Svedala-Demag DF 115 C User manual

Operating instructions
02-01.03
Road Finisher
900 98 06 40
DF 115 C
DF 135 C

V_DF115_135C_GB.fm 1-2 -- 02-01.03
Foreword
For safe operation of the machine, a specific knowledge is necessary, which is pro-
vided in these operating instructions. The information is provided in a concise, clear
form. The chapters are arranged according to letters. Each chapter begins with page
1. The page identification consists of the chapter letter and page number.
Example: Page B 2 is the second page in Chapter B.
In these operating instructions, various options are also documented. During opera-
tion and maintenance, it must be ensured that the description applicable to the avail-
able option is used.
Safety information and important explanations are identified by the following picto-
grams:
Precedes safety information to be observed to prevent danger to persons.
$Precedes information to be observed to prevent material damage.

Precedes information and explanations.
 Identifies standard equipment.
& Identifies additional equipment.
The manufacturer reserves the right in the interest of further technical advances, to
make changes maintaining the essential features of the described machine type,
without simultaneous amendment of these operating instructions.
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

I 1
DF115_135C_GBIVZ.fmI 1-6 -01.03
Table of contents
AUse for the intended purpose ................................................ 1
BVehicle description ................................................................. 1
1Description of application ........................................................................... 1
2 Assembly and functional description .......................................................... 2
2.1 Vehicle ....................................................................................................... 3
Design .................................................................................................... 3
Additional equipment ............................................................................. 3
3 Safety devices ............................................................................................ 6
3.1 Emergency button ..................................................................................... 6
3.2 Steering ...................................................................................................... 6
3.3 Ignition lock/lighting equipment ..................................................................6
3.4 Horn ........................................................................................................... 7
3.5 Power switch .............................................................................................. 7
3.6 Trough safety lock ...................................................................................... 7
3.7 Screed safety lock ...................................................................................... 7
3.8 Other safety devices .................................................................................. 8
4 Technical data standard type ..................................................................... 9
4.1 Performance data ...................................................................................... 9
4.2 Final drive/track group .............................................................................. 9
4.3 Engine ........................................................................................................ 9
4.4 Hydraulic system ...................................................................................... 10
4.5 Hopper (trough) ........................................................................................ 10
4.6 Weights (all values in t) ............................................................................ 10
4.7 Material feed ............................................................................................ 11
4.8 Material distribution .................................................................................. 11
4.9 Screed lift ................................................................................................. 11
4.10 Electrical equipment ................................................................................. 11
4.11 Dimensions (all dimensions in mm) ......................................................... 12
5 EN standards ........................................................................................... 13
5.1 Continuous sound pressure level .............................................................13
5.2 Operating conditions during measurements ............................................ 13
5.3 Measuring point arrangement .................................................................. 13
5.4 Whole body vibrations .............................................................................. 14
5.5 Hand-arm vibrations ................................................................................. 14
5.6 Electromagnetic compatibility (EMC) ....................................................... 14
6 Identification points for signs .................................................................... 15
6.1 Serial plate finisher (1) ............................................................................. 17
6.2 Serial plate liquefied petroleum gas system (2) ....................................... 18

I 2
DF115_135C_GBIVZ.fm 2-6 -01.03
C Transportation ......................................................................... 1
1Safety 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
Description of disconnect mechanism ................................................... 7
Disengaging procedure: ......................................................................... 7
6 Removing lateral flaps with screed raised. ................................................ 8
7 Safely parking the vehicle .......................................................................... 9
D Operation ................................................................................. 1
1Safety regulations ...................................................................................... 1
2 Operating elements .................................................................................... 2
2.1 Operating panel ...................................................................................... 2
2.2 Operating the input and display terminal ................................................. 24
Display keyboard ................................................................................. 24
Working in the menu ............................................................................ 25
2.3 Diagnosing and detecting malfunction ..................................................... 34
2.4 Engine error messages ............................................................................ 43
“Coolant level too low” error message ................................................. 44
2.5 Remote control ......................................................................................... 45
Emergency program for TDM-failure ................................................... 48
2.6 Special functions ...................................................................................... 50
Reversible conveyor ............................................................................ 50
2.7 Operating elements on the paver finisher ................................................ 51
Batteries (71) ....................................................................................... 51
Battery main switch (72) ...................................................................... 51
Transport safeguards for the hopper (73) ............................................ 52
Mechanical screed transport safeguard (to the left and the right
beneath the driver’s seat) (74) .............................................................52
Seat lock (behind the driver’s seat) (75) .............................................. 53
Separator fluid spraying system (80) (o) .............................................. 54
Lockingofthecollapsibleroof(LHandRHontheroofsconsole)(87): ........... 54
Conveyor limit switches (88) (left and right): ........................................ 55
Ultrasonic auger limit switches (90) (left and right) .............................. 56
Sockets for the remote control (left and right) (91) .............................. 56
Sockets for working lights (left and right) (92) ..................................... 56
Pressure control valve for screed charging/relieving (93) (o) .............. 57
Pressure control valve for screed stop with pretensioning (93a) (o) .... 57
Manometer for screed charging/relieving and screed stop
with pretensioning (93b) ...................................................................... 57

I 3
DF115_135C_GBIVZ.fmI 3-6 -01.03
3 Operation ................................................................................................. 58
3.1 Preparing for operation ............................................................................ 58
Required devices and aids .................................................................. 58
Before starting work (in the morning or when starting paving) ............ 58
Checklist for the machine operator ...................................................... 59
3.2 Starting the paver finisher ........................................................................ 61
Before starting the paver finisher ......................................................... 61
„Normal” starting .................................................................................. 61
External starting (starting aid) .............................................................. 62
After starting ........................................................................................ 63
Indicator lamps .................................................................................... 64
Coolant check (43) ............................................................................... 64
Oil pressure indicator lamp for the diesel engine (45) ......................... 64
Oil pressure indicator lamp for the traction drive (44) .......................... 64
Battery charge indicator (47) ............................................................... 65
3.3 Operation during transportation ............................................................... 66
Lifting and securing the screed ............................................................ 66
Driving and stopping the finisher ........................................................ 67
Switching off and securing the finisher ................................................ 67
3.4 Preparations for paving ............................................................................ 68
Separating agent ................................................................................. 68
Screed heater ...................................................................................... 68
Direction marks .................................................................................... 68
Loading/distributing material ............................................................... 69
3.5 Starting for paving .................................................................................... 70
3.6 Checks during paving .............................................................................. 72
Paver function ...................................................................................... 72
Quality of the layer ............................................................................... 72
3.7 Paving with screed stop and screed charging/relieving ........................... 73
General ................................................................................................ 73
Screed charging/relieving .................................................................... 73
Screed stop .......................................................................................... 74
Screed stop with pretensioning ............................................................ 74
Adjusting the pressure (o) ................................................................... 75
For screed stop with pretensioning ...................................................... 75
For screed charging/relieving .............................................................. 75
3.8 Interrupting/terminating operation ............................................................ 76
During breaks ...................................................................................... 76
During extended interruptions .............................................................. 76
When work is finished .......................................................................... 77
4 Malfunctions ............................................................................................. 79
4.1 Error codes for engine ............................................................................. 79
4.2 Problems during paving ........................................................................... 84
4.3 Malfunctions on the paver finisher or screed ........................................... 86
4.4 Emergency device/steering, drive system ............................................... 89

I 4
DF115_135C_GBIVZ.fm 4-6 -01.03
E Setting-up and field replacement .......................................... 1
1Special safety information .......................................................................... 1
2 Distribution spreader .................................................................................. 2
2.1 Height adjustment ...................................................................................... 2
2.2 For mechanical adjustment with ratchet .................................................... 2
2.3 For hydraulic adjustment (Optional) ........................................................... 3
2.4 Spreader enlargement ............................................................................... 3
2.5 Mounting extensions .................................................................................. 4
3 Screed ........................................................................................................ 6
4 Electrical connections ................................................................................ 6
4.1 Connect remotes ........................................................................................ 6
4.2 Connect grade transmitter ......................................................................... 6
4.3 Connect spreader limit switch .................................................................... 6
4.4 Connect floodlight ...................................................................................... 6
FMaintenance ............................................................................ 1
1Safety information on maintenance ........................................................... 1
2 Maintenance intervals ................................................................................ 2
2.1 Overview of assembliesn .......................................................................... 2
2.2 First maintenance (100 operating hours) ................................................... 4
2.3 Daily (or every 10 operating hours) ............................................................ 5
2.4 Weekly or every 50 operating hours .......................................................... 6
2.5 14 daily or every 100 operating hours ........................................................ 7
2.6 Monthly or every 250 operating hours ....................................................... 8
2.7 Every 3 months or every 500 operating hours ........................................... 9
2.8 Annually or every 1000 operating hours .................................................. 10
2.9 Every 2 years or every 2000 operating hours .......................................... 11
2.10 If necessary .............................................................................................. 12
2.11 Inspection and lubrication points .............................................................. 13
Pump distributor gear (1.1) .................................................................. 13
Lubricating oil - engine (1.2) ................................................................ 14
Oil level check ...................................................................................... 14
Oil change: ........................................................................................... 14
Engine - oil filter (1.3) ........................................................................... 15
Air cleaner (1.4) ................................................................................... 16
Cooling system engine and hydraulics (1.5) ........................................ 17
Water cooler ........................................................................................ 17
Hydraulic cooler ................................................................................... 17
Engine - fuel filter (1.6) ........................................................................ 18
Draining upstream filter - water: ........................................................... 18
Replacing upstream filter - filter cartridge ............................................ 18
Main filter - replacing filter cartridge ..................................................... 19
Venting fuel system ............................................................................. 19
V-belt and notched v-belt (1.7) ........................................................... 20
Engine mounting (1.8) ........................................................................ 20
Hoses and screw connections (1.9) ..................................................... 20
Fuel tank (1.10) .................................................................................... 21
Hydraulic oil tank (2.1) ......................................................................... 22
Changing main filter/return filter (2.2) .................................................. 22
Oil cooler (2.3) ..................................................................................... 22
High pressure filter (2.4) ...................................................................... 23

I 5
DF115_135C_GBIVZ.fmI 5-6 -01.03
Hydraulic cylinder (2.5) ........................................................................ 23
Track group (3.1) ................................................................................. 24
Conveyor drive transmission (3.2) ....................................................... 25
Idler wheel (3.3) ................................................................................... 25
Conveyor chain (4.1) ........................................................................... 26
Center conveyor bearing (4.2) ............................................................. 26
Conveyor drive transmission (4.3) ....................................................... 27
Auger planetary gear (4.4) ................................................................... 28
Conveyor auger drive chains (4.5) ....................................................... 29
Auger box (4.6) ................................................................................... 30
Outer auger bearing (4.7) .................................................................... 31
Visual inspections (5.1) ........................................................................ 31
Crossbeam guide (5.2) ........................................................................31
Nuts and bolts (5.3) ............................................................................. 32
Tightening torques ............................................................................... 32
Moving parts (5.4) ................................................................................ 32
Hydraulic screw connections (5.5) ....................................................... 32
Battery (6.1) ......................................................................................... 33
3 Fuels and lubricants ................................................................................. 34
3.1 Hydraulic oils ............................................................................................ 35
3.2 Capacities ................................................................................................ 36
4 Electric Fuses .......................................................................................... 37
4.1 Main fuses (next to the batteries) ............................................................ 37
4.2 Fuses in main terminal box (next to fuel tank) ......................................... 37
4.3 Fuses on control panel ............................................................................. 38

A 1
A A_DF115_135C_GB.fm. 1-2 - 02-01.03
A Use for the intended purpose

The ”Guide to the intended and proper use of road finishers” is included in the scope
of supply of this machine. It is an integral part of these operating instructions and must
be observed in any event. National requirements apply without restriction.
The road construction machine described in these operating instructions is a road fin-
isher that is suitable for laying material, rolled or lean-mixes concrete, track ballast
and uncombined mineral compounds for paving surfaces.
The finisher must be used, operated and maintained according to the information in
these operating instructions. Use for any other than the intended purpose is improper
and can cause injury to persons and cause damage to the road finisher or property.
Use for any other than the above described purpose is not for the intended purpose
and is expressly forbidden! For operation on slopes or for use for special purposes in
particular (landfill construction, dam construction) the manufacturer must be consult-
ed in any event.
Obligations of the operator: Operator in the sense of these operating instructions
is any natural or judicial person who uses the road finisher himself or on whose behalf
the machine is used. In exceptional cases (e.g. leasing, hire), the operator is the per-
son who is responsible for fulfilling the aforementioned obligations in accordance with
the contractual agreements concluded between the owner and the user of the road
finisher.
The operator must ensure that the road finisher is used only for the intended purpose
and dangers to the life and health of the user or third parties of any kind are avoided.
In addition. the accident prevention regulations, other safety rules as well as the op-
erating, maintenance and repair instructions must be observed. The operator must
ensure that all users have read and understood these operating instructions.
Mounting accessories: The road finisher can only be operated with the laying
screeds approved by the manufacturer. Additional equipment that affects or supple-
ments the functions of the road finisher may only be mounted or installed with the pri-
or written permission of the manufacturer. The permission of the local authorities may
be required in some cases.
The permission of the manufacturer is still required despite permission being given
by the authorities.

B 1
B DF 115/135C.GB 1-18 - 02-01.03
B Vehicle description
1 Description of application
The SVEDALA DEMAG road finisher is equipped with a crawler for laying bituminous
material, rolled or lean-mixes concrete, track ballast and uncombined mineral com-
pounds for paving surfaces.
Df_115_c.tif

B 2
B DF 115/135C.GB 2-18 - 02-01.03
2Assembly and functional description
Item Designation
1
+
Hopper (trough)
2
+
Push rollers for truck docking
3
+
Pipe for visual gauge (direction indicator) and trailing ski mount
4
+
Crawler
5
+
Levelling cylinder for laying thickness
6
+
Traction roller
7
+
Levelling arm draw bar
8
+
Laying thickness indicator
9
+
Levelling arm
10
+
Track drive
11
+
Spreader
12
+
Screed
13
+
Operator’s stand
14
+
Operation panel (laterally movable)
15
&
Weather protecting sunroof
+

= Standard equipment
& = Additional equipment
Df_115_c.tif
9865
3
2
10 12114
14 13
15
1
7

B 3
B DF 115/135C.GB 3-18 - 02-01.03
2.1 Vehicle
Design
The road finisher has a frame in a steel welded construction on which the individual
assemblies are mounted.
The track groups (4) level out surface unevenness and ensure high laying accuracy
due to the suspension of the screed (12). With the infinitely variable speed hydrostatic
drive (10), the speed of the road finisher can be adapted to suit the respective working
conditions.
Operation of the road finisher is greatly facilitated by the automatic material feed sys-
tem (1), separate final drives (10) and clearly arranged control elements (15).
Additional equipment
• Individual hopper control
• Electric refuelling pump
• Hydraulic spreader height adjustment
• Weather protection shed/weather protecting sunroof
• Screed enlargement
• Screed vibration system
• Generator
• Special paint finish
• Automatic levelling system and accessories
• Other accessories such as edge compactor floodlight, level, trailing shoe, rock
deflector
Available as special accessories (optional):
• Automatic levelling system/cross fall control
• Additional cut off shoe
• Larger operation widths
• Automatic central lubrication system for finisher and/or screed
• Weather protecting sunroof (16)
• Further equipment and upgrade options available on request.

B 4
B DF 115/135C.GB 4-18 - 02-01.03
Engine: The road finisher is driven by a water-cooled, six-cylinder Deutz diesel en-
gine. For further information, refer to the engine manual.
Track group: The two track groups are independently driven. They operate directly
without drive chains requiring care and maintenance.
The tension of the track groups can be adjusted via grease tensioners.
Hydraulics: The diesel engine drives the hydraulic pumps for all main drives of the
finisher via the flange-mounted distribution gear and its secondary drives.
Final drive: The infinitely variable speed final drive pumps are connected to the final
drive motors via appropriate high-pressure hydraulic hoses. These oil motors drive
track groups via planetary gears that are arranged directly in the drive sprockets of
the tracks.
Steering/Operator’s stand: The independent, hydrostatic final drives enable turning
on the spot.
The electronic synchro control ensures exact straight running and can be adjusted
from the operation panel.
By means of a lock, which can be reached from above, the movable operation panel
can be secured on the right or left side of the finisher.
Push roller crosshead: The push rollers for the material trucks are attached to a
crosshead, which is pivoted in the centre.
By means of the crosshead, the varying distances to the rear wheels of the material
trucks can be adjusted. The finisher is pushed less off course laying on bends is fa-
cilitated.
Hopper (trough): The trough inlet is provided with a flight bar conveyor system for
discharge and further transport to the distribution spreader.
The capacity is about 13,0 t.
For improved discharge and uniform material feed, each of the side covers of the
trough can be folded hydraulically (optional).
Material feed: The road finisher has two independently driven flight bar conveyors,
which transport the material from the trough to the distribution spreaders.
The flow capacity and speed during the laying operation is regulated fully automati-
cally via level scanning.
Distribution spreaders: Driving and actuation of the distribution spreaders take
place independent of the flight bar conveyors. The left and right spreader half can be
operated separately. The drive is fully hydraulic.
An inward or outward conveying direction can be selected as required. This ensures
a sufficient supply of material when large amounts of material are required on one
side. The spreader speed is continuously controlled by the material flow via ultrasonic
sensors.

B 5
B DF 115/135C.GB 5-18 - 02-01.03
Screed lift and enlargement: By means of the spreader lift and enlargement, opti-
mal adaptation to diverse laying thicknesses and widths is ensured.
During adjustment with ratchets, the height is adjusted with turnbuckle spindles at the
guide supports in the back panel.
In a further version with hydraulic cylinders (optional), the height can be adjusted from
the operation panel.
For adjustment to various operating widths, spreader segments in various fixed
lengths can be mounted and removed.
Levelling system/cross fall control: With the cross fall control (optional), the trac-
tion angle either on the left or right can be controlled with a defined difference with
respect to the opposite side.
The cross fall inclination always operates in combination with the screed lift on the
respectively opposite side.
By means of the levelling arm traction angle (traction roller) lift, the laying thickness
of the material or skimming level of the screed can be controlled.
Actuation takes place on both sides electro-hydraulically and can take place either
manually via a toggle switch or automatically via an electronic grade transmitter.
Screed hoist: The screed hoist serves for lifting the screed for transport purposes.
Hoisting takes place on both sides electro-hydraulically via the hydraulic cylinders at
the levelling arms and activated via toggle switches on the operation panel.
Automatic screed stopping system and screed load/release equipment: With
the automatic screed stopping system, any produced screed stopping marks can be
avoided. When the finisher is stopped (truck change), the control valves switched to
float position are closed and blocked to prevent the screed sagging while stopping.
By activating the screed release equipment, the track group is subjected to higher
load in order to improve traction.
By activating the screed load equipment, better compaction can be achieved for var-
ious laying operations.

B 6
B DF 115/135C.GB 6-18 - 02-01.03
3 Safety devices
Safe working is only possible with perfectly functioning control and safety devices as
well as properly fitted protective devices.

The functions of the devices must be tested at regular intervals (see Chapter D, Sec-
tion 2.1).
3.1 Emergency button
- on operation panel
- on both remotes (optional)
$When the emergency button is pressed,
motor, drives and steering are deactivat-
ed (any necessary countermeasures such as manoeuvring, screed lifting and similar)
are no longer possible! Risk of accident!
3.2 Steering
The finisher is steered with the steering
potentiometer.
3.3 Ignition lock/lighting equipment
The lighting can be switched on and off
by turning the ignition lock in the appro-
priate direction.
11.eps
F0069_a1.tif
9.eps

B 7
B DF 115/135C.GB 7-18 - 02-01.03
3.4 Horn
- on operation panel
- on both remotes
3.5 Power switch
The power switch is located on the right-
hand side of the paver finisher between
the central panel and hopper.
3.6 Trough safety lock
3.7 Screed safety lock
The screed safety locks are provided on
both sides on the operation panel behind
the seats.
Horn.tif
Horn_k.cdr
F0077_a1.eps
F0076A_A1.eps
F0083_a1.tif

B 8
B DF 115/135C.GB 8-18 - 02-01.03
3.8 Other safety devices
Other equipment:
- Wedges
- Warning triangle
- First-aid box
Item Designation
23 Engine covers
24 Side flaps
25 Catwalks
26 Screed covers
27 Material duct
28 Screed hazard lights
23
28
24
27
26
25
Df_115_c.tif