OPERATION & MAINTENANCE

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OPERATION & MAINTENANCE

Screed

Dynapac

R300TV / R300TV-(E)

Type 430 / 432

Keep for later use in document compartment 4812008847 (A5)

02-0513

Valid for:

_________________ - _________________ _________________ - _________________

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www.dynapac.com

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1

V Preface

Translation of the original operating instructions.

If the vehicle is to be operated safely, the information provided in these operating instructions will be required. The information is provided in a concise, clearly structured 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 vehicle options. Make sure that during operation and maintenance work the description appropriate to the vehicle option is used.

In the interest of continued development, the manufacturer reserves the right to make changes to the vehicle (which will not, however, change the essential features of the type of vehicle described) without updating the present operating instructions at the same time.

Dynapac GmbH Wardenburg

Ammerländer Strasse 93

D-26203 Wardenburg / Germany Telephone: +49 / (0)4407 / 972-0 Fax: +49 / (0)4407 / 972-228 www.dynapac.com

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V 2

1 General safety instructions

1.1 Laws, guidelines, accident prevention regulations

A

The locally applicable laws, guidelines and accident prevention regulations must always be observed, even if these are not expressly named here.

The user himself/herself is responsible for compliance with the resulting regulations and measures!

A

The following warnings, prohibitive symbols and instructive symbols indicate dangers for persons, the vehicle and the environment due to residual risks when operating the vehicle.

A

Failure to observe this information, prohibitions and instructions can result in life- threatening injuries!

A

The "Guidelines for the Correct Use and Application of Paver Finishers" compiled by Dynapac must also be observed!

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V 3 1.2 Safety signs, signal words

In the safety instructions, the signal words "Danger", "Warning", "Caution", "Note" are positioned in the coloured title block. They follow a certain hierarchy; in combination with the warning symbol, they indicate the severity of the danger or the type of note.

"Danger"!

Danger of personal injury.

Indication of an immediately threatening danger that result in fatal or severe injuries unless the corresponding actions are taken.

"Warning" !

Indication of a possible danger that can result in fatal or severe injuries unless the corresponding actions are taken.

"Caution" !

Indication of a possible danger that result in moderate or mi- nor injuries unless the corresponding actions are taken.

"Note" !

Indication of a possible drawback unless the corresponding

actions are taken, e.g. unwanted conditions or consequences can occur. 1.3 Other supplementary information

Other information and important explanations are identified by the following picto- grams:

f

Precedes safety instructions that must be observed in order to prevent danger to personnel.

m

Precedes notes that must be observed to prevent damage to equipment.

A

Precedes general notes and explanations.

DANGER

WARNING

CAUTION

NOTE

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V 4

1.4 Warnings

Warning on a dangerous area or hazard!

Failure to observe the warnings can result in life-threatening injuries!

Warning on danger of being pulled in!

m

In this working area/on this element there is a danger of being pulled in by rotating or conveying elements!

Only carry out activities with elements switched off! Warning on dangerous electrical voltage!

m

All maintenance and repair work on the screed's electrical system must always be carried out by an electrician!

Warning on suspended loads!

m

Never stand under suspended loads!

Warning on danger of crushing!

m

There is a danger of crushing when certain components are operated, or certain functions or vehicle movements are carried out. Always make sure that there are no persons within the endangered areas!

Warning on hand injuries!

Warning on hot surfaces or hot liquids!

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V 5 Warning on danger of falling!

Warning on dangers posed by batteries!

Warning on hazardous or irritating substances!

Warning on substances which constitute a fire hazard!

Warning on gas bottles!

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V 6

1.5 Prohibitive symbols

Opening/walking on/reaching in/carrying out/setting up are prohibited during operation or while the drive engine is running!

Do not start engine/drive!

Maintenance and repair work may only be carried out with the diesel engine shut down!

Spraying with water is prohibited!

Extinguishing with water is prohibited!

Unauthorised maintenance is prohibited!

Only qualified experts may conduct maintenance!

A

Consult the Dynapac Service Department

Fire!, naked flames and smoking are prohibited!

Do not switch!

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V 7 1.6 Protective equipment

A

Locally applicable regulations may require the wearing of various safety equipment! Always observe these regulations!

Wear safety goggles to protect your eyes!

Wear suitable head protection!

Wear suitable hearing protection to protect your hearing!

Wear suitable safety gloves to protect your hands!

Wear safety shoes to protect your feet!

Always wear close-fitting work clothing!

Wear a warning vest to be seen in time to avoid accidents!

Wear respiratory equipment if breathing air is contaminated!

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V 8

1.7 Environmental protection

A

The locally applicable laws, guidelines and accident prevention regulations for the proper recycling and disposal of waste must always be observed, even if these are not expressly named here.

Water-endangering substances like: - Lubricants (oil, grease)

- Hydraulic oil - Diesel fuel - Coolant

- Cleaning liquids

must not get into the soil or sewer system during cleaning, maintenance and repair work!

Substances must be caught, stored, transported and brought to pro- fessional disposal sites in suitable containers!

Environmentally hazardous substance!

1.8 Fire prevention

A

Locally applicable regulations may require suitable extinguishing agents to be carried on the vehicle!

Always observe these regulations! Fire extinguisher!

(optional equipment)

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V 9 1.9 Additional information

m

Also observe the manufacturer's documentation and additional documentation!

A

For example, the maintenance instructions of the engine manufacturer

m

Description / depiction applicable when equipped with gas heater!

m

Description / depiction applicable when equipped with electric heater!

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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V 10

2 CE identification and Declaration of Conformity (only applies to machines sold in the EU/EEC)

This machine has CE identification. This identification says that the machine fulfils the basic health and safety requirements pursuant to the Machinery Directive 2006/42/ EC together with all other valid regulations. The scope of supply of the machine includes a Declaration of Conformity as specified in the valid regulations and amend- ments together with harmonised standards and other valid provisions.

3 Guarantee conditions

A

The guarantee conditions are included in the scope of supply of the machine. This contains a complete specification of the valid conditions.

The guarantee becomes null and void if

- damage occurrs through malfunctions caused by improper use and incorrect operation.

- repairs or manipulations are carried out by persons who are neither trained nor au- thorised accordingly.

- accessories or spare parts are used that cause damage and which are not approved by Dynapac.

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V 11 4 Residual risks

These are risks that remain even if all possible measures and safety precautions have been taken to help minimise dangers (risks) or to reduce their probability and scope to zero.

Residual risks in the form of

- Danger to life and limb of persons at the machine - Danger to the environment posed by the machine

- Damage to property and restricted output and functionality of the machine - Damage to property in the operating range of the machine

caused by:

- wrong or improper use of the machine - defective or missing safety devices

- use of the machine by untrained, uninstructed staff - defective or damaged parts

- incorrect transport of the machine - incorrect maintenance or repairs - leaking operating substances - emission of noise and vibrations - impermissible operating substances

Existing residual risks can be avoided by complying and implementing the fol- lowing:

- warnings at the machine

- warnings and instructions in the safety manual for paver finishers and in the operating instructions of the paver finisher

- Operating instructions of the machine operator

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V 12

5 Sensibly predictable incorrect usage

Every kind of sensibly predictable incorrect usage of the machine constitutes misuse. Incorrect usage makes the manufacturer's warranty null and void: the operator bears sole responsibility.

Sensibly predictable incorrect usage of the machine includes: - presence in the danger zone of the machine

- transporting persons

- leaving the operator's platform while the machine is operating - removing protection or safety devices

- starting and using the machine outside the operator's platform - operating the machine with the screed walkway plate hinged up - failing to comply with the maintenance instructions

- omission or incorrect execution of maintenance or repair work - spraying the machine with high pressure cleaners

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A 1

A Correct use and application

A

The "Guidelines for the Correct Use and Application of Paver Finishers" compiled by Dynapac 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 these 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 these 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 to be 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 finisher is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities must be obtained.

Any approval obtained from local authorities does not, however, make approval by the manufacturer unnecessary.

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A 2

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B 1

B Description of the screed

1 Application

The Dynapac R300TV screed is operated in conjunction with a paver finisher. The screed is used for laying:

- bitumen materials,

- roll-down concrete or lean-mixed concrete, - track-laying ballast or

- unbound mineral aggregates for foundations for paving.

A

This screed with its possible combinations of different extension parts together with the attachment of a hydraulically extendable extension part is intended for paving many different widths.

For the screed's technical specifications, refer to the section "Technical data".

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B 2

2 Assemblies

Tamper and vibration elements: The tamper knives converging in the middle area prevent seams in the middle.

The tamper and the vibration elements can be individually switched on and off and controlled with regard to speed.

Continuous speed control always ensures optimum compacting results for the different materials and layer thicknesses.

Extension parts: With a co-ordinated system of extension parts, the operating width can be increased in several stages.

Extension part, hydraulically extendable (O): The hydraulically extendable exten- sion part consists of a main part and an adjustable part. The adjustable part extends parallel to the main part.

It can be fitted directly to the main screed or to the extension parts AT 750 or AT 1000. Side shields: The side shields serve to prevent the material from overflowing to the outside.

Removable walkways: The walkways are attached to the bracket provided.

Only in special cases (e.g. paving close to a wall) may the walkways be temporarily detached.

Lubricating system: The main screed has a central lubricating system. The exten- sion parts are supplied with lubricating grease at individual lubricating points.

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B 3 Screed heater: Two different heater systems are available as options:

Gas heater: The propane gas flame band heater features a tried-and-tested design and is easy to handle.

The electronic temperature and flame monitoring system ensures short heating times and constant temperatures.

Intermediate insulation above the bottom plates and the air ducts to the tamper knives and side plates ensure efficient usage of the heat.

Electric heater: The advantages of the electric screed heater are its tried-and-tested design, problem-free handling and maximum possible service friendliness thanks to maintenance-free operation.

Short heating times, constant temperatures and efficient heat utilisation are therefore assured thanks to the various, separately monitored and controlled heating sections. These are designed in the form of heating strips, sensibly arranged in the bottom plates and tamper knives of each screed section.

If extension parts are fitted to the screed, only one single, easily installed plug connection need be fitted to the supply and control cable leading to the neighbouring screed component.

The heating system is monitored and controlled in the switch cabinet.

Via electrical heating of the side shields (O), adherence of mixed material is prevent- ed and the surface texture within this area is improved.

A

Both types of heater and their operation are described in the following chapters of these operating instructions.

Symbols are assigned to the different descriptions and figures: - Description / depiction when equipped with gas heater

- Description / depiction when equipped with electric heater

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B 4

3 Safety

f

The safety devices of the paver finisher and of the screed are described in chapter B, section 3 of the operating instructions for the paver finisher.

3.1 Remaining risks at the screed Danger of squeezing!

f

At all moving parts of the screed, there is a danger of crushing, trap- ping or shearing.

Keep away from these parts! Danger of being pulled in!

f

A danger of catching, winding or drawing-in exists at all rotating or circulating parts of the screed.

Keep away from these parts! Danger of falling!

f

Never jump on or off the when the vehicle is in motion! Only use the access boards and steps provided!

f

Danger of fire and explosions!

Work on the heater system involves the danger of fire and explosion.

Do not smoke! No naked flames!

Danger of electric voltage

f

Any failure to follow the safety precautions and safety regulations when operating the electric screed heater (o) leads to the risk of electric shock.

Danger to life.

All maintenance and repair work on the screed's electrical system may be carried out by a specialist electrician only.

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B 5 Danger of burning!

f

Heating the screed heater leads to danger due to hot surfaces, par- ticularly on the bottom plates and side shields.

Keep away from these parts! Or wear protective gloves! - Always wear all protective clothing required!

Failure to wear protective clothing or wearing protective clothing in an improper manner can be dangerous to health.

- Ensure that all protective covers and hoods are fitted and secured accordingly! - Immediately rectify damage which as been ascertained! Operation must not be

continued when the vehicle is defective!

- Always make sure during work that no-one is endangered by the vehicle!

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B 6

4 Technical data 4.1 Dimensions

A

As regards extension of the screed, refer to the chapter entitled "Set-up and modifi- cation".

4.2 Weights

R300TV

Basic width 3.00 m

Working width:

min. width with 2 cut-off shoes 2.10 m

Depth of the bottom plates:

Main screed / extension parts 600 mm

R300TV

Main screed 2.40 t

plus:

side shields

per extension part 250 mm per extension part 500 mm per extension part 750 mm per extension part 1,000 mm per extension part 1,350 mm

210 kg 340 kg 530 kg 630 kg 1,978 kg

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B 7 4.3 Adjustment/equipment features

4.4 Compacting system Crowning:

- Adjustment range -2 %... +3 %

- Adjusting mechanism with ratchet via chain

Hinged walkway plate Standard

Lubrication system: Central lubricating system

Tamper system Vertical impact tamper

Tamper stroke 5 mm

Tamper frequency 0 ... 1560 rpm

(infinitely adjustable) (0 ... 26 Hz)

Vibration (option) 0 ... 3500 rpm

(infinitely adjustable) 0 ... 58 Hz)

Hydraulic motors:

- for tamper 2

- for vibration 2

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B 8

4.5 Gas heater system (o)

Fuel (liquefied gas) Propane gas

Burner type Flame band burner

Heater control system

(switch cabinet on the screed)

Electronic ignition, temperature monitoring, flame monitoring

Gas bottles (on the screed) - Capacity per bottle

- Gross weight per bottle

2 items/ 4 items (O) 78 l

33 kg Operating pressure (downstream of pressure

reducer) Approx. 1.5 bar

Gas consumption main screed

Gas consumption per 250 mm extension part Gas consumption per 500 mm extension part Gas consumption per 750 mm extension part Gas consumption per 1,000 mm extension part

2.84 kg/h 0.28 kg/h 0.86 kg/h 0.86 kg/h 1.12 kg/h

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B 9 4.6 Electric heater (o)

Type of heating

Electric heater with heating strips in bottom plates and tamper knives

Number of heating strips - On each bottom plate - On each tamper blade

2 1

items items Heating power:

- Main screed- bottom plate - Main screed - tamper blades - Side shield

- Extension part 1,000 mm - bottom plate - Extension part 1,000 mm - tamper blades - Extension part 1350 mm - bottom plate - Extension part 1350 mm - tamper blades - 1,350 mm extension part

(extendable part) - bottom plate - 1,350 mm extension part

(extendable part) - tamper blades

2300 1100 925 1600

720 2200 1000 1450 925

Watt

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B 10

4.7 Technical data - hydraulically extendable extension part (o) 4.8 Dimensions (per extension part (left/right)

A

As regards extension of the screed, refer to the chapter entitled "Set-up and modifi- cation".

4.9 Weights (per extension part (left/right)

4.10 Gas heater system

Basic width 1.375 m

Working width:

min. width with 2 cut-off shoes hydraulically extendable to

2.00 2.375

m m Depth of the bottom plates:

Main screed Extendable part

600 350

mm mm

AT 1375 1.98 t

plus:

Side shields ²¹⁰ ^kg

Fuel (liquefied gas) Propane gas

Burner type Flame band burner

Heater control system

(switch cabinet on the screed)

Electronic ignition, flame monitoring,

temperature monitoring (o) Gas consumption, main part + ext. parts 1.75 kg/h

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B 11 5 Location of instruction labels and type plates

Danger from missing or misunderstood vehicle signs Missing or misunderstood vehicle signs pose a danger of injuries!

- Never remove any warnings or information signs from the vehicle.

- Damaged or lost warning or information signs must be replaced immediately.

- Make yourself familiar with the meaning and position of the warning and information signs.

- Comply with all further information in these instructions and in the safety manual.

CAUTION

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B 12

5

(o)

4

2

3

1

4 (o)

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B 13 Identification points - extension parts

3

6

3 (o)

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B 14

* With "gas heater" equipment only

** With "electric heater" equipment only

*** On both sides of the screed Item Designation

1 Screed type plate

2 Gas system operating instructions * 3 Warning plate "Hot surfaces" ***

4 Safety symbol "Hazardous electrical voltage"** 5 Electric heater operating instructions**

6 Warning panel, "Risk of crushing"

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B 15 5.1 Screed type plate (1)

Item Designation 1 Screed type

2 Maximum operating weight of the screed 3 Screed number

4 Year of construction 5 Manufacturer

1

2

4 3

5

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B 16

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C 1

C Transportation

1 Safety regulations for transportation

m

Accidents can happen when the paver finisher and the screed are not properly pre- pared for transportation or when transportation is carried out improperly!

Dismantle all extension parts from the main screed.

Remove all loose and protruding parts (side shields, remote controls, etc.). When transporting under a special permit, secure these parts!

Stow all parts that are not permanently installed on the screed in the boxes provided for this purpose.

Properly reattach all guards after transportation.

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C 2

2 Transporting the removed screed

A

The procedure required to load and transport the screed when installed on the paver finisher is described in the operating instructions for the paver finisher.

All protruding or loose parts and the gas bottles for the screed heating system (o) (see Chapters E and D) must be removed. Hydraulic and electrical connections must be disconnected.

f

Heed the capacity of the fork-lift truck / of the crane and the lifting gear (chains, ca- bles, hooks, etc.)!

A

For the weights and the dimensions of the screed, refer to Chapter B, section "Tech- nical data".

2.1 Transportation by crane

- Attach the hooks to the attachment points (1, 2) provided for this purpose. - Use the securing points (3) and (4) provided on the extension parts.

m

Make sure that the screed is in a completely horizontal position when attached to the gear; otherwise, oil and grease can leak out.

This is harmful to the environment! 2.2 Transportation by fork-lift truck

m

Always note that the centre of gravity of the screed or accessories box may be off- centre.

f

When a fork-lift truck is used for transportation, there is the danger that the load may tip over or that parts may fall down. Keep away from the danger area!

Danger from suspended loads

Crane and/or raised vehicle can tilt when lifted and cause severe to fatal injuries!

- The vehicle may only be raised at the marked lifting points.

- Heed the operating weight of the vehicle. - Do not enter the danger zone.

- Use only lifting gear that can bear the load.

- Do not leave any load or loose parts on the vehicle. - Comply with all further information in these instructions

and in the safety manual.

WARNING

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C 3 2

1

4 3

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C 4

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D 1

D Operation

1 Notes regarding safety

f

Improper operation of the screed or the screed heater can endanger persons. - Ensure that all protective devices and covers are available and appropriately se-

cured!

- Immediately rectify damage which as been ascertained! Operation must not be continued when the vehicle is defective!

- Always ensure that no person is endangered when working! - Do not let any person ride along on the screed!

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D 2

Danger due to improper operation

Improper operation of the vehicle can cause severe to fatal injuries!

- The vehicle may only be used in the stipulated manner for its intended purpose.

- The vehicle may only be operated by trained staff. - The vehicle operators must have made themselves

familiar with the contents of the operating instructions. - Avoid jerky movements of the vehicle.

- Do not exceed the allowed angle of rise and slope. - Keep hoods and covering parts closed during operation. - In driving mode, all moving parts must be locked/

secured.

Danger of being pulled in by rotating or conveying vehicle parts

Rotating or conveying vehicle parts can cause severe or fatal injuries!

- Do not enter the danger zone.

- Do not reach into rotating or conveying parts. - Only wear close-fitting clothing.

- Comply with the warning and information signs on the vehicle.

- Stop the engine and remove the ignition key before any maintenance work.

DANGER

WARNING

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D 3 Danger of crushing from moving vehicle parts

Vehicle parts performing movements can cause severe or fatal injuries!

- Never stand in the danger zone of the vehicle! - Do not reach into the danger area.

- Comply with the warning and information signs on the vehicle.

Hot surfaces!

Surfaces including those behind covering parts, together with combustion fuels from the engine or screed heater can be very hot and cause injuries!

- Wear your personal safety gear. - Do not touch hot parts of the vehicle.

- Only perform maintenance and repair work after the vehicle has cooled down.

WARNING

CAUTION

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D 4

2 Operation of the screed

A

For all general functions of the paver finisher and the screed that are not special- ly related to the present screed, refer to the operating instructions of the paver finisher.

2.1 Extend / retract screed (o)

To extend or retract the hydraulically adjustable extension parts,

- actuate the switch (1) on the remote controls installed on the right-hand and the left-hand side of the screed. The screed hazard warning flasher flashes.

A

The function for extending/retracting extension parts can also be carried out from the paver finisher's operating panel.

m

There is a danger of crushing while extending or retracting the extension parts.

Make sure that there is no-one in the danger area! - A pointer (2) and a scale (3), from

which the extended width can be read off, can be found on each of the extendable parts.

1

3 2

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D 5 2.2 Adjusting the tamper

The tamper function is switched on and off using the button (8) on the paver finisher's operating panel (see paver finisher operating instructions).

A

The tamper frequency (number of strokes per minute) is set and displayed in the paver finisher control system / remote control compacting element setting menu (see paver finisher operating instructions).

Range of adjustment: 0 – 1560 rpm =

0 – 26 strokes per second 2.3 Adjusting the vibration

The vibration function is switched on and off using the button (9) on the paver finisher's operating panel (see paver finisher operating instructions).

A

The vibration frequency (number of strokes per minute) is set and displayed in the paver finisher control system / remote control compacting element setting menu (see paver finisher operating instructions).

Range of adjustment: 0 – 3500 rpm =

0 – 58 strokes per second

8

9

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D 6

3 Operation of the gas heater system with flame monitoring 3.1 Gas circuit diagram - main screed

Item Designation 1 Gas bottles

2 Pressure reducer with pressure gauge 3 Hose break safety devices

4 Stop-off valve 5 Gas filter

6 Solenoid valves 7 Hose coupling 8 Primary air throttle 9 Injector burner 1 2

3

4

5 6

7

8 9

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D 7 3.2 Gas circuit diagram - Hydraulically extendable extension part (o)

Item Designation 1 Gas bottles

2 Pressure reducer with pressure gauge 3 Hose break safety devices

4 Stop-off valve 5 Gas filter

6 Solenoid valves 7 Hose coupling 8 Primary air throttle 9 Injector burner

2 1

3

4

5 6

7

8 9 7

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D 8

3.3 General notes on the gas heater system

The heater of the screed burns propane gas (liquefied gas). The two gas bottles are on the screed.

The heater is equipped with an electronic flame and temperature monitoring system. The spark plug on the burner simultaneously serves to monitor the flame. The switch cabinet is mounted on the screed.

In the case of the temperature monitoring system, the temperature sensor is secured on the sliding plate; the ignition box is also located on the screed.

Heed the following points before commissioning the heater system: - The gas bottles must always be in the

position provided for this purpose on the screed, and must be secured using the supplied strap retainers. The bottles must be fixed in position so that they cannot turn around their longitudinal axis even while the paver finisher is in operation.

- The liquefied gas system must not be operated without the hose break safety device (20). It is also absolutely necessary that the pressure reducing valve is installed before the system is put into operation.

- The gas pressure must not fall below 1.0 bar. Danger of explosion in the burner!

- Check all gas hoses for externally vis-

ible damage before using them. If any defect is found, immediately replace the hose in question with a new one.

f

There is a danger of fire and explosions when handling gas bottles and working on the gas heater.

Do not smoke! No naked flames!

Gasflas.tif

20

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D 9 3.4 Connection and leak test

The gas pipe system of the main screed, extension parts and hydraulically extendable extension part (o) is permanently installed. To connect the gas bottles:

- Unscrew the protective caps from the bottle valves and screw onto the rear of the bottle bracket.

- Check whether the quick action valves are closed.

- Check that the bottle valves (21) are properly closed.

Install the gas hoses with the pressure reducers and the hose break safety devices (20) on the bottles.

A

^Note:

The gas connections always have left-handed threads!

m

Make sure the gas pipe system has no leaks.

Gasflas.tif

20 ₂₁

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D 10

3.5 Commissioning and checking the heater

The gas heating system is operated with two gas bottles.

- Check whether the battery master switch is switched on.

- Open the bottle valves (21).

Unlock the safety valve by pressing the hose break safety device (20). - Open the quick action valves.

A

The following sequence must be ad- hered to in order to guarantee a malfunction-free ignition and heating phase: - 1. Place screed on the ground

- 2. Fully retract the paver finisher's levelling cylinders

- 3. Ignite the screed and allow to heat slightly in this position

- 4. As soon as sufficient heat is available, the screed can be raised

Gasflas.tif

20 ₂₁

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D 11 3.6 Exchanging the gas bottles

- Check whether the quick action valves and both bottle valves (21) are closed. - Unscrew the gas hoses.

- Screw the protective caps for the bottle valves onto the gas bottles.

- Screw pressure reducer onto the available mounting bracket.

f

Gas bottles that are full or not completely emptied are under pressure.

Therefore, make sure that bottles with their protective valve caps removed are protected from severe impact (particu- larly in the area of the valves or on the valves themselves)!

- Connect new gas bottles (see the section "Connecting gas bottles and performing a leak test").

Gasflas.tif

21

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D 12

4 Screed heater system

4.1 Switch cabinet for screed heater

40

42 41 43 44

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D 13 Item Designation

40

Control and monitoring unit

- For actuating the heating system, setting and monitoring the set temperature.

41 Left main screed malfunction display, red 42 Left extension part(s) malfunction display, red 43 Right main screed malfunction display, red 44 Right extension part(s) malfunction display, red

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D 14

4.2 Operating the control and monitoring unit

45 46 55 47 48 49 50

53 54

51 52

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D 15 Item Designation / function

45

- Screed section selection

A

For selecting the screed sections for temperature display and adjustment.

A

The temperature is adjusted for all sections together.

47

- "Energy saving" selection

A

To reduce the heater output.

A

After switching on, the "Energy saving" status (ON/OFF) set during previous operation is assumed again.

47 - Plus button

A

To adjust the temperature. 48 - Minus button

A

To adjust the temperature. 49 ^{- Enter}

A

To confirm the input / temperature change. 50 ^{- Standby}

A

To switch between standby off / standby on.

51

- Screed section display

A

Displays the selected screed section. The temperature of the selected screed section is shown in display (52).

A

If no button has been pressed for a long time, the display is off, and the mean temperature value for all screed sections is shown in display (52). Return to the basic status takes place after 3 seconds without button actuation.

52

- Temperature gauge

A

Displays the temperature of the selected screed section.

A

If no screed section has been selected or no button has been pressed for a long time, the mean temperature value for all screed sections is shown. Return to the basic status takes place after 3 seconds without button actuation.

(56)

D 16

Item Designation / function

53

- "Sensor error" warning lamps

A

Warning lamps 1-4 for the individual screed sections light up if a defect is present on the corresponding sensor.

A

Check sensor. The controller operates in the emergency programme.

54

- Heater status display

A

Indicator lamps 1-4 for the individual screed section heaters light up if the corresponding heater circuit is engaged.

A

The lamps flash when the controller requests heating for the relevant section and this cannot be carried out at present due to a delay time or energy saving mode.

55 - "Energy saving" indicator lamp

A

Lights up when reduced heater output (energy saving) is activated.

45 46 55 47 48 49 50

53 54

51 52

(57)

D 17 Ignition process -

Procedure

- Actuate the on/off switch (50) in the switch cabinet; this

- opens the electromagnetic non-return valves for the gas supply to the burners;

- activates the electronic ignition system, causing the gas to be automatically ignited by the spark plugs and controlled by the flame monitoring system.

50

(58)

D 18

4.3 Function of the flame monitoring system

Item Designation

56 Left main screed malfunction display, red 57 Left extension part(s) malfunction display, red 58 Right main screed malfunction display, red 59 Right extension part(s) malfunction display, red 60 Ignition boxes on the individual screeds

61 Red indicator lamp on the ignition box in the corresponding screed 62 Yellow indicator lamp on the ignition box in the corresponding screed

61 62 60

57 ₅₆

58 ₅₉ 54 53

(59)

D 19 Via the temperature sensor and flame monitoring system, the electronics monitor gas heater operation. If there is no stable flame at the ignition burner within 7 seconds, the electronics indicate a malfunction. The gas supply is interrupted and the red indicator lamps on the ignition box and in the switch cabinet light up.

A

In the event of a malfunction during the switch-on phase, the starting process can be repeated up to three times. If the malfunction still occurs after three start-ups, the cause of the malfunction has to be eliminated before starting again.

When the flame is correct, the screed is heated until the temperature sensors in the individual screeds interrupt the heating process. During the heating phase, the red indicator lamps (54) in the switch cabinet and the yellow indicator lamps on the ignition boxes (62) indicate a correct flame at the burners.

In the event of a malfunction, the red indicator lamps (56, 57, 58, 59) in the switch cabinet and the red indicator lamps on the ignition boxes (61) indicate that the flame at the burners is not correct.

m

The indicator lamps are important for trouble-free operation of the ignition system. Therefore, defective bulbs should be immediately replaced!

(60)

D 20

4.4 Temperature display, setting temperature level

The temperature display and temperature level setting for the screed heater are carried out on the control and monitoring unit in the screed heater's switch cabinet. 4.5 Temperature setting

- Press button (47) or (48) to show the current nominal temperature on the display (52).

- According to the desired adjustment, press button (47) or (48) to change the nominal temperature.

A

Adjustment is carried out in 5°C steps. The maximum nominal temperature is 180°C. - Confirm the new nominal value setting by pressing the Enter button (49).

The current actual temperature is again shown on the display (52).

A

Adjustment is carried out for all screed sections together.

45 46 55 47 48 49 50

53 54

51 52

(61)

D 21 Energy saving mode / "Energy saving"

In this operating status, not all of the different screed sections' heaters are active at the same time.

Switching is carried out via temperature regulation. Whenever the nominal temperature is achieved in an actively heated section, the control system switches these sections off and activates those with the lowest temperature.

It is possible to heat the following sections together in this case. - Section 1 and section 3

- Section 2 and section 4 - Section 1 and section 4 - Section 2 and section 3 - Section 1 and section 2

A

After switching on, the "Energy saving" status (ON/OFF) set during previous operation is assumed again.

(62)

D 22

4.6 Status and error messages

A

When an error occurs, the warning lamp (53) for the affected screed section lights up and the controller runs in an emergency programme.

A warning signal is additionally sounded. The warning signal is acknowledged with the minus button (48).

After pressing the Enter button, an error code is shown on the display (52).

A

On selection of a faulty heater section with button (45), ---°C is displayed.

If several errors occur, the errors are shown in rolling form on pressing the Enter button (49).

52

45 48 49

53

(63)

D 23 Emergency programme with sensor error

In the event of sensor errors, the controller operates in an emergency programme. All zones with an intact sensor are regulated as normal. The temperature is only displayed with the intact sensors.

If more than 2 sensors are defective, the controller still continues to operate as long as at least 1 zone is intact. The zones with the defective sensors are then handled as if their temperature corresponds precisely to the mean value of the intact zones.

Error code Cause of error Measure

Error messages without button call-up Warning lamp

(53-1) lights up

- Sensor F1 defective

- Check sensor,

the controller operates in the emergency programme Warning lamp

(53-2) lights up

- Check sensor,

(53-3) lights up

- Check sensor,

(53-4) lights up

- Check sensor,

the controller operates in the emergency programme EP - Data loss in the

parameter memory - Controller repair Error messages with the Enter button pressed F1L - Sensor error F1, short-circuit - Check sensor,

the controller operates in the emergency programme F1H - Sensor error F1, sensor break

F2L - Sensor error F2, short-circuit - Check sensor,

(64)

D 24

4.7 Switching off the heater

After work has been completed, or when the heater is no longer required:

- Press the on/off button (50) in the switch cabinet.

- Close the quick action valves and both bottle valves.

m

If these valves are not closed, there is a danger of fire and explosion due to the possible escape of uncombusted gas! Always close the valves during breaks and after work has been completed!

50

(65)

D 25 5 Operating the electric heater

5.1 Switch cabinet for screed heater

A

The configuration of individual elements may vary slightly!

91

89

90

81 94

93

77

78

75

79

80 82

4 x 230 V 97

96 98 99

70

71 72 74 83 ⁸⁴

92 95

85

76 73 88 87 86

(66)

D 26

Item Designation

70 EMERGENCY STOP button

71 Test key for monitoring of insulation and indicator lamp for insulation defects 72 Reset key for insulation monitoring

73 Generator indicator lamp 74 Heating ON/OFF

75 Circuit breaker for heating section 1 76 Circuit breaker for heating section 2 77 Circuit breaker for heating section 3 78 Circuit breaker for heating section 4 79 Heating section 1 indicator lamp 80 Heating section 2 indicator lamp 81 Heating section 3 indicator lamp 82 Heating section 4 indicator lamp 83 Electrically heated side shield On / Off 84 Headlights On / Off (sockets 27+28) 85 Headlights On / Off (sockets 29+30) 86 Circuit breaker for sockets 27+28 87 Circuit breaker for sockets 29+30

88 Circuit breaker for electrically heated side shield 89 Socket (heater) for main screed on left

90 Socket (heater) for main screed on right 91 Socket (heater) for extension part(s) on left 92 Socket (heater) for extension part(s) on right 93 Circuit breaker for generator indicator lamp 94 Main fuse and EMERGENCY STOP trigger 95 Control and monitoring unit

96 230 volt socket for additional headlight 97 230 volt socket for additional headlight 98 230 volt socket for additional headlight 99 230 volt socket for additional headlight

(67)

D 27 5.2 Operating the control and monitoring unit

100 101 110 102 103 104 105

108 109

106 107

(68)

D 28

Item Designation / function

100

- Screed section selection

A

For selecting the screed sections for temperature display and adjustment.

A

The temperature is adjusted for all sections together.

101

- "Energy saving" selection

A

To reduce the heater output if the generator output is insufficient.

A

After switching on, the "Energy saving" status (ON/OFF) set during previous operation is assumed again.

102 - Plus button

A

To adjust the temperature. 103 - Minus button

A

To adjust the temperature. 104 ^{- Enter}

A

To confirm the input / temperature change. 105 ^{- Standby}

A

To switch between standby off / standby on.

106

- Screed section display

A

Displays the selected screed section. The temperature of the selected screed section is shown in display (8).

A

If no button has been pressed for a long time, the display is off, and the mean temperature value for all screed sections is shown in display (8). Return to the basic status takes place after 3 seconds without button actuation.

107

- Temperature gauge

A

Displays the temperature of the selected screed section.

A

If no screed section has been selected or no button has been pressed for a long time, the mean temperature value for all screed sections is shown. Return to the basic status takes place after 3 seconds without button actuation.

(69)

D 29 Item Designation / function

108

- "Sensor error" warning lamps

A

Warning lamps 1-4 for the individual screed sections light up if a defect is present on the corresponding sensor.

A

Check sensor. The controller operates in the emergency programme.

109

- Heater status display

A

Indicator lamps 1-4 for the individual screed section heaters light up if the corresponding heater circuit is engaged.

A

The lamps flash when the controller requests heating for the relevant section and this cannot be carried out at present due to a delay time or energy saving mode.

110 - "Energy saving" indicator lamp

A

Lights up when reduced heater output (energy saving) is activated.

100 101 110 102 103 104 105

108 109

106 107

(70)

D 30

5.3 General information on the heating system The electric heating system is supplied with power by a generator on board the paver finisher which is controlled fully- automatically in accordance with requirements.

Heating resistors in the form of heating strips ensure direct temperature transi- tion and even distribution of heat. Each screed section is heated by three heating strips. Two can be found on the bottom plate and one on the tamper knife.

The temperature display can be called up for the individual screed sections or as a mean value for all sections. Tem- perature regulation is carried out for all screed sections together.

The heater is connected to other fitted screed components via simple plug connections.

The heating system can be operated in an energy saving mode in which not all heating sections are active at the same time.

In the event of sensor failure, the heater can continue to be operated via an emergency programme.

The switch cabinet is equipped with an additional 230 V socket for external consumers (e.g. additional lighting).

Since fuels (gas, diesel) are not handled and insulation monitoring takes place, maximum possible protection of personnel is offered.

f

Beware of hot surfaces! Danger of burning!

f

Maintenance and repair work on electrical systems with medium voltage levels, e.g. the screed heater, may only be carried out by specialist electricians or persons in- structed in electrical engineering work if the appropriate test devices are used. Always comply with relevant technical electrical protection precautions. Danger to life as a result of accidents involving medium voltage levels.

(71)

D 31 Energy saving mode / "Energy saving"

Under certain conditions, e.g. large working widths, it is sensible to activate energy saving mode.

In this operating status, not all of the different screed sections' heaters are active at the same time.

Switching is carried out via temperature regulation. Whenever the nominal temperature is achieved in an actively heated section, the control system switches these sections off and activates those with the lowest temperature.

It is possible to heat the following sections together in this case. - Section 1 and section 3

- Section 2 and section 4 - Section 1 and section 4 - Section 2 and section 3 - Section 1 and section 2

A

After switching on, the "Energy saving" status (ON/OFF) set during previous operation is assumed again.

(72)

D 32

5.4 Insulation monitor

The function of the protective insulation monitoring measure must be checked every day before starting work.

A

This check only checks the function of the insulation monitor, not whether an insulation error has occurred on the heating sections or consumers.

- Start the paver finisher's drive engine. - Switch heating system switch (74)

to ON.

- Press test button (71).

- The indicator lamp integrated into the test button signals "insulation fault". - Press reset button (72) for at least 3 sec. to delete the simulated fault. - The indicator lamp goes out.

f

If the test is conducted successfully, work may be undertaken with the screed and external consumers may be used.

If the "insulation fault" indicator lamp displays a fault even before the test button is pressed or if no fault is displayed during the simulation, work must not be undertaken with the screed or with connected, external equipment.

f

The screed and equipment must be checked or repaired by a specialist electri- cian. Only then may work again be undertaken with the screed and equipment.

f

Danger due to electrical voltage

f

Non-adherence to the safety precautions and safety regulations when operating the electric screed heater leads to a risk of elec- tric shock.

Danger to life.

All maintenance and repair work on the screed's electrical system may be car- ried out by a specialist electrician only.

74

72 71

(73)

D 33 Insulation faults

A

If an insulation fault occurs during operation, and the indicator lamp displays an insulation fault, the operator may proceed as follows:

- Switch the switches of all external equipment and the heater to OFF and press the reset button for at least 3 seconds to delete the fault.

- If the indicator lamp does not go out, the fault lies in the generator.

f

No further work may be carried out.

- If the indicator lamp goes out, the switches of the heater and external equipment can be switched back to ON one after another until a message again appears and the system is shut-down.

- The equipment found to be faulty must be removed or must not be engaged, and the reset button must be pressed for at least 3 seconds to delete the fault.

A

Operation may now be continued - without the faulty equipment, of course.

A

The generator or electrical consumer found to be faulty must be checked or repaired by a specialist electrician. Only then may work again be carried out with the screed and equipment.

(74)

D 34

5.5 Commissioning and checking the heater

A

In order to reach the required temperature, the heater should be switched on approx. 15 - 20 minutes before the start of paving.

- Switch on the paver finisher's engine. - Switch on heating system

ON / OFF switch (74).

- Switch on the control and monitoring unit ON / OFF switch (105).

- Switch on the electrically heatable side shields' (o) ON / OFF switch (83).

The heating system is activated and the heating process begins.

During the heating process, the individual screed section heaters' indicator lamps (79-81) and the status displays (109) of the control and monitoring unit light up.

Once the set temperature has been reached, the indicator lamps go out one after another.

Once all screed parts have reached the desired temperature, paving operation may begin.

If additional heating occurs during paving operation, this is indicated by the indicator lamps (79-81).

A

The heater indicator lamps (109) in the control and monitoring unit can additionally be monitored.

74

79 83

105

109

80 81 82

(75)

D 35 5.6 Temperature display, setting temperature level

The temperature display and temperature level setting for the screed heater are carried out on the control and monitoring unit in the screed heater's switch cabinet. 5.7 Temperature setting

- Press button (102) or (103) to show the current nominal temperature on the display (107).

- According to the desired adjustment, press button (102) or (103) to change the nominal temperature.

A

Adjustment is carried out in 5°C steps. The maximum nominal temperature is 180°C. - Confirm the new nominal value setting by pressing the Enter button (104).

The current actual temperature is again shown on the display (107).

A

Adjustment is carried out for all screed sections together.

100 101 110 102 103 104 105

108 109

106 107

(76)

D 36

5.8 Status and error messages

A

When an error occurs, the warning lamp (108) for the affected screed section lights up and the controller runs in an emergency programme.

A warning signal is additionally sounded. The warning signal is acknowledged with the minus button (103).

After pressing the Enter button, an error code is shown on the display (5).

A

On selection of a faulty heater section with button (100), ---°C is displayed.

If several errors occur, the errors are shown in rolling form on pressing the Enter button (104).

107

104 108

103 100

OPERATION & MAINTENANCE