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

I 1
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

I 2
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

I 3
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

I 4
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

I 5
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

A 1
A.DF115_135P GB 1-2 - 01.03
A Correct use and application

The “Guidelines for the Correct Use and Application of Paver Finishers” compiled are
included in the scope of delivery for the present machine. The guidelines are part of
the present operating instructions and must always be heeded. National regulations
are fully applicable.
The road construction machine described in the present operating instructions is a
paver finisher that is suited for laying mixed materials, roll-down concrete or lean-
mixed concrete, track-laying ballast and unbound mineral aggregates for foundations
for paving.
The paver finisher must be used, operated and maintained according to the
instructions given in the present operating instructions. Any other use is regarded as
improper use and can cause injury to persons or damage to the paver finisher or other
equipment or property.
Any use going beyond the range of applications described above is regarded as
improper use and is expressly forbidden! Especially in those cases where the paver
finisher is to be operated on inclines or where it is to be used for special purposes
(construction of dumps, dams), it is absolutely necessary to contact the manufacturer.
Duties of the user: A “user” within the meaning of the present operating instructions
is defined as any natural or legal person who either uses the paver finisher himself,
or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is
considered the person who, in accordance with existing contractual agreements
between the owner and the user of the paver finisher, is charged with the observance
of the operating duties.
The user must ensure that the paver finisher is only used in the stipulated manner and
that all danger to life and limb of the operator, or third parties, is avoided. In addition
to this, it must be ensured that the relevant accident prevention regulations and other
safety-related provisions as well as the operating, servicing and maintenance
guidelines are observed. The user must also ensure that all persons operating the
paver finisher have read and understood the present operating instructions.
Mounting of attachments: The paver finisher must only be operated in conjunction
with screeds that have been approved by the manufacturer. Mounting or installation
of any attachments that will interfere with or supplement the functions of the paver fi-
nisher is permitted only after written approval by the manufacturer has been obtained.
If necessary, the approval of local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.

B 1
B DF115_135P.GB 1-18 - 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_p.tif
Df_135_p.tif

B 2
B DF115_135P.GB 2-18 - 01.03
2 Assembly 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
+
Front axle/wheels
5
+
Levelling cylinder for laying thickness
6
+
Traction roller
7
+
Levelling arm draw bar
8
+
Laying thickness indicator
9
+
Levelling arm
10
+
Rear wheels
11
+
Spreader
12
+
Screed
13
+
Operator’s stand
14
+
Operation panel (laterally movable)
15
&
Weather protecting sunroof
+

= Standard equipment
& = Additional equipment
Df_115_p.tif
9865
3
2
10 12114
14 13
15
1
7

B 3
B DF115_135P.GB 3-18 - 01.03
2.1 Vehicle
Design
The road finisher has a frame in a steel welded construction on which the individual
assemblies are mounted.
With the stepless final drive (10) and two-speed transmission, the speed of the road
finisher can be adapted to 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 control of hopper halves
• 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
Available as special accessories (optional):
• Two front-wheel drive with anti-spin
• Four front-wheel drive with anti-spin
• Two front-wheel drive without anti-spin
• Four front-wheel drive without anti-spin
• 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)
• Emergency push button/External operation panel
• Further equipment and upgrade options available on request

B 4
B DF115_135P.GB 4-18 - 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.
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. This petrol engine drives
the rear wheels (10) via a two-speed transmission.
Steering/Operator’s stand: 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 DF115_135P.GB 5-18 - 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 DF115_135P.GB 6-18 - 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
wheel.
3.3 Ignition lock/lighting equipment
The lighting can be switched on and off
by turning the ignition lock in the appro-
priate direction
3.4 Flasher
11.eps
F0127_a1.tif
9.eps
Blink.wmf

B 7
B DF115_135P.GB 7-18 - 01.03
3.5 Horn
- on operation panel
- on both remotes
3.6 Power switch
The power switch is located on the right-
hand side of the paver finisher between
the central panel and hopper.
3.7 Trough safety lock
3.8 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 DF115_135P.GB 8-18 - 01.03
3.9 Other safety devices
Other equipment:
- Wedges
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_p.tif
Df_135_p.tif