Dynapac SVEDALA DEMAG DF 65 C User manual

Operating instructions
01-0504
900 98 09 01
Paver Finisher
DF 65 C
875.......................

V_DF65C_GB.fm 1-2 0504
Preface
Safe operation of the machine requires specific knowledge that is imparted by these
operating instructions. The information is provided in a concise, clearly structured
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:
Precedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
$Precedes notes that must be observed to prevent damage to equipment.

Precedes general notes and explanations.
+ Used to indicate standard equipment.
& 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 these operating instructions at the same
time.
Dynapac GmbH
Niederlassung Lingen
Darmer Esch 81
D-49811 Lingen / Germany
Telefon: +49 / (0)591 / 91275-0
Fax: +49 / (0)591 / 91275-99
www.dynapac.com

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DF65C_GBIVZ.fm 1-4 0504
Table of contents
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 Safety devices ............................................................................................ 6
3.1 Emergency stop button ..............................................................................6
3.2 Steering ......................................................................................................6
3.3 Horn ...........................................................................................................6
3.4 Ignition key / lights .....................................................................................6
3.5 Safety devices on the gas heater system .................................................. 6
3.6 Master switch .............................................................................................8
3.7 Hopper transport safeguard ....................................................................... 8
3.8 Screed transport safeguard .......................................................................8
3.9 Latch for protective roof (1) ........................................................................9
3.10 Additional safety devices ........................................................................10
3.11 Miscellaneous equipment ........................................................................10
4 Technical data, standard configuration ....................................................11
4.1 Dimensions ..............................................................................................11
4.2 Weights ....................................................................................................12
4.3 Performance data ....................................................................................13
4.4 Traction drive/chassis .............................................................................. 13
4.5 Engine ......................................................................................................13
4.6 Hydraulic system ...................................................................................... 14
4.7 Material compartment (hopper) ................................................................ 14
4.8 Material conveying ...................................................................................14
4.9 Material distribution .................................................................................. 15
4.10 Screed control system ............................................................................. 15
4.11 Electrical system ......................................................................................16
4.12 Gas heating system for the screed (O) ....................................................16
5 Location of instruction labels and type plates ..........................................17
5.1 Identification label for the paver finisher (4) ............................................. 19
5.2 Identification label for the liquefied gas system (12) ............................... 20
6 EN standards ........................................................................................... 21
6.1 Continuous sound pressure level .............................................................21
6.2 Operating conditions during measurement ..............................................21
6.3 Measuring point configuration ..................................................................21
6.4 Vibration acting on the entire body ..........................................................22
6.5 Vibrations acting on hands and arms ....................................................... 22
6.6 Electromagnetic compatibility (EMC) ....................................................... 22

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C Transportation ......................................................................... 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 ..................................................................3
2.3 After transportation ....................................................................................3
3 Transportation on public roads .................................................................. 4
3.1 Preparations ...............................................................................................4
3.2 Driving on public roads ..............................................................................5
4 Loading by crane .......................................................................................6
5 Towing .......................................................................................................7
6 Safely parking the vehicle .......................................................................... 8
D Operation ................................................................................. 1
1 Safety regulations ......................................................................................1
2 Controls ...................................................................................................... 2
2.1 Operating panel .........................................................................................2
2.2 Remote control .........................................................................................20
Front ....................................................................................................20
Rear .....................................................................................................21
2.3 Operating elements on the paver finisher ................................................ 22
Engine speed adjuster (67) .................................................................. 22
Batteries (68) ....................................................................................... 23
Battery main switch (69) ......................................................................23
Transport safeguards for the hopper (70) ............................................23
Conveyor limit switch (paddle) (71) .....................................................24
Ultrasonic auger limit switch (72) .........................................................25
Sockets for working lights (left and right) (73) ..................................... 25
Sockets for automatic levelling/slope (74) ........................................... 26
Socket for remote control (75) .............................................................26
Vibration (76) and tamper (screed-specific) (77) speed control ........... 27
Emulsion spray system (80), (81) ........................................................28
Collapsible roof lock (LH and RH on the rear console) (82): ............... 28
Mechanical screed transport safeguard (left and right) (90) ................29
Seat lock (behind the driver’s seat) (91) .............................................. 30

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DF65C_GBIVZ.fm 3-4 0504
3 Operation .................................................................................................31
3.1 Preparing for operation ............................................................................31
Required devices and aids .................................................................. 31
Before starting work(in the morning or when starting paving) .............31
Check list for the machine operator .....................................................32
3.2 Starting the paver finisher ........................................................................ 33
Before starting the paver finisher .........................................................33
„Normal“ starting .................................................................................. 33
External starting (starting aid) ..............................................................34
After starting ........................................................................................35
Indicator lamps .................................................................................... 36
Oil pressure indicator lamp for the diesel engine (1) ........................... 36
Battery charge indicator (2) ................................................................. 36
3.3 Preparations for paving ............................................................................37
Separating agent ................................................................................. 37
Screed heater system ..........................................................................37
Direction marks ....................................................................................37
Loading/distributing material ................................................................ 38
3.4 Driving off for laying ................................................................................. 39
3.5 Checks during paving ..............................................................................41
Paver function ......................................................................................41
Quality of the layer ...............................................................................41
3.6 Paving with screed stop ...........................................................................42
General ................................................................................................42
Deactivation of floating position ........................................................... 42
3.7 Interrupting/terminating operation ............................................................ 43
During breaks (e.g. delays caused by material trucks) ........................43
During longer breaks (e.g. lunch break) ..............................................43
When work is finished .......................................................................... 44
4 Malfunctions .............................................................................................46
4.1 Problems during paving ...........................................................................46
4.2 Paver finisher malfunctions ......................................................................48
E Set-up and modification ......................................................... 1
1 Special notes on safety ..............................................................................1
2 Distribution auger .......................................................................................2
2.1 Height adjustment ......................................................................................2
2.2 Mechanical adjustment with ratchet ...........................................................3
2.3 Hydraulic adjustment (o) ............................................................................3
2.4 Auger extension ......................................................................................... 4
3 Screed ........................................................................................................5
4 Electrical connections ................................................................................ 5
4.1 Connect remote controls ............................................................................5
4.2 Connect levelling system ...........................................................................5
4.3 Connect auger limit switches ..................................................................... 6
4.4 Connect levelling device ............................................................................6
4.5 Connect working lights ...............................................................................6

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DF65C_GBIVZ.fm 4-4 0504
F Maintenance ............................................................................ 1
1 Notes regarding safety ...............................................................................1
2 Maintenance intervals ................................................................................ 2
2.1 Daily (or every 10 operating hours) ............................................................3
2.2 Weekly (or every 50 operating hours) ........................................................ 5
2.3 Every 500 operating hours .........................................................................7
2.4 Annually (or every 1000 operating hours) ..................................................7
2.5 Every 2 years (or every 2000 operating hours) .......................................... 9
3 Points for checking, lubricating and draining oil .......................................10
3.1 Checkpoints .............................................................................................11
Planetary gear conveyor (1) ................................................................ 11
Batteries (2) .........................................................................................12
Air filter (dry air filter) (3) ...................................................................... 12
Track tension of caterpillar drive (4) ....................................................13
Pump distributor gear (5) .....................................................................14
High-pressure hydraulic filter (6) .......................................................... 14
Conveyor drive chains (8) ....................................................................15
Outer auger bearing (9) .......................................................................16
Auger box filling level (11) ...................................................................17
Auger drive chains (12) ........................................................................ 18
Conveyor drive (13) ............................................................................18
Diesel engine (17) ................................................................................ 19
Conveyor deflection rollers (20) ........................................................... 19
V-belts (21) ..........................................................................................19
Fuel tank (22) ....................................................................................... 20
Fuel filter (23) .......................................................................................20
Hydraulic suction filter (24) .................................................................. 20
Hydraulic oil reservoir (25) ................................................................... 20
Chain tension, conveyor (27) ...............................................................21
General visual inspection ..................................................................... 22
Check by a specialist ........................................................................... 22
3.2 Oil drain points .........................................................................................23
Pump distribution gear (5) ................................................................... 23
Diesel engine (17) ................................................................................ 23
Fuel tank (22) ....................................................................................... 24
Hydraulic oil reservoir (25) ................................................................... 24
4 Lubricating agents and operating materials .............................................25
4.1 Hydraulic oil .............................................................................................26
4.2 Filling volumes .........................................................................................27
5 Electric Fuses ..........................................................................................28
5.1 Main fuses (1) ........................................................................................28
5.2 Fuses in the main terminal box ................................................................28
5.3 Fuses on operating panel ........................................................................30

A 1
A_DF65C_GB.fm 1-2 0504
A Correct use and application

The „Guidelines for the Correct Use and Application of Paver Finishers“ are included
in the scope of delivery for this present machine. The guidelines are part of these op-
erating instructions and must always be heeded. National regulations are fully appli-
cable.
The road construction machine described in these operating instructions is a paver
finisher that is suited for laying mixed materials, roll-down concrete or lean-mixed
concrete, track-laying ballast and unbound mineral aggregates for foundations for
paving.
The paver finisher must be used, operated and maintained according to the instruc-
tions given in these operating instructions. 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 exceeding the range of applications described above is regarded as improp-
er use and is expressly forbidden! Especially in those cases where the paver finisher
is to be operated on inclines or where it is to be used for special purposes (construc-
tion of dumps, dams), it is absolutely necessary to contact the manufacturer.
Duties of the user: A „user“ within the meaning of these operating instructions is de-
fined 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 consid-
ered to be the person who, in accordance with existing contractual agreements be-
tween the owner and the user of the paver finisher, is charged with the observance
of the operating duties.
The user must ensure that the paver finisher is only used in the stipulated manner and
that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance guide-
lines are observed. The user must ensure that all persons operating the paver finisher
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 must be obtained.
Any approval obtained from local authorities does not, however, make approval by
the manufacturer unnecessary.

B 1
B_DF65C_GB.fm.1-22 0504
B Vehicle description
1 Application
The SVEDALA DEMAG DF 65 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.

B 2
B_DF65C_GB.fm.2-22 0504
2 Description of assemblies and functions
Item Designation
1 t Auger
2 t Screed
3 t Control panel
4 t Paving thickness indicator
5 t Control box for screed heating
6 t Operating panel (can be moved to either side)
7 o Protective roof
8 t Material compartment (hopper)
9 t Truck push rollers
10 o Caterpillar drive
11 t Traction drive of the caterpillar drive
12 t Traction roller
13 t Crossbeam guide
14 t Levelling cylinder for paving thickness
15 t Arm
+ = Standard equipment & = Optional equipment
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B 3
B_DF65C_GB.fm.3-22 0504
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 a high paving precision. The continuously
adjustable hydrostatic traction drive allows the speed of the paver finisher to be
matched to all work conditions.
Operation of the paver finisher is facilitated by the automatic material handling sys-
tem, the separate traction drive and the clearly positioned operating and control ele-
ments.
The following extra equipment ( & ) is available:
- Automatic levelling/slope control system
- Additional cut-off shoe
- Larger working widths
- Protective roof
- Telescoping seat console
- Additional lighting
- Hydraulic extendable push roller cross bar
Further equipment and upgrade options on request.
Engine: The paver finisher is equipped with a air-cooled 4-cylinder Deutz diesel en-
gine. For further information please refer to the operating instructions for the engine.
Caterpillar drive: Both caterpillar drives are directly driven by separate drives with-
out any drive chains that would require maintenance and servicing.
The tension of the caterpillar chains can be readjusted using tensioners.
The tension of the drive chains can be mechanically adjusted.
Hydraulic system: The diesel engine drives the hydraulic pumps for all main drives
of the paver finisher via the attached distribution gear and its auxiliary drive shafts.

B 4
B_DF65C_GB.fm.4-22 0504
Traction drive: The continuously adjustable traction drive pumps are connected to
the traction motors by means of high pressure hydraulic hoses.
These oil motors drive the caterpillar chains via planetary gears that are mounted di-
rectly inside the drive wheels of the caterpillar chains.
Steering system/operator’s platform: The independent hydrostatic traction drives
allow the finisher to be turned on the spot.
The electronic synchronisation, controlled from the operating panel, ensures that the
finisher runs straight ahead.
Push roller cross bar: The push rollers for material trucks are fastened to a cross
bar that is pivoted at its centre.
The finisher deviates less from its course, thereby facilitating paving in curves.
A hydraulic extendable push roller cross bar which can be adapted perfectly to the
filling length characteristics of the material truck is available as an option.
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. 10 tons of material.
To facilitate emptying and to improve material transport, each of the lateral covers of
the hopper can be hydraulically moved ( & ).
Material transfer: The paver finisher is equipped with two separately driven convey-
ors that transfer the material from the hopper to the augers.
By scanning the filling height during the paving procedure, the transfer amount is reg-
ulated 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.

B 5
B_DF65C_GB.fm.5-22 0504
Height adjustment and extension of augers: Height adjustment and extension of
augers ensure optimum adaptation to a wide range of paving thicknesses and widths.
In the basic version, the height is adjusted by means of barrel nuts.
Another variant allows the height to be regulated at the control panel by means of hy-
draulic cylinders ( & ).
Auger segments of different lengths can be attached to easily adapt to the different
paving widths.
Levelling/slope control system: The slope control system ( & ) allows the traction
point to be regulated at the left-hand or the right-hand side with a defined difference
to the opposite side.
To determine the actual value, the two traction arms are linked with a slope control
rod.
The slope control system always operates in conjunction with the screed height ad-
justment of the opposite side.
By adjusting the height of the traction point of the arm (traction roller), the paving
height of the material or the laying height of the screed can be controlled.
Actuation occurs electrohydraulically on both sides and can be controlled manually
by means of toggle switches or automatically by means of an electronic grade control
system. For further information, please refer to the operating instructions for „Level-
ling Systems“.
Screed lifting device: The screed lifting device is used to lift the screed during trans-
portation. Lifting occurs electrohydraulically on both sides by actuating the hydraulic
cylinders on the arms and is controlled by means of toggle switches on the operating
panel.
Control box for the screed heating system: Depending on version, the screed
heating system is controlled and monitored using a control box on the screed or on
the rear of the machine.

B 6
B_DF65C_GB.fm.6-22 0504
3 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.

Check the function of these devices at regular intervals (see chapter D, section
„Check list for the machine operator“).
3.1 Emergency stop button
- on the operating panel
- on the remote control units ( & )
$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!
3.2 Steering
3.3 Horn
- on the operating panel
- on the two remote control units
3.4 Ignition key / lights
3.5 Safety devices on the gas heater system
- Bottle valve (1)
- Hose rupture protection (2)
- Main shut-off valve (3)
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B 7
B_DF65C_GB.fm.7-22 0504
- Indicator lamps (4) on the switch cabi-
net
- On/Off switch (5) in the switch cabinet
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B 8
B_DF65C_GB.fm.8-22 0504
3.6 Master switch
3.7 Hopper transport safeguard
3.8 Screed transport safeguard
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3.9 Latch for protective roof (1)
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B_DF65C_GB.fm.10-22 0504
3.10 Additional safety devices
3.11 Miscellaneous equipment
- Warning triangle (o)
- First-aid kit (o)
Item Designation
1 Walkway
2 Screed coverings
3 Screed hazard flasher
4 Engine hoods
5 Side flaps
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