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SD2500W
Dynapac SD2500W User Manual
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F 51 13
Checking and cleaning the radiator fins
-
If necessary, remove leaves, dus
t or sand from
the radiator.
A
Observe engine's operat
ing instructions!
Checking coolant concentration
-
Check the concentration using a
suitable tester (hydrometer).
-
Adjust the concentration if necessary.
A
Observe engine's operat
ing instructions!
384
386
Table of Contents
Table of contents
3
V Preface
13
1 General safety instructions
14
1.1 Laws, guidelines, accident prevention regulations
14
1.2 Warnings
14
1.3 Prohibitive symbols
16
1.4 Protective equipment
17
1.5 Environmental protection
18
1.6 Fire prevention
18
1.7 Additional information
19
2 CE identification and Declaration of Conformity
20
3 Guarantee conditions
20
4 Residual risks
21
5 Sensibly predictable incorrect usage
22
A Correct use and application
23
B Vehicle description
25
1 Application
25
2 Description of assemblies and functions
26
2.1 Vehicle
27
Construction
27
3 Danger zones
31
4 Safety devices
32
5 Technical data, standard configuration
34
5.1 Dimensions (all dimensions in mm)
34
5.2 Allowed angle of rise and slope
35
5.3 Permissible approach angle
35
5.4 Turning circle
35
5.5 Weights SD2500W (all weights in t)
36
5.6 Weights SD2500WS (all weights in t)
36
5.7 Performance data SD2500W
37
5.8 Performance data SD2500WS
38
5.9 Traction driv/De/chassis
39
5.10 Engine SD2500W
39
5.11 Engine SD2500WS
39
5.12 Hydraulic system
40
5.13 Material compartment (hopper)
40
5.14 Material transfer
40
5.15 Material distribution
40
5.16 Screed lifting device
41
5.17 Electrical system
41
5.18 Permissible temperature ranges
41
6 Location of instruction labels and identification plates
42
6.1 Warning signs
44
6.2 Information signs
47
6.3 CE marking
49
6.4 Instructive symbols, prohibitive symbols, warning symbols
49
6.5 Danger symbols
50
6.6 Further warnings and operating instructions
51
6.7 Identification label for the paver finisher (41)
53
7 EN standards
54
7.1 Continuous sound pressure SD2500W, Cummins QSB 6.7-C173
54
7.2 Operating conditions during measurement
54
7.3 Measuring point configuration
54
7.4 Continuous sound pressure SD2500WS, Cummins QSB 6.7-C173
55
7.5 Operating conditions during measurement
55
7.6 Measuring point configuration
55
7.7 Vibration acting on the entire body
56
7.8 Vibrations acting on hands and arms
56
7.9 Electromagnetic compatibility (EMC)
56
C 13 Transportation
57
1 Safety regulations for transportation
57
2 Transportation on low-bed trailers
58
2.1 Preparations
58
3 Securing the load
60
3.1 Prepare the low-bed trailer
60
3.2 Driving onto the low-bed trailer
61
3.3 Lashing equipment
62
3.4 Loading
63
3.5 Preparing the machine
64
4 Securing the load
65
4.1 Securing at the front and at the sides
65
Step 1: fasten lashing chains at the front
65
Step 2: fasten lashing chainsat the side
65
4.2 Securing at the rear - screed with side board
66
4.3 Securing at the rear - screed without side board
67
Step 1: fasten lashing straps
67
Step 2: fasten lashing chains
67
5 Control panel transport safeguard:
68
5.1 After transportation
69
6 Protective roof (o)
70
7 Transportation
71
7.1 Preparations
71
7.2 Driving mode
73
8 Loading by crane
74
9 Towing
76
10 Safely parking the vehicle
78
10.1 Lifting the vehicle with hydraulic lifts, lifting points
79
D 13 Operation
81
1 Safety regulations
81
2 Controls
82
2.1 Operating panel
82
2.2 Special functions
132
Reversible conveyor
132
3 Remote control
135
D 20 Operation
153
1 Operation of the input and display terminal
153
Button layout on the display
153
Command symbols
154
Menu range
154
1.1 Menu operation
155
Menu structure of the setting and display options
157
Main menu
158
Displays:
158
Menu 01 - diesel engine speed
160
Set-up menu 101 - diesel engine speed
160
Menu 02 - drive engine measured values
161
Sub-menu 201 - drive engine measured value display
161
Menu 03 - paving distance
162
Sub-menu 301 - displaying, resetting paving distance / automatic steering unit ON/OFF, steering monitoring
162
Menu 04 - external levelling
163
Setting menu 401 - external levelling
163
Menu 05 - paving thickness
164
Set-up menu 501 - paving thickness preselection
164
Menu 06 - screed parameters
165
Setting menu 600 - compacting element frequencies
166
Setting menu 601 - delayed screed start
166
Setting menu 602 - screed type selection
167
Setting menu 603 - screed heater system
167
Menu 07 - conveyor / auger capacity
168
Set-up menu 700 - conveyor / auger capacity
168
Menu 08 - system information
169
Menu 09 - service
170
Menu 10 - error memory
171
Query menu 111 - error memory:
171
Error display
172
Menu 11 - terminal settings
173
Setting menu 110 - terminal settings
173
System menu - Basic settings Display
174
Menu 12 - button function test
175
Test menu 120 - button function test
175
Menu 13 - camera display (camera 2)
176
Menu 13b - camera display (camera 1)
176
2 Terminal error messages
177
2.1 Drive engine error codes
197
2.2 Error codes
199
D 31 Operation
207
1 Operating elements on the paver finisher
207
1.1 Control elements on the operator's control station
207
Protective roof (o)
207
Protective cabin (o)
208
Windscreen wiper
208
Control panel, rigid
209
Operating panel, moveable
209
Control platform, moveable (o)
210
Operating panel, moveable
211
Operating panel, swivelling (o)
211
Control platform lock (o)
211
.Emergency actuation control platform, movable
212
Seat console, swivelling (o)
213
Seat console storage compartment
213
Driver's seat, type I
214
Driver's seat, type II
215
Service brake ("foot brake") (o)
216
Fuse box
217
Batteries
218
Main battery switch
218
Hopper transport safeguard
219
Screed lock, mechanical (o)
219
Screed lock, hydraulic (o)
220
Paving thickness indicator
221
Auger lighting (o)
222
Engine compartment lighting (o)
222
Xenon working light (o)
223
LED working light (o)
223
500 watt spotlight (o)
224
Camera (o)
224
Auger height adjustment ratchet (o)
225
Auger height indicators
225
Sensor rod / sensor rod extension
226
Manual separator fluid spray (o)
228
Separator fluid spraying system (o)
229
Conveyor limit switches - PLC version
230
Conveyor limit switches - conventional version
231
Ultrasonic auger limit switches (left and right) - PLC version
232
Ultrasonic auger limit switches (left and right) - conventional version
233
24 volt / 12 volt sockets (o)
234
Pressure control valve for screed charging/relieving
235
Pressure control valve for paving stop with relieving
235
Manometer for screed charging/relieving
235
Central lubrication system (o)
236
Screed eccentric adjustment
237
Push roller crossbar, adjustable
238
Storage box
239
Fire extinguisher (o)
239
Rotary beacon (o)
240
Fuelling pump (o)
241
Power moon (o)
242
D 43 Operation
245
1 Preparing for operation
245
Required devices and aids
245
Before starting work (in the morning or when starting paving)
246
Check list for the machine operator
246
1.1 Starting the paver finisher
249
Before starting the paver finisher
249
"Normal" starting
249
External starting (starting aid)
251
After starting
253
Observe indicator lamps
255
Engine coolant temperature check (79)
255
Battery charge indicator (83)
255
Oil pressure indicator lamp for the diesel engine (86)
255
Oil pressure indicator lamp for the travel drive (87)
257
1.2 Preparation for transportation
259
Driving and stopping the paver finisher
261
1.3 Preparations for paving
262
Separator fluid
262
Screed heater system
262
Direction marks
263
Loading/conveying material
265
1.4 Starting for paving
267
1.5 Checks during paving
268
Paver function
268
Quality of the layer
268
1.6 Paving with "screed control at paving stop" and "screed charging/relieving"
269
General
269
Screed charging/relieving
271
Screed control with paver finisher stop / in paving operation (screed stop / paving stop / floating paving)
271
Adjusting the pressure
274
Setting pressure for screed control with paving stop + relieving:
274
1.7 Interrupting/terminating operation
276
During breaks (e.g. the material supply truck is late)
276
During longer breaks (e.g. lunch break)
276
When work is finished
278
2 Malfunctions
279
2.1 Problems during paving
279
2.2 Malfunctions on the paver finisher or screed
281
E 13 Set-up and modification
285
1 Special notes on safety
285
2 Optional assemblies
286
3 Distribution auger
287
3.1 Height adjustment
287
Grain sizes up to 16 mm
287
Grain sizes > 16 mm
287
3.2 Mechanical adjustment with ratchet (o)
288
3.3 Hydraulic adjustment (o)
288
3.4 Height adjustment for large working widths / with brace -Auger Type A-
289
3.5 Height adjustment for large working widths / with brace -Auger Type B-
291
4 Auger extension -Auger Type A-
293
4.1 Mounting extension parts
294
Mounting the material shaft and auger extension
294
Mounting the outer auger bearing
295
Mounting the auger end bearing
296
4.2 Auger extension chart
297
Auger upgrading, working width 3.14m
299
Auger upgrading, working width 3.78m
299
Auger upgrading, working width 4.42m
299
Auger upgrading, working width 5.06m
300
Auger upgrading, working width 5.70m
300
Auger upgrading, working width 6.34m
301
Auger upgrading, working width 6.98m
302
Auger upgrading, working width 7.62m
303
Auger upgrading, working width 8.26m
304
4.3 Mounting the auger brace
305
4.4 Aligning the auger
307
5 Auger extension -Auger Type B-
308
5.1 Mounting extension parts
309
Mount auger extension
309
Mounting support tube extensions
311
Hydraulic hoses
312
Mount guides, guide extensions and supports
313
5.2 Auger extension chart
314
Auger upgrading, working width 3.06m
316
Auger upgrading, working width 3.35m
316
Auger upgrading, working width 3.93m
316
Auger upgrading, working width 4.22m
317
Auger upgrading, working width 5.08m
317
Auger upgrading, working width 5.66m
317
Auger upgrading, working width 6.53m
318
Auger upgrading, working width 7.40m
319
Auger upgrading, working width 8.00m
320
5.3 Mounting the auger brace
321
5.4 Aligning the auger
323
5.5 Material shaft, hinged -Auger Type A-
324
5.6 Hopper scraper
325
6 Offsetting the screed
326
7 Levelling
327
7.1 Slope controller
327
7.2 Mounting the sensor arm
328
7.3 Mounting the grade control system
328
7.4 Setting up the sensor arm
329
7.5 Big ski 9 m, big ski 13 m
330
Mounting the big ski bracket on the crossbeam
332
Mounting the swivel arms
333
Mounting the centre element
334
Extending the big ski
335
Mounting the sensor bracket
336
Mounting and aligning the sensors
337
Mounting the distributor box
338
Connection diagram
339
8 Limit switch
340
8.1 Auger limit switches (left and right) - mounting the PLC version
340
9 Screed
341
10 Electrical connections
341
10.1 Machine operation without remote control / side board
342
F 10 Maintenance
343
1 Notes regarding safety
343
F 24 Maintenance review
345
1 Maintenance review
345
2 Optional assemblies
346
F 31 Maintenance - conveyor
349
1 Maintenance - conveyor
349
1.1 Maintenance intervals
350
1.2 Points of maintenance
351
Chain tension, conveyor (1)
351
Conveyor drive - drive chains (2)
353
Conveyor deflectors / conveyor plates (3)
354
F 40 Maintenance - auger assembly
355
1 Maintenance - auger assembly
355
1.1 Maintenance intervals
356
1.2 Points of maintenance
358
Outer auger bearing (1)
358
Auger planetary gear (2)
359
Drive chains of the augers (3)
360
Auger box (4)
361
Seals and sealing rings (5)
362
Gearbox bolts Check tightening (6)
363
Mounting screws - Outer auger bearing Check tightening (7)
363
Auger blade (8)
364
F 41 Maintenance - auger assembly
365
1 Maintenance - auger assembly - external drive version
365
1.1 Maintenance intervals
366
1.2 Points of maintenance
367
Outer auger bearing (1)
367
Centre auger bearing (2)
368
Auger, gear neck bearing (3)
369
Auger bevel gear (left/ right) (4)
370
Auger blade (5)
371
F 51 Maintenance - engine assembly
373
1 Maintenance - engine assembly
373
1.1 Maintenance intervals
374
1.2 Points of maintenance
377
Engine fuel tank (1)
377
Engine lube oil system (2)
378
Engine fuel system (3)
380
Engine air filter (4)
382
Engine cooling system (5)
384
Engine drive belt (6)
386
F 61 Maintenance - hydraulic system
387
1 Maintenance - hydraulic system
387
1.1 Maintenance intervals
388
2 Safety instructions for working on the hydraulic system
390
Sfety instructions hydraulic reservoir
390
2.1 Points of maintenance
391
Hydraulic oil tank (1)
391
Suction/return flow hydraulic filter (2)
393
Bleeding the filter
394
High-pressure filter (3)
395
Pump distribution gear (4)
396
Bleeder
397
Hydraulic hoses (5)
398
Marking hydraulic hoses / storage period, period of use
400
Auxiliary flow filter (6)
401
F 72 Maintenance - travel drive, steering
403
1 Maintenance - travel drive, steering
403
1.1 Maintenance intervals
404
1.2 Points of maintenance
406
Planetary gear (1)
406
Drive wheels (2)
407
Replacing/dismantling and installing the wheels
408
Air pressure table
410
Pressures for equipment Bandag on Michelin XHA
410
Pressures for equipment Michelin XGC / Techking ETGC
410
Lubrication points (3)
412
Steering
412
F 83 Maintenance - electrical system
413
1 Maintenance - electrical system
413
1.1 Maintenance intervals
414
1.2 Points of maintenance
415
Batteries (1)
415
Alternator (2)
416
Insulation faults
417
Cleaning the generator
418
Electrical fuses / relays (3)
419
Fuses in terminal box (B)
420
Relays in terminal box (C)
423
Relays in the engine compartment (E)
425
F 90 Maintenance - lubricating points
427
1 Maintenance - lubricating points
427
1.1 Maintenance intervals
428
1.2 Points of maintenance
429
Central lubrication system (1)
429
Bearing points (2)
433
F 100 Tests, stopping ...
435
1 Tests, checks, cleaning, stopping
435
1.1 Maintenance intervals
436
2 General visual inspection
437
3 Inspection by an expert
437
4 Cleaning
438
4.1 Cleaning the hopper
439
4.2 Cleaning the conveyor and auger
439
5 Preserving the paver finisher
440
5.1 Shutdowns for up to 6 months
440
5.2 Shutdowns lasting from 6 months to 1 year
440
5.3 Recommissioning the machine
440
6 Environmental protection, disposal
441
6.1 Environmental protection
441
6.2 Disposal
441
F 111 Lubricants and operating substances
443
1 Lubricants and operating substances
443
2 Optional assemblies
444
2.1 Capacities
446
3 Lubricant specifications
447
3.1 Engine
447
3.2 Cooling system
447
3.3 Hydraulic system
447
3.4 Pump distribution gear
447
3.5 Travel drive planetary gear
448
3.6 Auger drive planetary gear type A
448
3.7 Auger box type A
448
3.8 Auger bevel gear type B
448
3.9 Grease
448
3.10 Hydraulic oil
449
4
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Dynapac SD2500W Specifications
General
Brand
Dynapac
Model
SD2500W
Category
Construction Equipment
Language
English
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