Fayat Group DYNAPAC SC2500WS User manual

Operating Instructions
Paver Finisher
SD2500W / SC2500WS
Type 897 / 898
11-0419
4812074033

www.dynapac.com

1
Table of contents
V Preface ..................................................................................... 1
1 General safety instructions ........................................................................ 2
1.1 Laws, guidelines, accident prevention regulations ..................................... 2
1.2 Safety signs, signal words ......................................................................... 3
"Danger"! ............................................................................................... 3
"Warning" ! ............................................................................................. 3
"Caution" ! .............................................................................................. 3
"Note" ! ................................................................................................... 3
1.3 Other supplementary information ............................................................... 3
1.4 Warnings .................................................................................................... 4
1.5 Prohibitive symbols .................................................................................... 6
1.6 Protective equipment ................................................................................. 7
1.7 Environmental protection ........................................................................... 8
1.8 Fire prevention ........................................................................................... 8
1.9 Additional information ................................................................................ 9
2 CE identification and Declaration of Conformity ...................................... 10
3 Guarantee conditions ............................................................................... 10
4 Residual risks ........................................................................................... 11
5 Sensibly predictable incorrect usage ....................................................... 12
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 ............................................................................................. 8
4 Safety devices ............................................................................................ 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 Turning circle ........................................................................................... 12
5.5 Weights SD2500W (all weights in t) ......................................................... 13
5.6 Weights SD2500WS (all weights in t) ...................................................... 13
5.7 Performance data SD2500W ................................................................... 14
5.8 Performance data SD2500WS ................................................................. 15
5.9 Travel drive/traction unit ........................................................................... 16
5.10 SD2500W - Engine EU IIIa / Tier 3 (o) ..................................................... 16
5.11 SD2500WS - Engine EU IIIa / Tier 3 (o) .................................................. 16
5.12 SD2500W - Engine Engine EU IV / Tier 4final (o) ................................... 17
5.13 SD2500WS - Engine Engine EU IV / Tier 4final (o) ................................. 17
5.14 SD2500W - Engine Stage V (o) ............................................................... 18
5.15 SD2500WS - Engine Stage V (o) ............................................................. 18

2
5.16 Hydraulic system ......................................................................................19
5.17 Material compartment (hopper) ................................................................19
5.18 Material transfer .......................................................................................19
5.19 Material distribution ..................................................................................19
5.20 Screed lifting device .................................................................................20
5.21 Electrical system ......................................................................................20
5.22 Permissible temperature ranges ..............................................................20
6 Identification points ...................................................................................21
6.1 Warning signs ...........................................................................................24
6.2 Information signs ......................................................................................27
6.3 CE marking ...............................................................................................29
6.4 Instructive symbols, prohibitive symbols, warning symbols .....................29
6.5 Danger symbols .......................................................................................30
6.6 Further warnings and operating instructions ............................................31
6.7 Identification label for the paver finisher (41) ........................................33
6.8 Explanation of 17-digit PIN serial number ................................................34
6.9 Engine type plate ......................................................................................35
7 EN standards ............................................................................................36
7.1 Continuous sound pressure SD2500W ....................................................36
7.2 Operating conditions during measurement ..............................................36
7.3 Continuous sound pressure SD2500WS ..................................................37
7.4 Operating conditions during measurement ..............................................37
7.5 Vibration acting on the entire body ...........................................................38
7.6 Vibrations acting on hands and arms .......................................................38
7.7 Electromagnetic compatibility (EMC) .......................................................38
C13 Transportation ......................................................................... 1
1 Safety regulations for transportation ..........................................................1
2 Transportation on low-bed trailers ..............................................................4
2.1 Preparations ...............................................................................................4
3 Securing the load .......................................................................................6
3.1 Prepare the low-bed trailer .........................................................................6
3.2 Driving onto the low-bed trailer ...................................................................7
3.3 Lashing equipment .....................................................................................8
3.4 Loading .......................................................................................................9
3.5 Preparing the vehicle ................................................................................10
4 Securing the load .....................................................................................11
4.1 Securing at the front and at the sides .......................................................11
Step 1: fasten lashing chains at the front .............................................11
Step 2: fasten lashing chains at the side ..............................................11
4.2 Securing at the rear - screed with side board ...........................................12
4.3 Securing at the rear - screed without side board ......................................13
Step 1: fasten lashing straps ................................................................13
Step 2: fasten lashing chains ...............................................................13
4.4 After transportation ...................................................................................14
Protective roof (o) .................................................................................15
5 Transportation ..........................................................................................17
5.1 Preparations .............................................................................................17
5.2 Driving mode ............................................................................................19

3
6 Loading by crane ..................................................................................... 20
7 Towing ..................................................................................................... 23
8 Safely parking the vehicle ........................................................................ 26
8.1 Lifting the vehicle with hydraulic lifts, lifting points ................................... 27
D13 Operation ................................................................................. 1
1 Safety regulations ...................................................................................... 1
2 Controls ...................................................................................................... 3
2.1 Operating panel ......................................................................................... 3
3 Remote control ......................................................................................... 60
D22 Operating the display ............................................................. 1
1 Operation of the input and display terminal ............................................... 2
Button layout on the display ................................................................... 2
1.1 Menu operation - procedure for adjusting parameters ............................... 5
Selecting and changing an adjustment parameter in a menu ................ 7
Selecting and changing a selection possibility in a menu ...................... 8
2 Menu structure ........................................................................................... 9
Menu of the "Home" displays ................................................................. 9
Displays: ................................................................................................ 9
"Home" menu - sub-menus .................................................................. 11
"Home" functions / "Quick settings" menu ........................................... 12
"Engine speed" menu / Engine measured value display ..................... 14
"Material management" measured value display ................................. 15
"Screed heater" adjustment and display menu (o) .............................. 16
"Paving area / Automatic steering unit" menu ..................................... 17
"Front wheel drive" measured value display (o) .................................. 18
"Particulate filter regeneration" menu (o) ............................................. 19
"Paving parameters" menu .................................................................. 21
Adjusting the paving parameters ......................................................... 23
Overview "Course thickness parameters" ........................................... 24
"Camera display" menu (o) .................................................................. 25
"Error memory" menu .......................................................................... 26
Detailed display "Error messages with travel drive stop" ..................... 27
Detailed display "Vehicle warning messages" ..................................... 28
Detailed display "Engine error messages" ........................................... 29
"Basic" menu ....................................................................................... 30
"Service" menu .................................................................................... 31
"Info & Settings" menu ......................................................................... 32
Display of the following information: .................................................... 32
"Screed" set-up menu .......................................................................... 33
"Paving / Travel" set-up menu ............................................................. 34
"Truck Assist / Set Assist" set-up menu ............................................... 36
"Day/night lighting" set-up menu .......................................................... 38
"Display" set-up menu ......................................................................... 39
"Camera / display" set-up menu .......................................................... 40
"Licence text" display ........................................................................... 41
"Remote lock" menu ............................................................................ 42

4
(B): Remote lock active ........................................................................43
Display of the following information: .....................................................43
"Lock menu" .........................................................................................44
"Service report" menu ..........................................................................45
Display of the following information: .....................................................45
Report for Dynapac service technician - step I ...................................46
Report for Dynapac service technician - step II ..................................47
Report for servicing carried out by the customer - step I ....................48
Report for servicing carried out by the customer - step II ...................49
3 Terminal error messages .........................................................................50
Status, warning and error messages symbols .....................................50
3.1 Error message drive lever ........................................................................57
3.2 Drive engine error codes ..........................................................................59
3.3 Error codes ...............................................................................................63
4 Menu structure of the setting and display menus .....................................64
D31 Mode of operation ................................................................... 1
1 Operating elements on the paver finisher ..................................................1
1.1 Control elements on the operator's control station .....................................1
Protective roof (o) ...................................................................................2
Ladder ....................................................................................................4
Storage space ........................................................................................4
Control platform, moveable (o) ...............................................................5
Control platform lock (o) .........................................................................6
Storage compartment .............................................................................6
Operating panel ......................................................................................7
Service brake ("foot brake") (o) ..............................................................8
Protective roof (o) ...................................................................................9
Windscreen wiper .................................................................................10
Emergency actuation control platform, movable ..................................11
Seat console ........................................................................................12
Driver's seat, type I .............................................................................13
Driver's seat, type II ............................................................................14
Fuse box ..............................................................................................15
Batteries ...............................................................................................16
Main battery switch ..............................................................................16
Hopper transport safeguard .................................................................17
Screed lock, mechanical (o) .................................................................17
Screed lock, hydraulic (o) .....................................................................18
Paving thickness indicator ...................................................................19
Auger lighting (o) ..................................................................................20
Engine compartment lighting (o) ..........................................................20
LED working light (o) ............................................................................21
500 watt spotlight (o) ............................................................................22
Camera (o) ...........................................................................................22
Auger height adjustment ratchet (o) .....................................................23
Auger height displays ..........................................................................23
Sensor rod / sensor rod extension ......................................................24
Manual separator fluid spray (o) ..........................................................26

5
Separator fluid spraying system (o) ..................................................... 27
Conveyor limit switches - PLC version ................................................ 28
Conveyor limit switches - conventional version ................................... 29
Ultrasonic auger limit switches (left and right) - PLC version .............. 30
Ultrasonic auger limit switches (left and right) - conventional version . 31
24 volt / 12 volt sockets (o) .................................................................. 32
Pressure setting front-wheel drive (o) .................................................. 32
Pressure control valve for screed charging/relieving ........................... 33
Pressure control valve for paving stop with relieving ........................... 33
Manometer for screed charging/relieving ............................................ 33
Central lubricating system (o): ............................................................. 34
Screed eccentric adjustment ............................................................... 35
Push roller crossbar, adjustable .......................................................... 36
Fire extinguisher (o) ............................................................................. 37
First-aid kit (o) ...................................................................................... 37
Rotary beacon (o) ................................................................................ 38
Fuelling pump (o) ................................................................................. 39
Illuminated balloon (o) ......................................................................... 40
Installation and operation ..................................................................... 42
Decommissioning ................................................................................ 43
Cleaning ............................................................................................... 43
Service safety ...................................................................................... 43
Truck Assist (o) .................................................................................... 44
Cool box (o) ......................................................................................... 45
D43 Mode of operation ................................................................... 1
1 Preparing for operation .............................................................................. 1
Required devices and aids .................................................................... 1
Before starting work (in the morning or when starting paving) .............. 3
Check list for the machine operator ....................................................... 3
1.1 Starting the paver finisher .......................................................................... 6
Before starting the paver finisher ........................................................... 6
"Normal" starting .................................................................................... 6
External starting (starting aid) ................................................................ 8
After starting ........................................................................................ 11
Observe indicator lamps ...................................................................... 13
Engine coolant temperature check (A) ................................................ 13
Battery charge indicator lamp (B) ........................................................ 13
Diesel engine oil pressure indicator lamp (C) ...................................... 13
Travel drive oil pressure indicator lamp (D) ......................................... 15
1.2 Preparation for transportation .................................................................. 17
Driving and stopping the paver finisher ............................................... 19
1.3 Preparations for paving ............................................................................ 20
Separator fluid ..................................................................................... 20
Screed heater system .......................................................................... 20
Direction marks .................................................................................... 21
Loading/conveying material ................................................................. 23
1.4 Starting for paving .................................................................................... 25
1.5 Checks during paving .............................................................................. 26

6
Paver function ......................................................................................26
Quality of the layer ...............................................................................26
1.6 Paving with "screed control at paving stop" and "screed
charging/relieving" ....................................................................................27
General ................................................................................................27
Screed charging/relieving .....................................................................29
Screed control with paver finisher stop / in paving operation
(screed stop / paving stop / floating paving) .........................................29
Adjusting the pressure .........................................................................33
Setting pressure for screed control with paving stop + relieving: .........33
1.7 Interrupting/terminating operation ............................................................35
During breaks in paving (e.g. delay due to material trucks) .................35
During longer breaks (e.g. lunch break) ...............................................35
When work is finished ..........................................................................37
2 Malfunctions .............................................................................................38
2.1 Problems during paving ............................................................................38
2.2 Malfunctions on the paver finisher or screed ............................................40
E13 Set-up and modification .........................................................1
1 Special notes on safety ..............................................................................1
2 Optional assemblies ...................................................................................2
3 Distribution auger .......................................................................................3
3.1 Height adjustment ......................................................................................3
Grain sizes up to 16 mm ........................................................................3
Grain sizes > 16 mm ..............................................................................3
3.2 Mechanical adjustment with ratchet (o) ......................................................4
3.3 Hydraulic adjustment (o) ............................................................................4
3.4 Height adjustment for large working widths / with brace - Auger Type A - .5
3.5 Height adjustment for large working widths / with brace - Auger Type B - .7
4 Auger extension - Auger Type A - ..............................................................9
4.1 Mounting extension parts .........................................................................10
Mounting the material shaft and auger extension ................................10
Mounting the outer auger bearing ........................................................11
Mounting the auger end bearing ..........................................................12
4.2 Auger extension chart ..............................................................................13
Auger upgrading, working width 3.14 m ...............................................15
Auger upgrading, working width 3.78 m ...............................................15
Auger upgrading, working width 4.42 m ...............................................15
Auger upgrading, working width 5.06 m ...............................................16
Auger upgrading, working width 5.70 m ...............................................16
Auger upgrading, working width 6.34 m ...............................................17
Auger upgrading, working width 6.98 m ...............................................18
Auger upgrading, working width 7.62 m ...............................................19
Auger upgrading, working width 8.26 m ...............................................20
4.3 Mounting the auger brace ........................................................................21
4.4 Aligning the auger ....................................................................................23
5 Auger extension - Auger Type B - ............................................................24
5.1 Mounting extension parts .........................................................................25
Mount auger extension .........................................................................25

7
Mounting support tube extensions ....................................................... 27
Hydraulic lines ..................................................................................... 28
Mount guides, guide extensions and supports .................................... 29
5.2 Auger extension chart .............................................................................. 30
Auger upgrading, working width 3.06m ............................................... 32
Auger upgrading, working width 3.35m ............................................... 32
Auger upgrading, working width 3.93m ............................................... 32
Auger upgrading, working width 4.22m ............................................... 33
Auger upgrading, working width 5.08m ............................................... 33
Auger upgrading, working width 5.66m ............................................... 33
Auger upgrading, working width 6.53m ............................................... 34
Auger upgrading, working width 7.40m ............................................... 35
Auger upgrading, working width 8.00m ............................................... 36
5.3 Mounting the auger brace ........................................................................ 37
5.4 Aligning the auger .................................................................................... 39
5.5 Material shaft, hinged - auger Type A- ..................................................... 40
5.6 Hopper scraper ........................................................................................ 41
5.7 Crossbeam guide ..................................................................................... 42
6 Offsetting the screed ................................................................................ 43
7 Lift axle ..................................................................................................... 44
8 Levelling ................................................................................................... 46
8.1 Slope controller ........................................................................................ 46
8.2 Fitting the height sensing device .............................................................. 47
8.3 Mounting the grade control system .......................................................... 47
8.4 Setting up the sensor arm ........................................................................ 48
8.5 Big ski 9 m, big ski 13 m ......................................................................... 49
Mounting the big ski bracket on the crossbeam .................................. 51
Mounting the swivel arms .................................................................... 52
Mounting the centre element ............................................................... 53
Extending the big ski ............................................................................ 54
Mounting the sensor bracket ............................................................... 55
Mounting and aligning the sensors ...................................................... 56
Mounting the distributor box ................................................................ 57
Connection diagram ............................................................................. 58
8.6 Levelling shoe 6m, 9m ............................................................................ 59
9 Auger temperature measurement (O) ...................................................... 61
10 Limit switch .............................................................................................. 62
10.1 Auger limit switches (left and right) - mounting the PLC version ............. 62
11 Screed ...................................................................................................... 63
11.1 Electrical connections side board - screed - Conventional version .......... 63
11.2 Electrical connections side board - screed PLC version .......................... 65
F10 Maintenance ............................................................................ 1
1 Notes regarding safety ............................................................................... 1
F29 Maintenance overview ............................................................ 1
1 Maintenance overview ............................................................................... 1
2 Optional assemblies ................................................................................... 2

8
F33 Maintenance - conveyor .........................................................1
1 Maintenance - conveyor .............................................................................1
1.1 Maintenance intervals ................................................................................3
1.2 Points of maintenance ................................................................................4
Chain tension, conveyor (1) ...................................................................4
Conveyor drive - drive chains (2) ...........................................................6
Conveyor deflectors /conveyor plates (3) ...............................................7
F40 Maintenance - auger assembly ..............................................1
1 Maintenance - auger assembly ..................................................................1
1.1 Maintenance intervals ................................................................................3
1.2 Points of maintenance ................................................................................5
Outer auger bearing (1) ..........................................................................5
Auger planetary gear (2) ........................................................................6
Drive chains of the augers (3) ................................................................7
Auger box (4) .........................................................................................8
Seals and sealing rings (5) .....................................................................9
Gearbox bolts Check tightening (6) ......................................................10
Mounting screws - Outer auger bearing Check tightening (7) ..............11
Auger blade (8) ....................................................................................12
F41 Maintenance - auger assembly ..............................................1
1 Maintenance - auger assembly - external drive version .............................1
1.1 Maintenance intervals ................................................................................3
1.2 Points of maintenance ................................................................................4
Outer auger bearing (1) .........................................................................4
Centre auger bearing (2) ........................................................................5
Auger, gear neck bearing (3) .................................................................6
Auger bevel gear (left/ right) (4) .............................................................7
Auger blade (5) ......................................................................................8
F51 Maintenance - engine assembly Tier 3 (o) ............................1
1 Maintenance - engine assembly .................................................................1
1.1 Maintenance intervals ................................................................................3
1.2 Points of maintenance ................................................................................6
Engine fuel tank (1) ...............................................................................6
Engine lube oil system (2) .....................................................................7
Engine fuel system (3) ........................................................................10
Engine air filter (4) ................................................................................12
Engine cooling system (5) ....................................................................14
Engine drive belt (6) .............................................................................16