Dynapac DF 145 CS Installation guide

04-0107
OPERATION
&
MAINTENANCE
Paver finisher
Svedala Demag
DF 145 C
DF 145 CS
Type 438 / 439
Keep this manual for future reference
Order number for this manual: D900981468
438.................
439.................

VALUE
QUALITY
THE ORIGINAL
Your Authorized Dynapac Dealer:

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 1-8
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 .............................................................................7
4.2 Steering ......................................................................................................7
4.3 Horn ...........................................................................................................7
4.4 Ignition key / lights .....................................................................................7
4.5 Main switch (17) ........................................................................................8
4.6 Hopper transport safeguards (18) .............................................................8
4.7 Screed transport safeguards (19) ..............................................................8
4.8 Latch for protective roof (20) ......................................................................8
5 Technical data, standard configuration ....................................................10
5.1 Dimensions (all dimensions in mm) .........................................................10
5.2 Allowed angle of rise and slope ...............................................................11
5.3 Allowed angle of driving up ......................................................................11
5.4 DF 145 C weights (all weights in t) ..........................................................12
5.5 DF 145 CS weights (all weights in t) ........................................................12
5.6 Performance data for the DF 145 C .........................................................13
5.7 Performance data for the DF 145 CS ......................................................14
5.8 Travel drive/traction unit ...........................................................................15
5.9 DF 145 C engine ......................................................................................15
5.10 DF 145 CS engine ...................................................................................15
5.11 Hydraulic system ......................................................................................15
5.12 Material compartment (hopper) ................................................................16
5.13 Material transfer .......................................................................................16
5.14 Material distribution ..................................................................................16
5.15 Screed lifting device .................................................................................17
5.16 Electrical system ......................................................................................17
6 Location of instruction labels and identification plates .............................18
6.1 Identification label for the paver finisher (6) ..........................................20

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 2-8
7 EN standards ...........................................................................................21
7.1 Continuous sound level ............................................................................21
DF 145 C vehicle .................................................................................21
DF 145 CS vehicle ...............................................................................21
7.2 Operating conditions during measurement ..............................................22
7.3 Measuring point configuration ..................................................................22
7.4 Vibration acting on the entire body ..........................................................23
7.5 Vibrations acting on hands and arms .......................................................23
7.6 Electromagnetic compatibility (EMC) .......................................................23
C1.5 Transportation .........................................................................1
1 Safety regulations for transportation ..........................................................1
2 Transportation on low-bed trailers .............................................................2
2.1 Preparations ...............................................................................................2
2.2 Drive onto the low-bed trailer .....................................................................4
2.3 Secure the paver finisher in its position to the low-bed trailer: ...................5
2.4 After transportation ....................................................................................5
3 Transportation ............................................................................................6
3.1 Preparations ...............................................................................................6
3.2 Driving mode ..............................................................................................8
4 Loading by crane .......................................................................................9
5 Towing .....................................................................................................10
6 Safely parking the vehicle ........................................................................13
D1.7 Operation .................................................................................1
1 Safety regulations ......................................................................................1
2 Operating elements ....................................................................................2
2.1 Operating panel .........................................................................................2
3 Remote control .........................................................................................24

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 3-8
D2.1 Operation .................................................................................1
1 Operation of the input and display terminal ...............................................1
Allocation of the keyboard of the display. ..............................................1
1.1 Working in the menu ..................................................................................2
Menu structure of the setting and display options .................................3
Main menu 00 ........................................................................................4
Display and function menu ....................................................................4
Menu 01 - Engine speed ........................................................................5
Submenu 101 - Setting the engine speed .............................................5
Menu 02 - Measuring value of drive engine ...........................................6
Submenu 103 - Display of measuring value Drive engine .....................6
Menu 03 - Trip meter and fuel gauge ....................................................7
Submenu 301 - Road section, fuel consumption display/reset .............7
Menu 04 - Emergency function / stopping the screed and turning
on the tamper .........................................................................................8
Submenu 401 - Emergency functions adjustment ................................8
Menu 05 - Layer thickness .....................................................................9
Submenu 501 - Preselection of layer thickness ....................................9
Submenu 502 - Setting the speed of auger ........................................10
Submenu 503 - Adjustment of the speed of conveyor ........................10
Menu 06 - Screed charging .................................................................11
Submenu 102 - Starting load setting ..................................................11
Menu 07 - Screed type ........................................................................12
Submenu 701 - Setting the screed type .............................................12
Menu 08 - Service hour meter .............................................................13
Menu 09 - Service ................................................................................14
Submenu 201 - Password prompt ......................................................14
Menu 10 - Error memory ......................................................................15
Error message display: .......................................................................15
Error display .........................................................................................15
Menu 11 - Error memory Computer of machine operation ..................16
Error message display: .......................................................................16
Error display .........................................................................................16
Menu 12 - Program version .................................................................17
Menu 13 - Terminal settings ................................................................18
Submenu 104 - Terminal settings .......................................................18
1.2 Further messages on the display .............................................................19
2 Terminal error messages .........................................................................20
2.1 Instructions related to error messages .....................................................26
2.2 Fault codes of the traction engine. ...........................................................27
2.3 Error messages ........................................................................................29
2.4 Special functions ......................................................................................36
Emergency operation program for the case of keyboard failure ..........36
Reversible conveyor ............................................................................37

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 4-8
D3.4 Operation .................................................................................1
1 Operating elements on the paver finisher ..................................................1
Batteries (71) .........................................................................................1
Battery main switch (72) ........................................................................1
Transport safeguards for the hopper (73) ..............................................2
Mechanical screed transport safeguard
(to the left and the right beneath the driver’s seat) (74) .........................3
Seat lock (behind the driver’s seat) (75) ................................................3
Separator fluid spraying system (80) (o) ................................................4
On / off switch for additional headlight in the roof (85): .........................5
On / off switch for filler pump fuel tank (85a) .........................................5
On / Off switch Special lighting (85b) .....................................................5
On / Off switch Asphalt fume control system (85c) ................................5
On/Off switch of working lights (85d): ....................................................6
On/Off switch of rotary beacon (85e): ....................................................6
230 V On / Off switch
Connection sockets (85f) .......................................................................6
Locking of the collapsible roof (LH and RH on the roofs console) (86) .7
Hydraulic folding roof (87) (o) ...............................................................8
Electric setting of the transportation volume of the conveyor (o) (88) ...9
Conveyor limit switches (89): ...............................................................10
Ultrasonic auger limit switches (90) (left and right) ..............................11
Sockets for working lights (left and right) (92) .....................................11
Pressure control valve for screed charging/relieving (93) (o) ..............12
Pressure control valve for screed stop with pretensioning (93a) (o) ....12
Manometer for screed charging/relieving and screed stop
with pretensioning (93b) ......................................................................12
Central lubrication unit (o) (100) ..........................................................13
Lane clearer (o) (101) ..........................................................................13
Particle filter – indicator lamp (102) (o) ...............................................14
Front and side window (o) (103) ..........................................................15
Adjustment of screed eccentric (o) (104) .............................................16

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 5-8
D4.13 Operation .................................................................................1
1 Preparation of operation ............................................................................1
Required devices and aids ....................................................................1
Before starting work (in the morning or when starting paving) ..............1
Checklist for the machine operator ........................................................2
1.1 Starting the paver finisher ..........................................................................4
Before starting the paver finisher ...........................................................4
"Normal" starting ....................................................................................4
External starting (starting aid) ................................................................5
After starting .......................................................................................6
Indicator lamps ......................................................................................6
Oil pressure indicator lamp for the travel drive (46) ...............................7
Battery charge indicator (49) .................................................................8
1.2 Operation in case of transportation ............................................................9
Lifting and securing the screed ..............................................................9
Driving and stopping the paver finisher ..............................................10
Switching off and securing the paver finisher ......................................10
1.3 Preparations for paving ............................................................................11
Separating fluid ....................................................................................11
Screed heater ......................................................................................11
Direction marks ....................................................................................12
Loading/distributing material ...............................................................12
1.4 Starting for paving ....................................................................................14
1.5 Checks during paving ..............................................................................16
Paver finisher function .........................................................................16
Quality of the layer ...............................................................................16
1.6 Paving with screed stop and screed charging/relieving ...........................16
General ................................................................................................16
Screed charging/relieving ....................................................................17
Screed stop with prestressing ..............................................................18
Screed stop with prestressing ..............................................................18
Adjusting the pressure (o) ....................................................................19
For screed charging/relieving: .............................................................19
1.7 Interrupting/terminating operation ............................................................20
During breaks: (e.g. the material supply truck is late) ..........................20
During extended interruptions (e.g. lunch break) .................................20
When work is finished ..........................................................................20
2 Malfunctions .............................................................................................23
2.1 Problems during paving ...........................................................................23
2.2 Malfunctions on the paver finisher or screed ...........................................25
3 Emergency device/steering, travel drive ..................................................28

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 6-8
E02 Set-up and modification .........................................................1
1 Special notes on safety ..............................................................................1
2 Distribution auger .......................................................................................2
2.1 Height adjustment ......................................................................................2
2.2 For mechanical adjustment with ratchet ....................................................2
2.3 With hydraulic adjustment (option) .............................................................3
3 Auger extension .........................................................................................4
3.1 Mounting extension parts ...........................................................................5
4 Offset screed position towards back ..........................................................7
5 Screed ........................................................................................................8
6 Electrical connections ................................................................................8
6.1 Connect remote controls ............................................................................8
6.2 Connect grade control ................................................................................8
6.3 Connect auger limit switches .....................................................................8
6.4 Connect working lights ...............................................................................8
F1.0 Maintenance ............................................................................1
1 Notes regarding safety ...............................................................................1
F2.9 Maintenance review ................................................................1
1 Maintenance review ...................................................................................1
F3.5 Maintenance - Conveyor ........................................................1
1 Maintenance - Conveyor ............................................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................3
Chain tightness of the conveyor (1) .......................................................3
Conveyor drive - drive chains (2) ...........................................................4
Conveyor drive planetary gear (left and right) (3) ..................................5
F4.1 Maintenance - Auger ...............................................................1
1 Maintenance - auger sub-unit ....................................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................3
Auger - outer bearing (1) .......................................................................3
Auger planetary gear (2) ........................................................................3
Drive chain (3) of the transport augers ..................................................4
Auger case (4) .......................................................................................6

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 7-8
F5.3 Maintenance - Engine .............................................................1
1 Maintenance - Engine ................................................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................4
Engine fuel tank (1) ...............................................................................4
Engine lube-oil system (2) ....................................................................5
Engine fuel system (3) ..........................................................................7
Engine air filter (4) .................................................................................9
Coolant system of the engine (5) .........................................................10
Engine drive belt (6) .............................................................................10
Engine exhaust system (7) .................................................................11
F6.2 Maintenance - Hydraulic system ...........................................1
1 Maintenance - Hydraulic system ................................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................3
Hydraulic oil tank (1) ..............................................................................3
Suction/return flow hydraulic filter (2) ....................................................4
High pressure filter (3) ...........................................................................5
Pump distribution gear (4) .....................................................................6
Hydraulic hoses (5) ................................................................................7
Auxiliary flow filter (6) .............................................................................8
F7.7 Maintenance – Drive units ......................................................1
1 Maintenance – Drive units .........................................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................3
Chain tightness (1) .................................................................................3
Planetary gear (2) ..................................................................................4

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DF145C_CS_OMM_PLC_04_GBIVZ.fm 8-8
F8.6 Maintenance - Electronic system ..........................................1
1 Maintenance - Electronic system ...............................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................5
Batteries (1) ...........................................................................................5
Generator (2) .........................................................................................6
Adjustment of belt tightness ...................................................................8
Replacement of belt ...............................................................................9
Checking / adjusting belt tension: ........................................................10
If necessary, adjust the belt tension: ...................................................10
Electric fuses (3) ..................................................................................11
Type of machine: Conventional electronics .........................................11
Fuses in terminal box (B) .....................................................................12
Relays in terminal box (C) ...................................................................13
Fuses on operating panel ....................................................................14
Relays in operating panel ....................................................................15
Type of machine: PLC electronics .......................................................16
Terminal box .......................................................................................16
Fuses in terminal box ..........................................................................17
Relays in terminal box (C) ...................................................................19
Fuses on operating panel ....................................................................20
F9.0 Maintenance - Points of lubrication ......................................1
1 Maintenance- Points of lubrication .............................................................1
1.1 Maintenance intervals ................................................................................2
1.2 Points of maintenance ...............................................................................3
Central lubrication (1) ............................................................................3
Bearings (2) ...........................................................................................7
F10.0 Checks, decommissioning .....................................................1
1 Tests, check-up, cleaning, stopping ...........................................................1
1.1 Maintenance intervals ................................................................................2
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
F11.2 Lubricants and operating substances ..................................1
1 Lubricants and operating substances .......................................................1
1.1 Hydraulic oils ..............................................................................................2
1.2 Filling volumes ...........................................................................................3
2 Notes on changing over from mineral oil to synthetic oil /
synthetic oil to mineral oil ...........................................................................4
2.1 Drive unit planetary gear ............................................................................4

V 1
V_01_GB.fm
VPreface
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:
fPrecedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
mPrecedes notes that must be observed to prevent damage to equipment.
APrecedes general notes and explanations.
tUsed to indicate standard equipment.
oUsed 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
www.dynapac.com

V 2
V_01_GB.fm
1 General safety instructions
1.1 Acts, directives, accident prevention regulations
AThe 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!
AThe following alerts, prohibitions and instructions refer to the risks to which people,
machinery and environment are exposed.
AIgnoring these instructions, bans and commands may lead to fatal injuries!
AFurthermore, 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!
mIn 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!
mAll maintenance and repair work on the screed's electrical system
must always be carried out by an electrician!
Attention: suspended load!
mNever stand under suspended load!
Warning: risk of squeezing!
mRisk 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!

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V_01_GB.fm
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 4
V_01_GB.fm
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!
AContact the Dynapac service!
Danger of fire: do not use open flame and no smoking!
Do not turn on!

V 5
V_01_GB.fm
1.4 Protective gear
AThe 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 6
V_01_GB.fm
1.5 Environmental protection
AThe 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
-gasoil
- coolant
- detergents
may not enter the soil or the sewer system!
Thesematerials shall be collected, stored, transported in the correct
containers until professional disposal!
Material harmful for the environment!
1.6 Fire prevention
AThe applicable local regulations may specify the mounting of appropriate fire extin-
guishers!
Observe these specifications!
Fire fighting device
(optional equipment)

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V_01_GB.fm
1.7 Further instructions
mObserve the manufacturer's and other instructions!
Ae.g. the maintenance instructions of the engine manufacturer
mDescription / figure in case of an electrically heated design!
mDescription / figure in case of an electrically heated design!

A 1
A_01_GB.fm 1-2
A Correct use and application
AThe “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 purposeof the intended
work as included in the operation manual. Any other use is regardedas 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
(constructionof dumps, dams), itis absolutely necessary tocontact 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.
Theusermustensure that the paverfinisheris only usedin the stipulatedmanner 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 willinterfere 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.