Fayat group Dynapac f2500c Installation guide

OPERATION & MAINTENANCE

Paver Finisher

F2500C / F2500CS

Type 890 / 891

05-0419

4812073969

www.dynapac.com

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 ............................................................................................. 7

4 Safety devices ............................................................................................ 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 Permissible approach angle ..................................................................... 11

5.4 Weights F2500C (all weights in t) ............................................................ 12

5.5 Weights F2500CS (all weights in t) .......................................................... 12

5.6 Performance data F2500C ....................................................................... 13

5.7 Performance data F2500CS .................................................................... 14

5.8 Travel drive/traction unit ........................................................................... 15

5.9 Engine F2500C ........................................................................................ 15

5.10 Engine F2500CS ...................................................................................... 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

5.17 Permissible temperature ranges ..............................................................17

6 Identification points ...................................................................................18

6.1 Warning signs ...........................................................................................21

6.2 Information signs ......................................................................................24

6.3 CE marking ...............................................................................................26

6.4 Instructive symbols, prohibitive symbols, warning symbols .....................27

6.5 Danger symbols .......................................................................................28

6.6 Further warnings and operating instructions ............................................29

6.7 Identification label for the paver finisher (41) ........................................31

6.8 Explanation of 17-digit PIN serial number ................................................32

6.9 Engine type plate ......................................................................................33

7 EN standards ............................................................................................34

7.1 Continuous sound pressure F2500C, Cummins QSB 6.7-C173 ..............34

7.2 Operating conditions during measurement ..............................................34

7.3 Continuous sound pressure F2500CS, Cummins QSB 6.7-C173 ............35

7.4 Operating conditions during measurement ..............................................35

7.5 Vibration acting on the entire body ...........................................................36

7.6 Vibrations acting on hands and arms .......................................................36

7.7 Electromagnetic compatibility (EMC) .......................................................36

C10 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 sides ................................................................................11

4.2 Securing at the front .................................................................................11

4.3 Securing at the rear - screed with side board ...........................................12

4.4 Securing at the rear - screed without side board ......................................13

Step 1: fasten lashing straps ................................................................13

Step 2: fasten lashing chains ...............................................................13

4.5 After transportation ...................................................................................14

Protective roof (o) .................................................................................15

5 Transportation ..........................................................................................17

5.1 Preparations .............................................................................................17

5.2 Driving mode ............................................................................................19

6 Loading by crane ......................................................................................20

7 Towing ......................................................................................................23

8 Safely parking the vehicle ........................................................................25

8.1 Lifting the vehicle with hydraulic lifts, lifting points ...................................26

D10 Operation ................................................................................. 1

1 Safety regulations ...................................................................................... 1

2 Controls ...................................................................................................... 3

2.1 Operating panel ......................................................................................... 3

2.2 Truck-Assist-System (o) ........................................................................... 34

3 Remote control ......................................................................................... 40

D30 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

Protective roof (o) .................................................................................. 8

Windscreen wiper .................................................................................. 9

Emergency actuation control platform, movable .................................. 10

Seat console ........................................................................................ 11

Driver's seat, type I ............................................................................. 12

Driver's seat, type II ............................................................................ 13

Fuse box .............................................................................................. 14

Batteries ............................................................................................... 15

Main battery switch .............................................................................. 15

Hopper transport safeguard ................................................................. 16

Screed lock, mechanical (o) ................................................................ 16

Screed lock, hydraulic (o) .................................................................... 17

Paving thickness indicator .................................................................. 18

Auger lighting (o) ................................................................................. 19

Engine compartment lighting (o) .......................................................... 19

LED working light (o) ........................................................................... 20

500 watt spotlight (o) ........................................................................... 21

Camera (o) ........................................................................................... 21

Auger height adjustment ratchet (o) .................................................... 22

Auger height displays .......................................................................... 22

Sensor rod / sensor rod extension ...................................................... 23

Manual separator fluid spray (o) .......................................................... 25

Separator fluid spraying system (o) ..................................................... 26

Conveyor limit switches - PLC version ................................................ 27

Conveyor limit switches - conventional version ................................... 28

Ultrasonic auger limit switches

(left and right) - PLC version ................................................................ 29

Ultrasonic auger limit switches

(left and right) - conventional version ................................................... 30

24 volt / 12 volt sockets (o) .................................................................. 31

Pressure control valve for screed charging/relieving ........................... 32

Pressure control valve for paving stop with relieving ...........................32

Manometer for screed charging/relieving .............................................32

Central lubricating system (o): .............................................................33

Track clearer, mechanical (o) ...............................................................34

Lane clearer, electric (o) ......................................................................35

Screed eccentric adjustment ................................................................36

Push roller crossbar, adjustable ...........................................................37

Push roller crossbar, hydraulically extendable (o) ...............................38

Push roller damping, hydraulic (o) .......................................................38

Fire extinguisher (o) .............................................................................39

First-aid kit (o) ......................................................................................39

Rotary beacon (o) ................................................................................40

Fuelling pump (o) .................................................................................41

Illuminated balloon (o) ..........................................................................42

Installation and operation .....................................................................44

Decommissioning .................................................................................45

Cleaning ...............................................................................................45

Service safety .......................................................................................45

Truck Assist (o) ....................................................................................46

Cool box (o) ..........................................................................................47

D40 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 (1) .................................................13

Battery charge indicator (2) ..................................................................13

Oil pressure indicator lamp for the diesel engine (3) ............................13

1.2 Preparation for transportation ...................................................................15

Driving and stopping the paver finisher ................................................17

1.3 Preparations for paving ............................................................................18

Separator fluid ......................................................................................18

Screed heater system ..........................................................................18

Direction marks ....................................................................................19

Loading/conveying material .................................................................21

1.4 Starting for paving ....................................................................................23

1.5 Checks during paving ...............................................................................24

Paver function ......................................................................................24

Quality of the layer ...............................................................................24

1.6 Paving with "screed control at paver finisher stop"

and "screed charging/relieving" ................................................................25

General ................................................................................................25

Screed charging/relieving .................................................................... 27

Screed control with paver finisher stop / in paving operation

(screed stop / floating stop / floating paving) ....................................... 27

Screed control with paver finisher stop - floating stop with relief ......... 29

Adjusting the pressure ......................................................................... 29

Set pressure for screed charging or relieving ...................................... 29

Setting pressure for screed control with paver finisher stop -

floating stop with relief ......................................................................... 31

1.7 Interrupting/terminating operation ............................................................ 33

During breaks in paving (e.g. delay due to material trucks) ................. 33

During extended interruptions (e.g. lunch break) ................................. 33

When work is finished .......................................................................... 35

2 Malfunctions ............................................................................................. 36

2.1 Error code query for engine ..................................................................... 36

Output of numerical code ..................................................................... 38

2.2 Error codes .............................................................................................. 40

2.3 Problems during paving ........................................................................... 41

2.4 Malfunctions on the paver finisher or screed ........................................... 43

E10 Set-up and modification ......................................................... 1

1 Special notes on safety .............................................................................. 1

2 Distribution auger ....................................................................................... 2

2.1 Height adjustment ...................................................................................... 2

Grain sizes up to 16 mm ........................................................................ 2

Grain sizes > 16 mm .............................................................................. 2

2.2 Mechanical adjustment with ratchet (o) ..................................................... 3

2.3 Hydraulic adjustment (o) ............................................................................ 3

2.4 Height adjustment for large working widths / with brace ............................ 4

3 Auger extension ......................................................................................... 6

3.1 Mounting extension parts ........................................................................... 7

Mounting the material shaft and auger extension .................................. 7

Mounting the outer auger bearing .......................................................... 8

Mounting the auger end bearing ............................................................ 9

3.2 Auger extension chart .............................................................................. 10

Auger upgrading, working width 3.14 m .............................................. 12

Auger upgrading, working width 3.78 m .............................................. 12

Auger upgrading, working width 4.42 m .............................................. 12

Auger upgrading, working width 5.06 m .............................................. 13

Auger upgrading, working width 5.70 m .............................................. 13

Auger upgrading, working width 6.34 m .............................................. 14

Auger upgrading, working width 6.98 m .............................................. 15

Auger upgrading, working width 7.62 m .............................................. 16

Auger upgrading, working width 8.26 m .............................................. 17

Auger upgrading, working width 8.90 m .............................................. 18

3.3 Mounting the auger brace ........................................................................ 19

3.4 Aligning the auger .................................................................................... 21

3.5 Material shaft, hinged ............................................................................... 22

3.6 Hopper scraper ........................................................................................ 23

3.7 Crossbeam guide ..................................................................................... 24

4 Offsetting the screed ................................................................................25

5 Levelling ...................................................................................................26

5.1 Slope controller ........................................................................................26

5.2 Fitting the height sensing device ..............................................................27

5.3 Mounting the grade control system ..........................................................27

5.4 Setting up the sensor arm ........................................................................28

5.5 Big ski 9 m, big ski 13 m ..........................................................................29

Mounting the big ski bracket on the crossbeam ...................................31

Mounting the swivel arms .....................................................................32

Mounting the centre element ................................................................33

Extending the big ski ............................................................................34

Mounting the sensor bracket ................................................................35

Mounting and aligning the sensors ......................................................36

Mounting the distributor box .................................................................37

Connection diagram .............................................................................38

5.6 Levelling shoe 6m, 9m ............................................................................39

6 Automatic steering unit .............................................................................41

6.1 Mounting the automatic steering unit on the paver finisher ......................42

Mounting and aligning the sensor ........................................................43

Connecting the sensor .........................................................................43

Automatic steering unit operating instructions .....................................44

7 Emergency stop during feeder operation .................................................45

8 Auger temperature measurement (O) ......................................................46

9 MATTRACKER (O) ..................................................................................47

10 Limit switch ...............................................................................................48

10.1 Auger limit switches (left and right) - mount PLC version .........................48

10.2 Auger limit switches (left and right) -

mounting the conventional version ...........................................................49

11 Special accessories ..................................................................................50

11.1 Material bucket .........................................................................................50

Application ............................................................................................50

Description of assemblies and functions ..............................................51

Technical data ......................................................................................52

Dimensions, bucket MH2500 - short version .......................................52

Dimensions, bucket MH2550 - long version .........................................53

Weights ...............................................................................................54

Volume .................................................................................................54

12 Identification points ...................................................................................55

12.1 Information signs ......................................................................................56

12.2 Warning signs ...........................................................................................56

12.3 Further warnings and operating instructions ............................................56

12.4 Instructive symbols, prohibitive symbols, warning symbols .....................57

Load securing - bucket .........................................................................58

Prepare the low-bed trailer ...................................................................58

Lashing equipment ...............................................................................59

Lashing .................................................................................................60

Loading with the crane - MH2500 ........................................................62

Loading with the crane - MH2550 ........................................................63

Lash the bucket in the paver ................................................................65

Mode of operation ................................................................................67

Operation with a feeder with slewing belt ............................................ 68

Preparations for paving ........................................................................ 68

Separator fluid ..................................................................................... 68

Cleaning the bucket ............................................................................. 69

13 Screed ...................................................................................................... 70

13.1 Electrical connections side board - screed - Conventional version .......... 70

13.2 Electrical connections side board - screed PLC version .......................... 72

F10 Maintenance ............................................................................ 1

1 Notes regarding safety ............................................................................... 1

F20 Maintenance review ................................................................ 1

1 Maintenance review ................................................................................... 1

F30 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

F50 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

F60 Maintenance - hydraulic system ............................................ 1

1 Maintenance - hydraulic system .................................................................1

1.1 Maintenance intervals ................................................................................4

1.2 Points of maintenance ................................................................................6

Hydraulic oil tank (1) ..............................................................................6

Suction/return flow hydraulic filter (2) .....................................................8

Bleeding the filter ...................................................................................9

Ventilation filter .......................................................................................9

High-pressure filter (3) .........................................................................10

Pump distribution gear (4) ....................................................................11

Bleeder ................................................................................................12

Hydraulic hoses (5) ..............................................................................13

Marking hydraulic hoses / storage period, period of use ......................15

Auxiliary flow filter (6) ...........................................................................16

F73 Maintenance - drive units .......................................................1

1 Maintenance - drive units ...........................................................................1

1.1 Maintenance intervals ................................................................................3

1.2 Maintenance points ....................................................................................6

Chain tension (1) ....................................................................................6

Bottom plates (2) ....................................................................................9

Rollers (3) .............................................................................................10

Planetary gear (4) ................................................................................11

Screw connections ...............................................................................13

F80 Maintenance - electrical system ............................................ 1

1 Maintenance - electrical system .................................................................1

1.1 Maintenance intervals ................................................................................3

1.2 Maintenance points ....................................................................................4

Batteries (1) ............................................................................................4

Recharging the batteries ........................................................................5

Alternator (2) ..........................................................................................6

Cleaning the alternator ...........................................................................7

Electrical fuses / relays (3) .....................................................................8

Fuses ....................................................................................................8

Relays in the engine compartment....................................................... 11

Relays in terminal box .........................................................................12

Relays in operating panel ....................................................................14

Relay in connection box under the operating platform .........................15

F90 Maintenance - lubricating points ........................................... 1

1 Maintenance - lubricating points .................................................................1

1.1 Maintenance intervals ................................................................................2

1.2 Points of maintenance ................................................................................3

Central lubrication system (1) ................................................................3

Bearing points (2) ...................................................................................7

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