F_2.3_01_GB.fm 1-2

F 2.3 1

F 2.3 Maintenance overview

1 Maintenance review

7.2

4.1

5.1

6 8 9 10

Main Page

Table of Contents3
Preface11
General Safety Instructions12
Acts, Directives, Accident Prevention Regulations12
Warning Instructions12
Prohibitive Signs14
Protective Gear15
Environmental Protection16
Fire Prevention16
Further Instructions17
A Correct Use and Application19
B Vehicle Description21
Application21
Description of Assemblies and Functions22
Vehicle23
Construction23
Danger Zones26
Safety Devices27
Emergency Stop Button27
Steering27
Horn27
Ignition Key / Lights27
Main Switch (17)28
Hopper Transport Safeguards (18)28
Screed Transport Safeguard (19)28
Latch for Protective Roof (20)28
Technical Data, Standard Configuration30
Dimensions (All Dimensions in MM)30
Allowed Angle of Rise and Slope31
Allowed Angle of Driving up31
Weights DF 115 C (All Weights in T)32
Weights DF 135 C (All Weights in T)32
Performance Data DF 115 C33
Performance Data DF 135 C34
Traction Drive/Chassis35
Engine DF 115 C35
Engine DF 135 C35
Hydraulic System35
Material Compartment (Hopper)36
Material Conveying36
Material Distribution36
Screed Lifting Device37
Electrical System37
Location of Instruction Labels and Identification Plates38
Identification Label for the Paver Finisher (6)40
Standards41
Continuous Sound Level DF115C, Deutz TCD 2013L4641
Operating Conditions During Measurement41
Measuring Point Configuration41
Continuous Sound Level DF135C, Deutz TCD 2013L0642
Operating Conditions During Measurement42
Measuring Point Configuration42
Vibration Acting on the Entire Body43
Vibrations Acting on Hands and Arms43
Electromagnetic Compatibility (EMC)43
C1.1 Transportation45
Safety Regulations for Transportation45
Transportation on Low-Bed Trailers46
Preparations46
Driving Onto the Low-Bed Trailer48
Secure the Paver Finisher in Its Position to the Low-Bed Trailer49
After Transportation49
Transportation50
Preparations50
Traction Drive52
Loading by Crane53
Towing54
Safely Parking the Vehicle57
D1.4 Operation59
Safety Regulations59
Operating Elements60
Operating Panel60
Remote Control78
Front Side79
Reverse Side80
D3.1 Operation81
Operating Elements on the Paver Finisher81
Batteries (71)81
Battery Main Switch (72)81
Transport Safeguards for the Hopper (73)82
Mechanical Screed Transport Safeguard (to the Left and the Right Beneath the Driver's Seat) (74)83
Seat Lock (Behind the Driver's Seat) (75)83
Separator Fluid Spraying System (80) (O)84
On / off Switch for Additional Headlight in the Roof (85)85
On / off Switch for Fuel Tank Filler Pump (85A)85
On / off Switch Special Lighting (85B)85
On/Off Switch85
Exhaust of Asphalt Vapours (85C)85
On/Off Switch of Work Headlights (85D)86
On/Off Switch of Flasher (85E)86
On / off Switch Connection Sockets (85F)86
Locking of the Collapsible Roof (LH and RH on the Roofs Console) (86)86
Hydraulic Folding Roof (87) (O)87
Electric Setting of the Transportation Volume of the Conveyor (O) (88)88
Conveyor Limit Switches (89)89
Ultrasonic Auger Limit Switches (90) (Left and Right)90
Sockets for Working Lights (Left and Right) (92)90
Pressure Control Valve for Screed Charging/Relieving (93)91
Pressure Control Valve for Screed Stop with Pretensioning (93A)91
Pressure Gauge for Screed Charging/Relieving and Screed Stop with Pretensioning (93B)91
Central Lubrication Unit (O) (100)92
Track Cleaner (O) (101)92
Particle Filter - Control Light (102) (O)93
Front and Side Window (O) (103)94
Adjustment of Screed Eccentric (O) (104)95
D4.6 Operation97
Preparation of Operation97
Required Devices and Aids97
Before Starting Work (in the Morning or When Starting Paving)98
Checklist for the Machine Operator98
Starting the Paver Finisher100
Before Starting the Paver Finisher100
Normal" Starting100
External Starting (Starting Aid)101
After Starting102
Indicator Lamps102
Battery Charge Indicator (1)102
Oil Pressure Indicator Lamp for the Traction Drive (2)102
Preparations for Paving104
Separating Agent104
Screed Heater104
Direction Marks104
Loading/Distributing Material105
Starting for Paving107
Checks During Paving109
Paver Function109
Quality of the Layer109
Paving with Functions „Screed Control, Stopping of Paver Finisher" and „Screed Loading / Unloading110
General110
Screed Charging/Relieving111
Screed Control with the Paver Finisher Standing Still (Floating Position with and Without Prestressing)111
Screed Control with the Paver Finisher at Standstill - with Floating Position Prestressing112
Adjusting the Pressure112
Adjustment of Pressure for the Loading/Offloading of the Screed113
Screed Control Pressure with the Paver Finisher at Standstill - Set the Floating Position with Prestressing (O)113
Interrupting/Terminating Operation114
During Breaks (E.g. the Material Supply Truck Is Late)114
During Extended Interruptions (E.g. Lunch Break)114
When Work Is Finished115
Malfunctions117
Querying the Error Messages of the Traction Engine117
Display of the Number Code117
Error Messages120
FMI-Codes125
Problems During Paving126
Malfunctions on the Paver Finisher or Screed128
Emergency Device/Steering, Drive System131
E01 Set-Up and Modification135
Special Notes on Safety135
Auger136
Height Adjustment136
Auger Crossbeam Installed in a Fixed Position136
Mechanical Adjustment with Ratchet (Optional)137
In Case of Hydraulic Adjustment (Option)137
Auger Extension, Auger Type I139
Mounting Extension Parts140
Mounting Support Tube Extensions141
Installing Tunnel Plates142
Installing Additional Braces143
Auger Mounting Chart for Ø 310 MM Auger144
Auger Mounting Chart for Ø 380 MM Auger145
Auger Extension, Auger Type II146
Mounting Extension Parts147
Auger Modification Plan149
Screed151
Electrical Connections151
Remote Controls151
Grade Control151
Auger Limit Switches151
Working Lights151
F1.0 Maintenance153
Notes Regarding Safety153
F2.3 Maintenance Overview155
Maintenance Review155
F3.0 Maintenance - Conveyor157
Maintenance - Conveyor157
Maintenance Intervals158
Points of Maintenance158
Chain Tightness of the Conveyor (1)159
The Drive of Conveyor (to the Left/To the Right) (2)160
F4.1 Maintenance - Auger161
Maintenance - Auger Sub-Unit161
Maintenance Intervals162
Points of Maintenance162
Auger - Outer Bearing (1)162
Auger Planetary Gear (2)163
Drive Chain (3) of the Transport Augers164
Auger Case (4)166
F5.1 Maintenance - Engine169
Maintenance - Engine Sub-Unit169
Maintenance Intervals170
Points of Maintenance170
Engine Fuel Tank (1)172
Engine Lube-Oil System (2)173
Engine Fuel System (3)175
Engine Air Filter (4)177
Coolant System of the Engine (5)178
Engine Drive Belt (6)178
Engine Exhaust System (7)179
F6.0 Maintenance - Hydraulic System181
Maintenance - Hydraulic System181
Maintenance Intervals182
Points of Maintenance182
Hydraulic Oil Tank (1)182
Suction/Return Flow Hydraulic Filter (2)184
Venting the Filter185
High Pressure Filter (3)186
Pump Distribution Gear (4)187
Hydraulic Hoses (5)188
F7.2 Maintenance - Running Gear189
Maintenance - Running Gear189
Maintenance Intervals190
Points of Maintenance190
Track Tightness (1)191
Planetary Gear (2)192
F8.1 Maintenance - Electronic System193
Maintenance - Electronic System193
Maintenance Intervals194
Points of Maintenance194
Batteries (1)197
Generator (2)198
Adjustment of Belt Tightness200
Replacement of Belt201
Checking / Adjusting Belt Tension202
If Necessary, Adjust the Belt Tension202
Electric Fuses (3)203
Type of Machine: Conventional Electronics203
Switch Box203
Fuses in the Switching Cabinet (B)204
Relays in the Switching Cabinet (C)205
Fuses on the Operating Panel206
Relays on the Operating Panel207
Type of Machine: PLC- Electronics208
Switch Box208
Fuses in the Switching Cabinet209
Relays in the Switching Cabinet (C)211
Fuses on the Operating Panel212
F9.0 Maintenance - Points of Lubrication213
Maintenance- Points of Lubrication213
Maintenance Intervals214
Points of Maintenance214
Central Lubrication (1)215
Bearings (2)219
F10.0 Checks, Decommissioning221
Tests, Check-Up, Cleaning, Stopping221
Maintenance Intervals222
General Observation223
Checks by a Specialist223
Cleaning224
Conservation of Paver Finisher225
Downtime up to 6 Months225
Downtime between 6 Months and 1 Year225
Re-Commissioning225
F11.0 Lubricants and Fuels227
Lubricants and Fuels227
Hydraulic Oil228
Instructions Referring to the Oil Types Applied229
Filling Volumes230
Instructions to Change from Mineral Oil to Synthetic Oil / from Synthetic Oil to Mineral Oil234
Caterpillar Drive - Planetary Gear234

Atlas Copco DYNAPAC Svedala Demag DF 115 C - F2.3 Maintenance Overview; Maintenance Review

Table of Contents