Svedala-Demag DF 115 P User manual

Operating instructions
02-0103
Paver Finisher
900 98 06 33
DF 115 P
DF 135 P

V 0001.GB 1-2 - 01.03
Preface
Safe operation of the machine requires specific knowledge that is imparted by the
present operating instructions. The information is provided in a concise, clearly struc-
tured form. The individual chapters are arranged in alphabetical order and every
chapter starts with page 1. The individual pages are identified by the chapter letter
and the page number.
Example: Page B 2 is the second page of chapter B.
These operating instructions cover various machine options. Make sure that during
operation and maintenance work the description appropriate to the machine option is
used.
Safety instructions and important notes are identified by the following pictograms:
Precedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
$Precedes notes that must be observed to prevent damage to equipment.

Precedes general notes and explanations.
+ Used to indicate standard equipment.
& Used to indicate optional equipment.
In the interest of continued development, the manufacturer reserves the right to make
changes to the machine (which will not, however, change the essential features of the
type of machine described) without updating the present operating instructions at the
same time.
Dynapac GmbH
Niederlassung Lingen
Darmer Esch 81
D-49811 Lingen / Germany
Telephone: +49 / (0)591 / 91275-0
Fax: +49 / (0)591 / 91275-0
www.dynapac.com

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DF115_135P_GBIVZ.fmI 1-6 - 01.03
Table of contents
A Correct use and application ................................................... 1
B Vehicle description ................................................................. 1
1 Description 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 Flasher ....................................................................................................... 6
3.5 Horn ........................................................................................................... 7
3.6 Power switch .............................................................................................. 7
3.7 Trough safety lock ...................................................................................... 7
3.8 Screed safety lock ...................................................................................... 7
3.9 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
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_135P_GBIVZ.fm 2-6 - 01.03
C Transport ................................................................................. 1
1 Safety regulations for transportation .......................................................... 1
2 Transportation on low-bed trailers ............................................................. 2
2.1 Preparations ............................................................................................... 2
2.2 Driving onto the low-bed trailer .................................................................. 3
2.3 After transportation .................................................................................... 3
3 Transportation on public roads .................................................................. 4
3.1 Preparations ............................................................................................... 4
3.2 Driving on public roads .............................................................................. 5
4 Loading by crane ....................................................................................... 6
5 Towing ....................................................................................................... 7
6 Removing lateral flaps with screed raised. ................................................ 7
7 Safely parking the vehicle .......................................................................... 8
D Operation 1
1 Safety regulations ...................................................................................... 1
2 Controls ...................................................................................................... 2
2.1 Operating panel ......................................................................................... 2
2.2 Remote control ......................................................................................... 22
Front .................................................................................................... 22
Rear ..................................................................................................... 23
2.3 Operating elements on the paver finisher ................................................ 24
Batteries (71) ....................................................................................... 24
Battery main switch (72) ...................................................................... 24
Transport safeguards for the hopper (73) ............................................ 25
Mechanical screed transport safeguard
(to the left and the right beneath the driver’s seat) (74) ....................... 25
Seat lock (behind the driver’s seat) (75) .............................................. 26
Service brake (”foot brake”) (76) .......................................................... 26
Parking brake (”hand brake”) (77) ....................................................... 26
Switch lever for two-speed transmission (78) ...................................... 27
Switch lever for the differential lock (79) .............................................. 27
Separator fluid spraying system (80) (o) .............................................. 28
Locking of the collapsible roof (LH and RH on the roofs console) (87):28
Electrical adjustment of the conveyor performance
(depending on the configuration) (88) .................................................. 29
Conveyor limit switches (89) (left and right): ........................................ 29
Ultrasonic auger limit switches (90) (left and right) .............................. 30
Sockets for the remote control (left and right) (91) .............................. 30
Sockets for working lights (left and right) (92) ..................................... 30
Pressure control valve for screed charging/relieving (93)(o) ............... 31
Pressure control valve for screed stop with pretensioning (93a) (o) .... 31
Manometer for screed charging/relieving and screed stop
with pretensioning (93b) ...................................................................... 31
Manometer for front wheel drive (94a) (o) ........................................... 32

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DF115_135P_GBIVZ.fmI 3-6 - 01.03
3 Operation ................................................................................................. 33
3.1 Preparing for operation ............................................................................ 33
Required devices and aids .................................................................. 33
Before starting work (in the morning or when starting paving) ............ 33
Checklist for the machine operator ...................................................... 34
3.2 Starting the paver finisher ........................................................................ 36
Before starting the paver finisher ......................................................... 36
”Normal” starting .................................................................................. 36
External starting (starting aid) .............................................................. 37
After starting ........................................................................................ 38
Indicator lamps .................................................................................... 39
Oil pressure indicator lamp for the diesel engine (1) ........................... 39
Battery charge indicator (2) ................................................................. 39
Coolant check (3) ................................................................................. 39
Oil pressure indicator lamp for the traction drive (4) ............................ 40
3.3 Preparations for paving ............................................................................ 41
Separating agent ................................................................................. 41
Screed heater ...................................................................................... 41
Direction marks .................................................................................... 41
Loading/distributing material ................................................................ 42
3.4 Starting for paving .................................................................................... 44
3.5 Checks during paving .............................................................................. 46
Paver function ...................................................................................... 46
Quality of the layer ............................................................................... 46
3.6 Paving with screed stop and screed charging/relieving ........................... 47
General ................................................................................................ 47
Screed charging/relieving .................................................................... 47
Screed stop .......................................................................................... 47
Screed stop with pretensioning ............................................................ 48
Adjusting the pressure ......................................................................... 48
Adjusting the pressure for screed charging/relieving ........................... 49
Adjusting the pressure for screed stop with pretensioning (o) ............. 49
3.7 Interrupting/terminating operation ............................................................ 50
During breaks (e.g. delays caused by material trucks) ........................ 50
During longer breaks (e.g. lunch break) .............................................. 50
When work is finished .......................................................................... 51
4 Malfunctions ............................................................................................. 53
4.1 Error code inquiry engine ......................................................................... 53
Expenditure of the numeric code ......................................................... 53
4.2 Error codes for engine ............................................................................. 56
4.1 Problems during paving ........................................................................... 61
4.2 Malfunctions on the paver finisher or screed ........................................... 63

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DF115_135P_GBIVZ.fm 4-6 - 01.03
E Setting-up and field replacement .......................................... 1
1 Special 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
F Maintenance ............................................................................ 1
1 Safety information on maintenance ........................................................... 1
2 Maintenance intervals ................................................................................ 2
2.1 Overview of assemblies ............................................................................ 2
2.2 First maintenance (100 operating hours) ................................................... 5
2.3 Daily (or every 10 operating hours) ............................................................ 6
2.4 Weekly or every 50 operating hours .......................................................... 7
2.5 14 daily or every 100 operating hours ........................................................ 8
2.6 Monthly or every 250 operating hours ....................................................... 9
2.7 Every 3 months or every 500 operating hours ......................................... 10
2.8 Annually or every 1000 operating hours .................................................. 11
2.9 Every 2 years or every 2000 operating hours .......................................... 12
2.10 If necessary .............................................................................................. 13
2.11 Inspection and lubrication points .............................................................. 14
Pump distributor gear (1.1) .................................................................. 14
Lubricating oil - engine (1.2) ................................................................ 15
Oil level check ...................................................................................... 15
Oil change: ........................................................................................... 15
Engine - oil filter (1.3) ........................................................................... 16
Air cleaner (1.4) ................................................................................... 17
Cooling system engine and hydraulics (1.5) ........................................18
Water cooler ........................................................................................ 18
Hydraulic cooler ................................................................................... 18
Engine - fuel filter (1.6) ........................................................................ 19
Draining upstream filter - water: ........................................................... 19
Replacing upstream filter - filter cartridge ............................................ 19
Main filter - replacing filter cartridge ..................................................... 20
Venting fuel system .............................................................................20
V-belt and notched v-belt (1.7) ............................................................ 21
Engine mounting (1.8) ......................................................................... 21
Hoses and hose connections (1.9) ...................................................... 21
Fuel tank (1.10) .................................................................................... 22
Hydraulic oil tank (2.1) ......................................................................... 23
Changing main filter/return filter (2.2) .................................................. 23
Oil cooler (2.3) ..................................................................................... 23
High pressure filter (2.4) ...................................................................... 24

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DF115_135P_GBIVZ.fmI 5-6 - 01.03
Hydraulic cylinder (2.5) ........................................................................ 24
Drive chains (3.1) ................................................................................. 25
Tensioning of chain (1): ....................................................................... 25
Manual transmission (3.2) ................................................................... 26
Brake fluid tank (3.3) ............................................................................ 26
Brake system (3.4) ............................................................................... 26
Wheels (3.5) ........................................................................................ 27
Steering axle (3.6) ............................................................................... 27
Floating axle (3.7) ................................................................................ 27
Steering lever (3.8) .............................................................................. 27
Steering system hoses (3.9) ................................................................ 27
Conveyor chain (4.1) ........................................................................... 28
Center conveyor bearing (4.2) ............................................................. 28
Conveyor drive transmission (4.3) ....................................................... 29
Auger planetary gear (4.4) ................................................................... 30
Conveyor auger drive chains (4.5) ....................................................... 31
Auger box (4.6) .................................................................................... 32
Outer auger bearing (4.7) .................................................................... 33
Visual inspections (5.1) ........................................................................ 33
Crossbeam guide (5.2) ........................................................................ 33
Nuts and bolts (5.3) ............................................................................. 34
Tightening torques ............................................................................... 34
Moving parts (5.4) ................................................................................ 34
Hydraulic screw connections (5.5) ....................................................... 34
Battery (6.1) ......................................................................................... 35
3 Fuels and lubricants ................................................................................. 36
3.1 Hydraulic oils ............................................................................................ 37
3.2 Capacities ................................................................................................ 38
3.3 Tyre inflation pressure ............................................................................. 38
4 Electric Fuses .......................................................................................... 39
4.1 Main fuses (next to the batteries) ............................................................ 39
4.2 Fuses in main terminal box (next to fuel tank) ......................................... 39
4.3 Fuses on control panel ............................................................................. 40