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

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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

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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